3553_556_B.pdf

TP: 3553

(HM&E MANUAL)

TECHNICAL MANUAL

HYDRAULIC POWER UNIT (HPU)

MODEL 39496

225’ WLB CLASS CUTTERS

DISTRIBUTION STATEMENT D. – Distribution authorized to Department of Homeland Security, DoD and their contractors to protect publications required for official use or for administrative or operational purposes only;

determined on 7 January 1997. Other requests for this document shall be referred to Commander, USCG Surfaces Forces Logistics Center, ESD – Tech Info Mgmt Br, 2401 Hawkins Point Road, Baltimore, MD 21226.

WARNING – This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979 (Title 50, U.S.C., App. 2401 et seq.), as amended. Violations of these export laws are subject to severe criminal penalties.

DESTRUCTION NOTICE. - For unclassified, limited documents, destroy by any method that will prevent disclosure of contents or reconstruction of the document.

PUBLISHED UNDER AUTHORITY OF THE U.S. COAST GUARD

SWBS 556

SECTION B

Department of Homeland Security

UNITED STATES

COAST GUARD

Individual Manual Application Sheet

Technical Publications Number

Secton Applicability

SWBS Number 556 SWBS Element Title HYDRAULIC FLUID SYSTEM

Section Identifier B

Equipment Functional Description

HYDRAULIC POWER UNIT (HPU) -

MODEL 39496

CI Functional Description ESWBS Code Remarks

Planset Hulls

225-WLB 201, 202, 203, 204, 205

APPLICABILITY NOTICE

This section applies to 225’ A-Class Buoy Tenders that have not had the HPU Pump Replacement Kit, P/N 49531, installed per

Engineering Change 225-A-085.

For those cutters that have had this replacement kit installed, see Technical

Publication 4634

TECHNICAL MANUAL

HYDRAULIC POWER SYSTEM

MODEL HPU

MANUFACTURED BY

ALLIED SYSTEMS COMPANY

SHERWOOD, OR U.S.A.

CONTRACT NO. DTCG 23-93-C-AWL401

U.S. COAST GUARD

SEAGOING BUOY TENDER

WLB JUNIPER CLASS

01 NOVEMBER 1996

CHANGE 1 – 15 FEBRUARY 1999

CHANGE 2 – 22 FEBRUARY 2006

FOR OFFICIAL USE ONLY

A Change 2

LIST OF EFFECTIVE PAGES

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

NOTE: The portion of the text, tables, and figures affected by the changes are indicated by a vertical line in the outer margin of the page.

Date of issue for original and changed pages are:

Original......................0 .................. 01 Nov 1996 Change.......................1 .................. 15 Feb 1999 Change ......................2 .................. 22 Feb 2006

PAGES IN THIS PUBLICATION, CONSISTING OF THE FOLLOWING:

Page No. Chg. No.* Page No. Chg. No.*

Title Page List of Effective Pages Change Record Validation Certificate Foreward/List of Abbreviations/Acronyms i thru iii iv thru v vi thru ix x 1-1 1-2 thru 1-3 1-4 1-5 thru 1-6 2-1 thru 2-6 3-1 3-2 thru 3-4 3-5 3-6 3-7 thru 3-8 3-9 thru 3-10 3-11 thru 3-12 3-13 3-14 thru 3-16 3-17 thru 3-28 3-29 thru 3-30 3-31 thru 3-32 3-33 thru 3-42 3-43 thru 3-48 4-1 thru 4-3 4-4 4-5 thru 4-6 5-1 thru 5-2 6-1 thru 6-2 6-3 6-4 thru 6-12 7-1 7-2 7-3 thru 7-4 7-5 thru 7-7 7-8 thru 7-9

(*) Zero indicates an original page

7-10 7-11 thru 7-13 7-14 thru 7-17 7-18 7-19 7-20 7-21 thru 7-22 7-23 7-24 7-25 thru 7-26 7-27 thru 7-28 7-29 thru 7-35 7-36 thru 7-37 7-38 thru 7-39 7-40 7-41 thru 7-43 7-44 thru 7-47 7-48 7-49 7-50 7-51 thru 7-52 7-53 7-54 7-55 thru 7-56 7-57 thru 7-58 7-59 thru 7-65 7-66 7-67 7-68 thru 7-91 (Deleted) 7-92 7-93 thru 7-98 7-99 thru 7-100 7-101 7-102 thru 7-105 7-105a 7-106 thru 7-109 7-110 thru 7-113 7-114 8-1 8-2 Index 1 thru index 2

Change 2

CHANGE RECORD

CHANGE

NO.

