ABCO DOC.: M30110000

REVISION: 0

OPERATIONS MANUAL

750 TON ABCO Traveling Block Assembly

ASSY MODEL NO.: B60G750 AMERICAN BLOCK PART NO: 3036000

ABCO DOC.: M3036

REVISION: 0

TABLE OF CONTENTS

1.0 GENERAL INFORMATION 1.1 Equipment Specifications 1.2 Certificate of Compliance 1.3 Warranty Information 2.0 OPERATION AND ROUTINE MAINTENANCE 2.1 Operation

2.2 Required Routine Maintenance 2.3 Spare Parts List

3.0 ASSEMBLY / DISASSEMBLY 3.1 Disassembly 3.2 Reassembly 3.3 Testing After Reassembly 4.0 ASSEMBLY DRAWING

PAGE 1 - 2

ABCO DOC.: M3036

REVISION: 0

1.0 GENERAL INFORMATION 1.1 Equipment Specifications 1.2 Certificate of Compliance 1.3 Warranty Information

PAGE 1 - 3

ABCO DOC.: M3036

REVISION: 0

1.1 Equipment Specifications

Product Description: 750T Traveling Block Assembly Model Number: B60G750 Maximum Load Rating – Block Assy: 750 Short Tons

Maximum Load Rating – Lifting Beam: 80 Short Tons

Ambient Temperature (for Max. Load Ratings): SEE CERTIFICATE

OF COMPLIANCE Weight of Block Assembly: 31,000 lbs Block: Number of Sheaves: 7 Sheave Diameter (OD): 60.0 inches The 750 Ton Traveling Block Assembly is hereafter called the “block assembly” for simplicity.

PAGE 1 - 5

ABCO DOC.: M3036

REVISION: 0

Remove this page and replace with Certificate of

Compliance

PAGE 1 - 6

ABCO DOC.: M3036

REVISION: 0

1.3 Warranty Information Product information and support is provided during normal business hours by contacting: Manufacturer: American Block Manufacturing Company Address: 6311 Breen Road Houston, Texas 77086 U.S.A Telephone Number: (281) – 820-5332 Facsimile Number: (281) – 820-3861 Internet Address: ABCO@americanblock.com

PAGE 2 - 1

ABCO DOC.: M3036

REVISION: 0

2.0 OPERATION AND ROUTINE MAINTENANCE 2.1 Operation 2.2 Required Routine Maintenance

PAGE 2 - 2

ABCO DOC.: M3036

REVISION: 0

2.1 Operation

All operational instructions reference the block assembly components by item numbers listed in the Assembly drawing 30360000 in Section 5.0.

WARNING: THE BLOCK IS NEITHER DESIGNED NOR INTENDED FOR USE IN MOVING OR LIFTING PEOPLE OR THINGS OVER PEOPLE.

WARNING: MAKE SURE THAT PERSONNEL AND FOREIGN

OBJECTS ARE CLEAR OF THE BLOCK BEFORE START UP. DO NOT REMOVE GUARDS. KEEP HANDS FREE OF MOVING PARTS.

2.1.1 Installation

Remove Screws/Pivot Pins (Lower) and Washers (Items 9 and 24) from the Side Guards (Items 13), swing Side Guards upward and secure them from falling down. String up the 1-3/4” dia wire rope through the Sheaves (Items 15) and the slots in the guards.

Fasten the side guards back in place.

PAGE 2 - 3

ABCO DOC.: M3036

REVISION: 0

2.2 Required Routine Maintenance

Routine maintenance of the block assembly consists of visual inspections performed at the intervals specified below in Section 2.2.1, and periodic lubrication of components as specified in Section 2.2.2.

2.2.1 Inspection Schedule and Procedures 2.2.1.1 Daily Inspection

- For daily inspection, block assembly should NOT be disassembled. - Exterior of entire block assembly should be cleaned to allow

thorough visual inspection of all exterior parts for undue wear on exposed parts, loose items, cracks, or corroded surfaces.

- Wear surfaces and load path components should show only

gradual wear and elongation over short periods of time. Any significant changes in wear patterns or elongation seen during daily inspections should be investigated immediately and corrective action should be completed prior to placing the hook assembly back into service.

- Any deficiencies noted (loose items, corroded surfaces) should be

corrected immediately. - Written and dated records should be kept of all deficiencies noted

and the corrective actions taken and filed with the equipment maintenance records.

- Lubrication of the block assembly components should be performed

as required per Section 2.2.2.

- Written and dated lubrication records should be kept and filed with the equipment maintenance records.

2.2.1.2 Shop Inspection (Six Month Intervals)

- The block assembly should be removed from service and taken to a suitable shop approved by American Block Company for disassembly per procedure in Section 3.1 and thorough cleaning to allow a comprehensive inspection of all internal and external parts.

PAGE 2 - 4

ABCO DOC.: M3036

REVISION: 0

- Once disassembled and cleaned, all external and internal parts

should be visually examined for cracks, corrosion, wear, elongation, and any other signs of damage. Any worn or damaged parts should be noted and replacements ordered from American Block Company (ABCO). American Block Company must approve any repairs to damaged/worn parts in writing prior to starting repair work.

Failure to use American Block approved replacement parts may void ABCO’s warranty. Repair of any worn/damaged part without written approval of repair and reinspection procedures from American Block Company may void ABCO’s warranty.

- A trained and certified operator should inspect all critical load path

components listed below using MPI.

