GENERAL INSTALLATION.pdf

NPCC Rev: 01NOV10

INSTALLATION

Foundation at point of crane placement must be designed to accommodate 2 x the maximum tipping moment of crane as well as the axial load of the crane plus 2x live load. The crane pedestal is designed to weld to a customer supplied foundation.

Placing Pedestal

Use a suitable lifting device and rigging to handle the load. Rig pedestal for level lift and place on ship’s foundation. Secure pedestal assembly to foundation using shipyard’s standard welding and inspection procedures. North Pacific Crane Company recommends using those found in

AWS D1.1-92. The weld(s) must be adequate for the rated crane loads plus a safety factor. Use suitable shim rock or other method to maintain a 0.8mm bearing flange flatness. It is advised to align the pedestal access opening away from expected sea conditions. Weld pedestal gussets to pedestal and foundation.

Installing Turret and Platform Assemblies

Use a suitable lifting device and rigging to handle the load. Rig turret/platform for level lift and place on the pedestal assembly. It is recommended to use ratcheting level adjustors for side to side level adjustment and slings (or chains) for fore and aft adjustment. Use pry/alignment bars to align bolt holes between bearing and pedestal flange. Install the supplied cap screws and hardened flat washers.

NOTE: Coat capscrew threads with anti-seize lubricant before installing.

NOTE: All capscrews must be installed prior to tightening. Otherwise, the alignment of the bolt holes can be a problem and will require reaming to fit bolts.

Torque capscrews in a sequential pattern-in 150 ft-lb steps. Final torque value for the capscrews can be found in following chart.

When turret is installed on pedestal, you will notice two brackets welded to the inside of pedestal wall. The brackets are to hold the torque arm bar for the rotoseal. The bar is placed between the two plates and holds the can of the rotoseal from rotating. When the turret is bolted to the pedestal, the torque arm bar must be positioned between the plates. If it is not, then remove the bar and rotate the can around until the bar will line up with the brackets and re-install the bar. If the bar is not between the brackets, when the crane is rotated, the hoses will twist up and damage will result.

Installing Boom Lift Cylinders to Main Boom

Use suitable lifting device and rigging to handle the load. Rig lift cylinder(s) for level pick and lift into place on main boom. Install rod end pin and secure with locking bolt and nut. Lift cylinder until it is nearly level with bottom of main boom. Lash cylinder with suitable strapping to hold cylinder in this position. Repeat for remaining cylinder.

NOTE: Coat cylinder pins with anti-seize lubricant before installing.

Use hammer to drive pins through bosses.

NOTE: Align pin locking bolt hole with hold in boss before pin is installed all the way through the bosses. Otherwise, pin will need to be driven back out of the inside boss and re-aligned.

Installing Crane Booms

Use suitable lifting device and rigging to handle the load. Rig boom assembly for level pick, using lifting eyes on boom and align main boom hinge bosses to turret pin bosses.

CAUTION: Main boom must be level side to side before attempting the installation of the main boom pins. Failure to ensure levelness can cause damage to main hinge pins and/or main hinge bushings.

NOTE: Main boom pins and bushings must be lubricated prior to installation of pins. Use anti-seize or EP-2 grease for lubrication.

Rig main hinge pin with suitable lifting device and install main hinge pin through turret and main boom bosses. Use of a 15 lb. driving hammer will be required to drive pin into the bosses. Use alignment tool to align lock bolt hold in pin to lock bolt hole in boss, while installing pin. Install pin retaining capscrew(s) and lock nut through the pin locking bolt hole. Install flat washer and nylock nut on main hinge pin. Tighten nylock nut until washer can no longer be turned by hand and at least three (3) full threads are showing through the nylon material.

NOTE: Do not remove the rigging or lifting device from main boom, or use a different lifting device to raise/lower boom assemblies during cylinder pin installation.