DATE TITLE AND / OR

BRIEF DESCRIPTION

SIGNATURE

02/15/99

02/22/06

Minor changes to some schematics.

Numerous changes to Chapter 7, including relay kits to control box panels and the modified HPU tanks. All parts lists now reflect as built.

The purpose of this change is to edit text and figures that reference HPU-3 (SORS Transfer), which was removed.

APPROVAL AND PROCUREMENT RECORD

APPROVAL DATA FOR:

TITLE OF MANUAL: HYDRAULIC POWER SYSTEM, MODEL HPU

APPROVAL AUTHORITY: SUPERVISOR OF SHIPBUILDING, CONVERSION

AND REPAIR, US COAST GUARD

CONTRACT SHIP QUANTITY QUANTITY BUILDING

NUMBER APPLICABILITY OF OF YARD

MANUALS EQUIPMENT

DTCG WLB Juniper 29 copies plus 1 system per ship Marinette 23-93-AWL401 Class 1 Camera Marine ready copy Corp.

Marinette, WI

54143

REMARKS:

Alvlh�

- qW

CERTIFICATION: UA I F-:

IT IS HEREBY CERTIFIED THAT TO BE PROVIDED UNDER

CONTRACT NUMBER DTCG 23-93-C-AWL401 HAS BEEN APPROVED BY THE APPROVAL

AUTHORITY SHOWN ABOVE.

Al I&Zysterns Co.

Allied Marine Crane Division 230b N.E. Oregon Street Sherwood, Oregon 97140-9799

CAGE: 60848

INTENTIONALLY BLANK

TECHNICAL MANUAL VALIDATION CERTIFICATE

TECHNICA.L MANUAL TITLE

HYDRAULIC POWER SYSTEM--MODEL BPU CHANGE1

COAST GUARD TECENICAL PUBLICATION NUMBER DATE

3553 MMC P/N 556-01-E4 TAB A 02/15199

CONTRACT/TMCR NO. DTCG23-93-C-AW1A01(WLB)

I - VALIDATION

Except as stated in II, the technical manual identified above has been satisfactorily validated in accordance with all require---.--.-.'--of the applicable TMCR and the approved Validation Plan. The technical manual is hereby certified to be accurate and complete, and the information, instructions, text and illustrations conforrn in all respects to the applicable general and detailed specifications.

II-EXCEPTIONS

EXCEPTIONS AUTHORIZED BY

SIGNATURE OF PUBLICATIONS QUALJTY ASSURANCE OFFICER DATE

.�� I

OA I J'q�- I qq

FOREWORD

This technical manual includes installation, operation, maintenance, and repair instructions, with a parts list, for the HYDRAULIC POWER SYSTEM equipment aboard WLB JUNIPER class ships. This manual covers the following:

Chapter No . . . . . . . . . . . . . . . . . . . . Title

1 . General Information and Safety Precautions 2 . . . . . . . . . . . . . . . . . . . . . . Operation 3 . . . . . . . . . . . . . . . Functional Description 4 . . . . . . . . . . . . . . Scheduled Maintenance 5 . . . . . . . . . . . . . . . . . . . Troubleshooting 6 . . . . . . . . . . . . . . . Corrective Maintenance

7 . . . . . . . . . . . . . . . . . . . . . . . Parts List 8 . . . . . . . . . . . . . . . . . . . . . . Installation

"Ships, training activities, supply points, depots, and Supervisors of Shipbuilding are requested to arrange for the maximum practical use and evaluation of U.S. Coast Guard technical publications.

All errors, omissions, discrepancies, and suggestions for improvement to U.S. Coast Guard technical publications shall be reported to the Commander, U.S. Coast Guard."

LIST OF ABBREVIATIONS/ACRONYMS

Adj . . . . . . . . . Adjust/Adjustable ADV . . . . . . . . Advance AIR . . . . . . . . . As Required ASC . . . . . . . . Allied Systems Company Asm/Assy . . . . . Assembly Aux . . . . . . . . . Auxiliary CAGE . . . . . . . Commercial And Government Entity CIC . . . . . . . . . Channel Index Change cid . . . . . . . . . cubic inch displacement COM AL ACK . . . Common Alarm Acknowledgment Cpscr . . . . . . . . Capscrew CW . . . . . . . M . Clockwise CCW . . . . . . . . Counter-Clockwise DIN . . . . . . . . . Deutsche International Norm ESNA . . . . . . . . Elastic Stop Nut Association F . . . . . . . . .. Fahrenheit C . . . . . . . . . .Celsius FSCM . . . . . . . Federal Supply Code for Manufacturers G/GR . . . . . . . . Grade Gal . . . . . . . . . Gallon Gnd . . . . . . . . . Ground GPM . . . . . . . . Gallon Per Minute Hd . . . . . . . . . Head He[ . . . . . . . . . Helical HP . . . . . . . . . Horse Power HPU . . . . . . . . Hydraulic Power Unit Hyd . . . . . . . . . Hydraulic Hz . . . . . . . . . Hertz (cycles per second) IEEE . . . . . . . . Institute of Electrical and Electronics Engineers Instl . . . . . . . . . Installation kPa . . . . . . . . . kilopascal KW . . . . . . . . . Kilowatt