Critical Load Path Items for MPI Inspection: (Reference: Assembly Drawing 30360000 in Section 5.0) Assy Item No. Part Description 1 Frame Weldment 2 Sheaves Shaft 3 Lifting Beam

6 Clevis Pin (Qty 2) 7 Sleeve (Qty 4) 10 Clevis 15 Sheave ( Qty 7) 16 Bearing Assembly ( Qty 7)

- Equipment should be reassembled carefully per procedure in

Section 3.2, replacing any worn or damaged parts noted during visual examination and taking special care to lubricate and/or tighten all parts appropriately during assembly.

- Required shop inspection records include written and dated MPI

inspection results of the critical load path components listed above and written visual observations of all parts inspected. All parts repaired or replaced during shop inspection should have reason for repair/replacement and action taken. All inspection and repaired/replacement part records should be filed with the owner’s equipment maintenance/repair data.

PAGE 2 - 5

ABCO DOC.: M3036

REVISION: 0

2.2.2 Lubrication Schedule and Procedure

2.2.2.1 The block assembly should be lubricated once for every 8 hours of active usage

Apply grease-to-grease fittings at the following locations with a grease gun (Use a Moly-EP quality grease):

Qty (7) grease zerks for Sheave Bearings (see Items 18)

PAGE 2 - 6

ABCO DOC.: M3036

REVISION: 0

2.3 Spare Parts List ITEM NO. DESCRIPTION PART NUMBER QUANTITY

1 SHEAVE BEARING 107-0027 7 2 SHEAVE SEAL 125-0027 14

PAGE 3 - 1

ABCO DOC.: M3036

REVISION: 0

3.0 ASSEMBLY / DISASSEMBLY 3.1 Disassembly 3.2 Reassembly 3.3 Testing After Reassembly

PAGE 3 - 2

ABCO DOC.: M3036

REVISION: 0

3.1 Disassembly

The 750 Ton Traveling Block Assembly can be disassembled into (2) main sub-assemblies, as follows:

1. Block 2. Clevis

3.1.1 Disassembly of Block Sub - Assembly

1. Position and support hook so that block face containing Sheaves Shaft Nut (Item 4) is facing upward and Clevis Sub-Assembly is suitably supported to keep its components from moving and the bottom Housing Side Plate is supported high enough to allow space to remove Sheaves Shaft (Item 2).

2. Remove Items 21 and 22 from retaining the position of the Shaft

Nut (Item 4). 3. Remove fasteners (Item 21,22) and Key (Item 14) from bottom

of Sheaves Shaft (Item 2). 4. Remove fasteners (Items 8) from Lifting Beam (Item 3), and

remove lower Side Sheave Guard fasteners (Items 9 and 24). Remove both Side Sheave Guards (Items 13). Remove Lifting Beam.

5. Remove fasteners (Items 19,20) from Bottom Sheave Guard

(Item 12), and remove the Bottom Sheave Guard.

6. Install 1”-8 UNC threaded eyebolt into center of threaded end of Sheaves Shaft (Item 2). Attach hoisting sling to 1” eyebolt.

7. Partially loosen shaft nut (Item 4).

8. Take the load of the Sheaves Shaft (Item 2) with the hoist/sling

of step (6) above.

9. Fully loosen the Sheaves Shaft Nut (Item 4) and fully lower and withdraw the Sheaves Shaft (Item 2).

PAGE 3 - 3

ABCO DOC.: M3036

REVISION: 0

10. Pick off the spacer (Item 5), sheaves (Items 15), and bearings

(Items 16) from the inside of the Frame. 3.1.2 Disassembly of Clevis

1. Remove fasteners (Items 23,24) from Clevis Pin Lock Plate

(Item 11). 2. Remove Clevis Pins (Item 6) from Frame (Item 1) and Clevis

(Item 10). 3. Remove Clevis (Item 10).

PAGE 3 - 4

ABCO DOC.: M3036

REVISION: 0

3.2 Reassembly

Reassembly is the exact opposite of the previous disassembly instructions. However, the following items should be noted:

3.2.1 Block Reassembly

1. Purge and clean the sheave bearing greasing holes in the Sheaves Shaft (Item 2).

2. Clean and thoroughly inspect the sheave bearings (Items 16). 3. Replace the sheave bearing seals (Items 17). 4. Remove any burrs from the threads of the Sheaves Shaft (Item

2). Fit the mating nut (Items 4) prior to final assembly to assure a free fit.

5. Install all components prior to tightening any bolt or nut.

6. Tighten the Sheaves Shaft Nut (Item 4) first, followed by all

other fastener. Tighten item 4 so that locking fasteners (Items 21 and 22) may be reinstalled at factory supplied positions.

NOTE: THE SHEAVES SHAFT (ITEM 2), AND ASSOCIATED NUT

(ITEM 4), MUST BE TIGHTENED SUFFICIENTLY TO SUFFICIENTLY “CLAMP” THE INNER RACES OF THE SHEAVE BEARINGS (ITEMS 16). USE “NEVER-SEIZE” OR PIPE DOPE ON ALL THREADS TO PREVENT GALLING.

7. Relubricate the sheave bearings.

PAGE 3 - 5

ABCO DOC.: M3036

REVISION: 0

3.3 Testing After Reassembly 3.3.1 Block Sub-Assembly

1. Verify tightness of Lifting Beam (Item 3) retaining fasteners (4x Items 8).

2. Verify tightness of all shaft nut secondary locking screws (Items

21 and 22). 3. Verify adequate greasing of the sheave bearings (Items 16). 4. Verify that sheaves will rotate freely.

3.3.2 Clevis Sub-Assembly

1. Verify tightness of Clevis Pin Locking Plate fasteners (Items 23 and 24).

ABCO DOC.: M3036

REVISION: 0

4.0 FIGURES FIGURE 1: DERATING OF CLEVIS

ABCO DOC.: M3036

REVISION: 0

FIGURE 1: DERATING OF CLEVIS