Use suitable lifting device and Nylon or Dacron sling to handle the load. Wrap sling around one of the main boom cylinders and remove strap from that cylinder, lower and align cylinder anchor boss to turret cylinder pin bosses. Install cylinder turret pin and retain with supplied bolt and locknut. Repeat for other lift cylinder.

NOTE: Cylinder pins and bushings must be lubricated prior to installation of pins. Use of anti-seize or EP-2 grease for lubrication.

Rear and Front Platform Installation (if applicable)

Use a suitable lifting device and rigging to handle the load. Rig rear/front platform for level pick and lift into place on main platform. Install guide tubes into guide rails on main platform.

Position rear/front platform onto guide tubes and push rear/front platform to main platform.

Adjust rigging height to align tubes. Secure platform(s) with supplied bolts, washers, and nuts.

Torque per following chart. Remove rigging.

Winch Installation

Use a suitable lifting device and rigging to handle the load. Wrap lifting sling around winch drum and adjust for level pick. Raise winch onto mounting pads on main boom and secure winch with supplied bolts and hardened flat washers. Coat bolts with anti-seize compound and torque per following chart. Remove rigging from sheave.

Sheave Head Installation

Use a suitable lifting device and rigging to handle the load. Wrap lifting sling around center sheave and adjust for level pick. Lift sheave head onto sheave mounting plate and align mounting bolts holes. Install sheave plate spacers between sheave plates and secure sheave head with bolts, nuts, and hardened flat washers. Coat bolts with anti-seize compound and torque per following chart. Remove rigging from sheave.

Platform Ladder Installation (if applicable)

Use suitable lifting device and rigging to handle the ladder and rig ladder for level pick. Lift up under rear platform and align with bolt holes. Secure ladder to platform with bolts, washers, and nylock nuts. Torque per following chart. Remove rigging.

Slip-ring Installation (if applicable)

Remove slip-ring assembly from its shipping container. Install slip-ring to bottom of rotoseal, access through pedestal opening, and secure with bolts, washers, and etc as required. Connect wiring from slip-ring to ship’s wiring, (supplied by others) as tagged. Connect slip-ring wiring

(upper end) to distribution junction box on turret, as tagged.

WARNING: Insure that power is removed from crane feeder buss before attempting to make wiring connections. Failure to do so will result death or injury to personnel.

CAUTION: Insure that slip ring enclosure is restrained so it cannot rotate.

Failure to do so will result in slip-ring rotation, which can lead to electrification of the crane structure.

Crane Hose and Wiring Connections

Connect suction and pressure hoses between reservoir and control valves, as tagged. Connect hydraulic work lines to boom cylinders telescope cylinder piping, and winch work ports as tagged. Insure that the tagged lines are connected to the correct function port. After all lines are checked for correct connections and tightness, open suction valves on reservoir and begin filling tank (see Operator and Maintenance Manual for fluid requirement).

Connect cab control wiring harness from starter panel to cab per wiring tags. Connect main supply wiring from slip ring to starter panel, as tagged. Connect boom wiring harness from cab control junction box to boom junction box if applicable. Install anti-two block sensor (if applicable) to sheave head and connect wiring harness to plug on boom.

Reeving Crane

Locate wire rope reel and place on a suitable support structure that allows reel to turn (see

Operator’s Manual for example). Pull winch end from reel and reeve through load block and sheave head (see Operator’s and Maintenance Manual for reeving examples). Secure wire rope to winch drum supplied (see Operator’s and Maintenance Manual for recommended installation instructions).

Crane is now ready for start-up procedures.

STARTING CRANE

This crane was shipped with our standard factory settings and some adjustments will be required to optimize the crane for service. These adjustments should only be done by qualified hydraulic service personnel.

Observe that no obstacle is in the boom’s path and operate swing control function to bleed air from the systems. This may take 2 or 4 revolutions in both directions. Operate boom, telescope and winch controls functions in like manner until all air is bled from the system – in other words, the control is no longer “mushy” or “jumpy”. Check hydraulic system for leaks during and after each functional test. Confirm that crane controls operate as indicated by placards.