LED . . . . . . . . . Light Emitting Diode -continued on next page -

LIST OF ABBREVIATIONS/ACRONYMS (continueD

... Machine/Machinery

. . . Maximum

. . . 0.001 millimeter

. . . Normally Closed/National Coarse

. . . National Electrical Manufacturer's Association

. . . National Fine

. . . National Lubrication Grease Institute

. . . Newton-meter

. . . Normally Open

. . . Not Serviced Separately . . . Pressure Compensator . . . Part Number . . . Potentiometer . . . Pressure

. Program . . . pounds per square inch . . . Provisioning Technical Documentation . . . Quantity . . . Round . . . Reference

Relay . . . Revolutions Per Minute . . . Society of Automotive Engineers . . . Silicon Controlled Rectifier/Screw . . . Spilled Oil Recovery System . . . Spring . . . Stainless Steel . . . Switch . . . Temperature . . . Terminal . . . Technical Manual Contract Requirement . . . Volts Alternating Current

Mach Max micron

NC

NEMA

NF

NLGI

Nm

NO

NSS

PC

P/N Pot Press

PROG

psi

PTD

Qty Rd Ref Rel

RPM

SAE

SCR

SORS

Spr Ss

SW

Temp Term

TMCR

VAC

TABLE OF CONTENTS

i

PAGE CHAPTER/PARAGRAPHCHAPTER/PARAGRAPH PAGE

Hydraulic Tank Filtration Oil Cooler

ELECTRICAL SYSTEM

Reduced Voltage Starters . .

Motor0verload Protection .

. . . 3-2

. . 3-13

. . 3-13

. . 3-13

. . 3-13

. . 3-14

. . 3-14

. . 3-14

. . 3-14

. . 3-14 . . 3-14 . . 3-14 . . 3-14 . . 3-14 . . 3-14 . . 3-14

3-3.2 3-3.3

1-1 3-3.4 1-1 3-4 1-1 3-4.1 1-1 3-4.2 1-2 3-4.3 1-2 3-4.4 1-2 3-4.5 1-2 3-4.5.1 1-2 3-4.5.2 1-2 3-4.5.3

3-4.5.4 I i r

SAFETY PRECAUTIONS

Warnings And Cautions ...

General Safety Precautions General Rules

INTRODUCTION

Purpose Scope . . . . . . . . . . . . . . . . .Applicability

SHIPBOARD MAINTENANCE

Scope

INTERMEDIATE AND DEPOT

MAINTENANCE

EQUIPMENT DESCRIPTION

Overall Capabilities Physical Data Electric Motors Hydraulic Pumps Control Panel Hydarulic Reservoir (Tank) Oil Temperature Control

Filtration Motor Starters

OPERATION

INTRODUCTION

GENERAL . . . . . . . . . . . . . . . .INSTRUMENTS AND CONTROLS

PRE-OPERATION CHECKS

STARTING THE HPU

STOPPING THE HPU

HYDRAULIC TEMPERATURE MONITOR

1-1

1-1.1 1-1.2 1-1.3 1-2 1-2.1 1-2.2 1-2.3 1-3 1-3.1 1-4

1-5 1-5.1

1-5 '2 1-5.3

1-5 '4 1-5.5

- 1-5.6 1-5.7 1-5.8 1-5.9

2-1 2-2 2-3 2-4 2-5 2-6 2-7

%.�VIIUUI %.III full

Space Heaters Indicator And Warning Lights . . .

POWER ON Light Filter Indicator Lights Tank Level Warning Light LOW PRESSURE Warning Light OPEN SENSOR Warning Light Hydraulic Temperature Monitor .

Hydraulic Tank Heater Controller

3-4.5.E

3-4.5.E 3-4.5.7

1-2 1-2 1-2 1-2 1-4 1-4 1-4 1-4 1-4 1-4 1-4

2-1 2-1 2-1 2-3 2-3 2-3 2-4

SCHEDULED MAINTENANCE

4-1 GENERAL ................. 4-1

4-2 PREVENTIVE-MAINTENANCE ...... 4-1

4-3 SCHEDULED MAINTENANCE

RECOMMENDATIONS .......... 4-1

4-3.1 Walk Around Inspection ......... 4-1 4-3.2 Lubricant Specifications ......... 4-1 4-3.3 Scheduled Maintenance Instructions . .4-1

4-4 HYDRAULIC OIL MAINTENANCE .... 4-3

4-4.1 Storage & Handling ........... 4-3 4-4.2 In-Operation Care ............ 4-3 4-4.3 Determining Oil Condition ....... 4-4

4-5 EXTENDED STORAGE PRO .4-

4-6 ELECTRIC MOTOR STORAGE ...... 4-4

4-6.1 Electric Motor Storage Auxiliary Heat .4-4 4-6.2 Electric Motor Storage Maintenance . .4-4 4-6.3 Extended Electric Motor Storage .... 4-5

3 FUNCTIONAL DESCRIPTION

INTRODUCTION

PHYSICAL DATA

Electric Motors Hydraulic Pumps Pump Relief/Unloader Valve Hydraulic Reservoir (Tank) Oil Temperature Control . .

Filtration Control Panel Motor Starters

OPERATIONAL DESCRIPTION

Hydraulic Pump

3-1

3-1

3-1

3-1

3-2 3-2 3-2 3-2 3-2 3-2 3-2 3-2

3-1

3-2 3-2.1 3-2.2 3-2.3 3-2.4 3-2.5 3-2.6 3-2.7 3-2.8 3-3 3-3.1

INTRODUCTION ............. 5-1

Purpose . . . . . . . . . . . . . . . . . 5-1 Scope . . . . . . . . . . . . . . . . . . 5-1 Safety . . . . . . . . . . . . . . . . . . 5-1 Problem Area Isolation . . . . . . . . . 5-1

PRELIMINARY TROUBLESHOOTING . .5-1

Preliminary Checks . . . . . . . . . . . 5-1 Probable Mechanical Causes . . . . . . 5-1 Probable Hydraulic Causes . . . . . . . 5-1 Probable Electrical Causes . . . . . . . 5-1

5-1 5-1.1 5-1.2 5-1.3 5-1.4 5-2 5-2.1 5-2.2 5-2.3 5-2.4

1 GENERAL INFORMATION

5 TROUBLESHOOTING

TABLE OF CONTENTS (continued)

CHAPTER/PARAGRAPH

6 CORRECTIVE MAINTENANCE

6-1 INTRODUCTION

6-1.1 Purpose 6-1.2 Scope 6-1.3 Arrangement 6-1.4 Tools And Equipment 6-1.5 Corrective Maintenance Notes . . .

6-2 ADJUSTMENTS

6-2.1 Unloader/Relief Valve 6-2.2 Pump Control Adjustment 6-2.3 Pump Control Adjustment 6-2.4 Reduced Volt. Motor Starter Adjust.

6-2.5 Torque Adjustment 6-2.6 Acceleration Time Adjustment . . .

6-2.7 Current Limit Adjustment 6-2.8 Hydraulic Oil Heater Temperature

Control Calibration 6-2.8.1 Full Range Calibration 6-2.8.2 Single Point Calibration

6-3 REPAIR

6-3.1 Pump Service 6-3.1.1 Hydraulic Pump (V40-110/140) .

6-3.1 � 1. 1 Disassembly

6-3.1.1.2 Inspection of Components 6-3.1.1.3 Assembly 6-3.1.2 Hydraulic Pump (P30) 6-3.1.2.1 Disassembly 6-3.1.2.2 Inspection of Components 6-3.1.23 Assembly

PAGE CHAPTER/PARAGRAPH PAGE

7 PARTS LIST

7-1

7-1

6-1

6-1

6-1

6-1

6-1 6-2 6-2 6-3 6-3 6-3 6-4 6-4 6-4 6-4

6-4 6-4 6-5 6-5 6.-5

6-5 6-5 6-7 6-7

6-10 6-10 6-11 6-11

7-1

7-1.1

7-1.2 7-2 7-3 7-4 7-4.1 7-4.2 7-4.3 7-4.4 7-4.5 7-4.6 7-4.7 7-4.8 7-4.9

INTRODUCTION

General

Subassemblies & Components

LIST OF MAJOR COMPONENTS

LIST OF MANUFACTURERS

PARTS LIST

Form at

Item N otes

ASC P/N

Q ty

Description C A G E Manufacturer's P/N Compliance with Provisioning Technical Documentation