It may be required to switch hydraulic hoses to achieve the desired function control. When operator is satisfied that system is operating correctly, check reservoir level and top to full mark with clean hydraulic oil. Operate crane unloaded for 20 cycles for operator familiarization and to practice controlled metering of each function Always monitor hydraulic oil level and temperature during this practice session.

Adjustments

Relief Valve

Loosen lock nut on control valve relief, located at the inlet section. Install pressure (0-3000 psi) gauge in line with the pressure line. Start power unit and fully retract boom/extension cylinder.

Observe pressure gauge and adjust inlet relief valve for 2500 psi. Lock jam nut. If control valve has mid-inlet, install 2nd 3000 psi gauge in mid-inlet pressure line. Follow the same procedure using boom/extension cylinder as determined by hydraulic schematic in Operator’s Manual.

Counterbalance Valves

Assemble load for 125% of maximum rated load capacity for both retracted and extended (2 different loads). Insure booms are fully retracted and position hook over load for that radius and connect load to hook. Pick load and boom up slightly. Shut off power unit and then loosen locknut on boom cylinder counterbalance valve. With Allen wrench, turn adjusting screw CCW

(counterclockwise) until it stops. Have assistant operate and hold the boom down function.

Slowly turn adjusting screw CW (clockwise) until boom just starts to creep. Turn adjusting screw

CCW to stop creeping and tighten lock nut without turning adjusting screw. Start power unit and test crane in both loaded and unloaded conditions. If boom tends to bounce in the loaded condition, turn adjusting screw CCW until bounce stops. Boom fully up and extend fully out.

Connect lighter test load to crane and adjust telescope cylinder counterbalance valve in similar manner, except tighten lock nut when creeping has stopped.

Load Testing

Perform load testing of crane to satisfaction of attending surveyor. Generally the load test consists of lifting 125% of load chart rating and holding this test load for 5 minutes. This test is done at minimum, or intermediate or maximum load radii as requested by surveyor. The attending surveyor may require a vessel stability test to be performed in addition to the crane load test. Note: Making the 125% lift may require the adjustment of the main relief valve above its normal setting. Be sure to return the setting to normal after the test.

Crane is read to be place into service upon successful completion of load testing.

STABILITY CHECK

Before the crane can be placed into service, a vessel stability check must be performed to determine if any areas of vessel instability occur with respect to crane slewing at rated load. The following procedure outlines the requirements for this test:

1. Install crane as previously described.

2. Trim vessel for 0o list and pitch, and laden vessel to its least operational weight.

3. To stability check vessel, assemble test load weights of 125% of rated capacity of crane at maximum load radius, intermediate load radius and minimum load radius for both fully retracted and fully extended boom conditions.

4. Starting with boom(s) retracted, hoist Maximum Load Radius test weight 6" off deck.

Increase load radius to maximum. Keep load 6" above deck by paying out with winch.

Continue to increase load radius until telescope boom(s) are fully extended OR until vessel has a 5o pitch, whichever occurs first. If vessel produces a 5o pitch first, note load radius were this occurred. Trim vessel to 0o pitch before proceeding.

5. Carefully slew crane athwart-ship both directions until boom is perpendicular to ship’s axis

OR until vessel lists 5o either side, whichever occurs first. If vessel produces a 5o list first, note bearing and distance from ship’s axis. If trimming is required to maintain 0o list, note amount of trim required.

6. If a list or pitch of 5o occurs, one of the following corrective actions must be implemented:

a. Re-test crane with lesser load until crane can be operated without inducing any list or pitch. Divide the new test load by 1.25. This becomes the new maximum crane rating and a decal must be affixed to crane defining the areas of full stability

(instability).

b. Increase the operational weight of vessel or counter-weight (ballast) vessel.

c. Note the amount of ballast required to maintain stability and affix a decal to the crane detailing this amount.