7-1

7-1

7-3 7-5 7-5 7-5 7-5 7-5 7-5 7-5 7-5 7-5

7-5

8-1 8-2 8-3 8-4 8-5 8-6 8-7

GENERAL ................. 8-1

HYDRAULIC SYSTEM CONNECTIONS , 8-1

ELECTRICAL SYSTEM CONNECTIONS 8-1

PRESTART CHECKS ........... 8-1

INITIAL START-UP ............ 8-1

POSTSTART CHECKS .......... 8-2

PREPARATION FOR RESHIPMENT ... 8-2

8 INSTALLATION

LIST OF ILLUSTRATIONS

iii

FIGURE FIGURE PAGEPAGE

Hydraulic Power Unit HPU-11-1 Component Identification . . . . . . . . 1-3 1-2 Hydraulic Power Unit

Interconnecting Diagram . . . . . . . . 1-5 2-1 Control Box (typical) . . . . . . . . . . 2-1 2-2 Starter Box (typical) . . . . . . . . . . . 2-2 2-3 Temperature Monitor

Front Panel Identification . . . . . . . . 2-4 3-1 Typical Hydraulic Power Unit . . . . . . 3-1 3-2 Pressure Compensator

Control Schematic . . . . . . . . . . . . 3-2 3-3 Hydraulic Power Unit

Interconnecting Diagram . . . . . . . . 3-5 3-4 Hydraulic System Schematic

HPU-1 & HPU-2 . . . . . . . . . . . . . 3-7

3-5 Hydraulic System Schematic

HPU-3 . . . 3-9

3-6 Hydraulic System Schematic

HPU-4 . . . . . . . . . . . . . . . . . . 3-11

3-7 Pressure Control Diagram . . . . . . . . 3-13 3-8 Start Control Circuit Schematic . . . . . 3-13 3-9 Starter Electrical Schematic . . . . . . . 3-15 3-10 Electrical Schematic, HPU-1 & HPU-2 . . . . . . . . . . . . . 3-17

3-11 Electrical Schematic, Starter Box (1) (HPU-1 & HPIJ-2) . . . . . 3-19 3-12 Electrical Schematic, Starter Box (2) (HPU-1 & HPU-2) . . . . 3-21 3-13 Wiring Diagram, Control Box Door, HPU-11 & HPU-2 . . . 3-23 3-14 Electrical Schematic, HPIJ-3 . . . . . . 3-29 3-15 Electrical Schematic, HPLI-4 . . . . . . 3-31 3-16 Electrical Schematic, Starter Box (1 & 4) (HPU-3 & HPU-4) . . . . 3-33 3-17 Electrical Schematic, Starter Box (2,3 & 5) (HPU-3 & H PU-4) 3-35 3-18 Wiring Diagram, Control Box Door, HPIJ-3 . . . . . . . . 3-37 3-19 Wiring Diagram, Control Box Door, HPU-4 . . . . . . . . 3-43 4-1 Scheduled Maintenance Diagram . . . 4-2 6-1 Pump Control Adjustment . . . . . . . . 6-3 6-2 Motor Starter Adjustment Locations 6-4 6-3 Temperature Controller

Potentiometer Location . . . . . . . . . 6-5 6-4 Hydraulic Pump (V40-110/140) . . . . . 6-6 6-5 Special Tools: Collar 1 and Collar 2 . . 6-8 6-6 Determining Shim Thickness . . . . . . 6-9 6-7 Hydraulic Pump (P30) . . . . . . . . . . 6-10

Hydraulic Power Unit Hydraulic Tank Assembly . . .

Frame Assembly Motor/Pump Assembly Motor/Pump Assembly Hydraulic Pump (V40-140) - - Hydraulic Pump (P30) Hydraulic Pump (V40-1 10) Hydraulic Pump (V40-1 1 0) Hydraulic System Case Drain Flush System . . .

High Pressure Hydraulic Filter Return Hydraulic Filter Suction Strainer Electrical System Starter Unit Starter Box Assembly (1) � - - Starter Box Assembly (2) . . .

Control Box Assembly Control Box Panel Assembly Power Box Assembly

. . . . . . 7-7

. . . . . . 7-8 7-10 7-12 7-13 7-14 7-15 7-16 7-17 7-18 7-21 7-22 7-23 7-24 7-25 7-27 7-28 7-30 7-32 7-34 7-36

7-1

7-2 7-3 7-4 7-5 7-6 7-7 7-8 7-9 7-10 7-11 7-12 7-13 7-14 7-15 7-16 7-17 7-18 7-19 7-20 7-21

Hydraulic Power Unit HPU-2

Hydraulic Power Unit . . . . . . . . . . 7-37 Hydraulic Tank Assembly . . . . . . . . 7-38 Frame Assembly . . . . . . . . . . . . 7-40 Motor/Pump Assembly . . . . . . . . . 7-42 Motor/Pump Assembly . . . . . . . . . 7-43 Hydraulic Pump (V40-140) . . . . . . . 7-44 Hydraulic Pump (P30) . . . . . . . . . 7-45 Hydraulic Pump (V40-1 1 0) . . . . . . . 7-46 Hydraulic Pump (V40-1 10) . . . . . . . 7-47 Hydraulic System . . . . . . . . . . . . 7-48 Case Drain Flush System . . . . . . . . 7-51 High Pressure Hydraulic Filter . . . . . 7-52 Return Hydraulic Filter . . . . . . . . . 7-53 Suction Strainer . . . . . . . . . . . . . 7-54 Electrical System . . . . . . . . . . . . 7-5� Starter Unit . . . . . . . . . . . . . . . 7-57 Starter Box Assembly (3) . . . . . . . . 7-58 Starter Box Assembly (4) . . . . . . . . 7-60 Control Box Assembly . . . . . . . . . 7-62 Control Box Panel Assembly . . . . . . 7-64 Power Box Assembly . . . . . . . . . . 7-66

7-22 7-23 7-24 7-25 7-26 7-27 7-28 7-29 7-30 7-31 7-32 7-38 7-34 7-35 7-36 7-37 7-38 7-39 7-40 7-41 7-42

Change 2 iv

LIST OF ILLUSTRATIONS

FIGURE

7-59 7-60 7-61 7-62 7-63 7-64 7-65 7-66 7-67 7-67a 7-68 7-69 7-70 7-71 7-72

PAGE

Hydraulic Power Unit HPU-4

Hydraulic Power Unit .......................7-93 Hydraulic Tank Assembly ................7-96 Motor/Pump Assembly ....................7-98 Hydraulic Pump (V40-110) ..............7-99 High Pressure Hydraulic Filter .........7-100 Return Hydraulic Filter .....................7-101 Suction Strainer ...............................7-102 Panel Assembly...............................7-103 Electrical System .............................7-104 Starter Unit ......................................7-105a Starter Box Assembly (4).................7-106 Starter Box Assembly (5).................7-108 Control Box Assembly .....................7-110 Panel Assembly, Control Box ..........7-112 Power Box Assembly.......................7-114

Change 2 v

LIST OF TABLES

TABLE

1-1 3-1

4-1 5-1 6-1 6-2 7-A 7-B

7-1 7-2 7-3 7-4 7-5 7-6 7-7 7-8 7-9 7-10 7-11 7-12 7-13 7-14 7-15 7-16 7-17 7-18 7-19 7-20 7-21

7-22 7-23 7-24 7-25 7-26 7-27 7-28 7-29 7-30 7-31 7-32 7-33 7-34 7-35 7-36 7-37 7-38 7-39 7-40 7-41 7-42

Reference Data ........................................1-4 Hydraulic Pump Performance Curves ......................................................3-3 Scheduled Maintenance Chart .................4-2 Troubleshooting Table..............................5-2 Tools and Equipment................................6-1 Hydraulic Pressure Settings .....................6-3 List of Major Components.........................7-1 List of Manufacturers ................................7-3

Hydraulic Power Unit, HPU-1

Hydraulic Power Unit Parts List ................7-7 Hydraulic Tank Assembly Parts List .........7-9 Frame Assembly Parts List.......................7-11 Motor/Pump Assembly Parts List..............7-12 Motor/Pump Assembly Parts List..............7-13 Hydraulic Pump (V40-140) Parts List .......7-14 Hydraulic Pump (P30) Parts List...............7-15 Hydraulic Pump (V40-110) Parts List .......7-16 Hydraulic Pump (V40-110) Parts List .......7-17 Hydraulic System Parts List......................7-19 Case Drain Flush System Parts List .........7-21 High Pressure Hydraulic Filter Parts List ..7-22 Return Hydraulic Filter Parts List ..............7-23 Suction Strainer Parts List ........................7-24 Electrical System Parts List ......................7-26 Starter Unit Parts List ...............................7-27 Starter Box Assembly (1) Parts List..........7-29 Starter Box Assembly (2) Parts List..........7-31 Control Box Assembly Parts List ..............7-33 Control Box Panel Assembly Parts List ....7-35 Power Box Assembly Parts List................7-36