Repeat the Stability Test for each load radius, 6 tests required, and take corrective action as required.

RECOMMENDED TORQUE VALUES

BOLT

SIZE

S.A.E. GRADE 8

TYPICAL USAGE

CLAMP

LOAD

(LBS.)

DRY

TORQUE

(FT-LBS.)

¼ - 20 2,850 12 Cab Accessories, Plaques, Small Parts

¼ - 28 3,250 14

5/16 – 18 4,700 24 Cab Accessories, Small Parts, Wear Pad

Retainers, Bearing Retainers 5/16 – 24 5,200 27

3/8 – 16 7,000 45 Sheave Pin, Wear Pad, Bearing Retainers, Valve Mounting, Roto-Seal Head, Cab

Accessories 3/8 – 24 7,900 50

7/16 – 14 9,550 70 Motor, Pump, Valve Mounting, Small

Winches, Boom Accessories 7/16 – 20 10,650 78

½ - 13 12,750 105 Motor, Pump, Valve, Reservoir, Swing

Motor/Brake Mounting, Pin Locking, Small

Winches, Boom Accessories ½ - 20 14,400 120

5/8 – 11 20,350 210 Ride Around Platform Mounting, Winch, Motor, Pump, Swing Drive Mounting, Small Rotek Bearings 5/8 – 18 23,000 240

¾ - 10 30,100 375 Ride Around Platform Mounting, Winch

Mounting, Rotek Bearings, Large Swing

Drives, Detachable Sheave Frames ¾ - 16 33,500 420

7/8 – 9 41,600 610 Ride Around Platform Mounting, Winch

Mounting, Rotek Bearings, Turret

Mounting, Engine Mounts 7/8 – 14 45,800 675

1 – 8 54,500 910 Ride Around Platform Mounting, Turret

Mounting, Winch Mounting, Rotek

Bearings, Engine Mounts 1 – 12 59,700 1,000

1 ¼ - 7 87,200 1,820 Turret Mounting, Rotek Bearings, Ride

Around Platform Mounting 1 ¼ - 12 96,600 2,000

1 ½ - 6 126,500 3,160 Turret Mounting, Rotek Bearings, Ride

Around Platform Mounting 1 ½ - 12 142,200 3,560

1 ¾ - 5 171,000 4,990 Turret Mounting, Rotek Bearings, Ride

Around Platform Mounting 1 ¾ - 12 197,000 5,740

NOTES:

(1) Torque values are for dry threads only.

(2) For plated or lubricated threads, reduce torque values by 25% - 35%.

(3) This chart is valid only for SAE J429/ASTM 354BD/ASTM 490 materials.

RECOMMENDED TORQUE VALUES

BOLT

SIZE

316 SS

TYPICAL USAGE

CLAMP

LOAD

(LBS.)

DRY

TORQUE

(in-LBS.)

¼ - 20 1,570 78.8 Cab Accessories, Plaques, Small Parts

¼ - 28 1,980 99

5/16 – 18 2,210 138 Cab Accessories, Small Parts, Wear Pad

Retainers, Bearing Retainers 5/16 – 24 2,350 147

3/8 – 16 3,390 247 Sheave Pin, Wear Pad, Bearing Retainers, Valve Mounting, Roto-Seal Head, Cab

Accessories 3/8 – 24 3,600 271

7/16 – 14 4,490 393 Motor, Pump, Valve Mounting, Boom

Accessories 7/16 – 20 4,780 418

½ - 13 5,420 542 Motor, Pump, Valve, Reservoir, Pin Locking, Boom Accessories ½ - 20 5,650 565

NOTES:

(1) Torque values are for dry threads only.

(2) For plated or lubricated threads, reduce torque values by 25% - 35%.

(3) This chart is valid only for 304/316 STAINLESS STEEL.