Hydraulic Power Unit, HPU-2

Hydraulic Power Unit Parts List ................7-37 Hydraulic Tank Assembly Parts List .........7-39 Frame Assembly Parts List.......................7-41 Motor/Pump Assembly Parts List..............7-42 Motor/Pump Assembly Parts List..............7-43 Hydraulic Pump (V40-140) Parts List .......7-44 Hydraulic Pump (P30) Parts List...............7-45 Hydraulic Pump (V40-110) Parts List .......7-46 Hydraulic Pump (V40-110) Parts List .......7-47 Hydraulic System Parts List......................7-49 Case Drain Flush System Parts List .........7-51 High Pressure Hydraulic Filter Parts List ..7-52 Return Hydraulic Filter Parts List ..............7-53 Suction Strainer Parts List ........................7-54 Electrical System Parts List ......................7-56 Starter Unit Parts List ...............................7-57 Starter Box Assembly (3) Parts List..........7-59 Starter Box Assembly (4) Parts List..........7-61 Control Box Assembly Parts List ..............7-63 Panel Assembly, Control Box Parts List ...7-65 Power Box Assembly Parts List................7-66

TABLE

7-59 7-60 7-61 7-62 7-63 7-64 7-65 7-66 7-67 7-67a 7-68 7-69 7-70 7-71 7-72

Hydraulic Power Unit HPU-4

Hydraulic Power Unit Parts List ................7-93 Hydraulic Tank Assembly Parts List .........7-96 Motor/Pump Assembly Parts List..............7-98 Hydraulic Pump (V40-110) Parts List........7-99 High Pressure Hydraulic Filter Parts List ..7-100 Return Hydraulic Filter Parts List ..............7-101 Suction Strainer Parts List ........................7-102 Panel Assembly Parts List ........................7-103 Electrical System Parts List ......................7-104 Starter Unit Parts List................................7-105a Starter Box Assembly (4) Parts List ..........7-106 Starter Box Assembly (5) Parts List ..........7-108 Control Box Assembly Parts List...............7-110 Panel Assembly, Control Box Parts List ...7-112 Power Box Assembly Parts List ................7-114 v i

WHENEVER POTENTIAL PERSONAL INJURY

OR DEATH SITUATIONS EXIST REQUIRING

CORRECT PROCEDURES OR PRACTICES

FOR PREVENTION, THIS 'WARNING"

SYMBOL IS USED. THIS SAFETY ALERT

SYMBOL INDICATES IMPORTANT SAFETY

MESSAGES IN THIS MANUAL. WHEN YOU

SEE THIS SYMBOL, CAREFULLY READ THE

MESSAGE THAT FOLLOWS AND BE ALERT

TO THE POSSIBILITY OF PERSONAL INJURY

OR DEATH.

GENERAL SAFETY NOTICES

The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual. They are recommended precautions that must be understood and applied during operation and maintenance of the equipment covered herein. Should situations arise that are not covered in the genera or specific safety precautions, the commanding officer or other authority will issue orders as deemed necessary to cover the situation.

This equipment can be dangerous it operated or maintained incorrectly. The equipment, as all hydraulically operated mechanical equipment, must be operated by experienced and trained personnel. Any equipment is only as safe as its operator.

SAFETY TERMS

The following terms define the various precautions and notices in this manual:

NOTE: Whenever information exists that requires additional emphasis beyond the standard text, the term "NOTE" is used.

IMPORTANT: Whenever information exists that requires special attention to procedures or to ensure proper operation of the equipment, or to prevent its possible failure, the term "IMPORTANT" is used.

CAUTION: Whenever potential damage to equipment exists requiring correct procedures for prevention, the term "CAUTION" is used.

NOTE: All possible safety hazards cannot be foreseen so as to be included in this.

manual. Therefore, the operator must always be alert to possible hazards that could endanger personnel or damage the equipment.

OPERATION SAFETY

OPERATORTRAINING

You must be trained in the operation of this equipment prior to operation.

Be extremely careful if you do not normally operate this equipment. Re-orient yourself to the equipment before starting, and then proceed slowly. However, you must not operate without having received proper training.

DO NOT OPERATE ALONE

Never operate this equipment alone. It is essential that someone be on the deck to give hand signals and watch clearances. Be certain that he's clear of the crane and load before you move it. Never move the crane or load if your signaler is out of sight. He's your eyes and ears.

GENERAL OPERATION SAFETY

Do not operate this equipment if you know of malfunctions, missing parts, and/or mis-adjustments.

These situations can cause or contribute to an accident or damage to the equipment. Lower the load and stop the crane immediately if problems arise after starting.

Do not start the electric motor if the "start" switch has been tagged with a "DO NOT START" or "RED" tag.

Be aware that the load capacity of the crane can vary with changes in boom position, load, and the position of the attachments. Do not exceed the rated load of this crane.

Never allow anyone under the load. Sound the warning horn and wait for the area to be cleared before moving the crane or load.

Never attempt any lifting operation with fewer than three wrapsofcableonthewinchdrum. Cableclampsarenot designed to hold loads, Never attempt to dismantle any of the safety devices built into the equipment. This may include, but is not limited to, the winch up and down limit controls, anti-2-block system, and the overload safety system.

vii

SAFETY SUMMARY

SAFETY SUMMARY 0Never swing the load over anyone.

When swinging the boom, always be sure that the boom has adequate clearance for both the boom and the power pack or operator's plaff orm.

Always operate within the capacity of the equipment and its reeving components. Do not overload this equipment. Refer to the hydraulic capacity chart and the reeving capacity chart for the equipment's lifting capacity.

Inspect often any slings, chokers and other rigging devices for cuts, abrasion, rust, kinks or other damage.

Do not use any suspect equipment to lift or move a load.

Destroy any obviously damaged slings or chokers. They are not worth the risk.

Always wear appropriate safety clothes and equipment.

This includes hard hat, safety shoes, gloves, eye protection, etc.

Be a6curate in load placement; Ws important to know what the load will do when it's released.

Lower or remove the load before leaving the equipment or shutting down the electri& motor.

Electrical energy under high voltage can discharge to ground through the equipment without direct contact with the equipment's.structure. Minimum clearances from energized power lines or other power sources must be maintained. If electrical energy does discharge through the equipment, stay clear of the equipment.

Do not permit anyone to come into contact with the equipment's structure.

MAINTENANCE AND SERVICE SAFETY

DO NOT REPAIR OR ADJUST ALONE

Under no circumstances should repair or adjustment of energized equipment be attempted alone. The immediate presence of someone capable of rendering aid is required.

Before making adjustments, be sure to protect against grounding. If possible, adjustments should be made with one hand, with the other hand free and clear of equipment. Even when power has been removed from equipment circuits, dangerous potentials may still exist due to retention of charges by_capacitors. Circuits must be grounded and all capacitors must be discharged prior to attempting repairs.

QUALIFIED PERSONNEL

Maintenance, lubrication and repair of this equipment can be dangerous unless performed properly. Each person must have the necessary skills and information, proper tools and equipment, and work safely.

Do not attempt to make adjustments, or perform maintenance or service unless you are authorized and qualified to do so.

TEST EQUIPMENT

Make certain test equipment is in good condition. If a test meter must be held, ground the case of the meter before starting measurement; do not touch live equipment or personnel working on live equipment while holding a test meter. Some types of measuring devices should not be grounded; these devices should not be held while taking measurements.

HEAVY EQUIPMENT

To avoid personal injury or equipment damage, use a lifting device with a lifting capacity greater than twice the weight of any item to be lifted.

PRESSURIZED EQUIPMENT

Wear safety goggles when working on or near equipment that is or may be pressurized.

Before disconnecting hydraulic lines, be sure to lower all loads and relieve all hydraulic pressure. The load could fall on you, or escaping hydraulic oil could cause severe personal injury. Never try to stop a hydraulic leak with any part of your body.

REMOVE LOADS AND SHUT-OFF POWER

Never rely on the hydraulic system to support any part of the equipment during maintenance or lubrication. If necessary, support components with appropriate safety stands. Never stand under a component that is supported only by the hydraulics. Make sure it is resting on its mechanical stops.

Never attempt maintenance or lubrication procedures while the equipment is moving or the electric motor is running.

Unless otherwise directed by this manual, never attempt maintenance or repair procedures while the main power to the equipment is ON.

Tag the "start" switch and/or disconnect switch with a "DO NOT START" sign when required.

viii

Ix

ONLY QUALIFIED PERSONNEL SHOULD

TROUBLESHOOT AND PERFORM REPAIRS

AND ADJUSTMENTS TO ELECTRI AL

SYSTEMS. (Page 5-2)

IP ELECTRICAL HAZARDS

Service personnel must at all times observe all safety regulations. Do not replace components or make adjustments inside the equipment with the high voltage supply energized. Under certain conditions, dangerous potentials, due to the charges retained by capacitors may exist when power is off. To avoid casualties, always disconnect the power and discharge the circuit before touching it.

The electrical system uses 460 volt, 3 phase power. An electric shock could be fatal. Do not attempt electrical repairs unless you are qualified to do so. Make sure that the power to the equipment is OFF before opening the electrical box(s). Never attempt electrical testing or repairs while standing in water.

Under no circumstance should any person reach into an enclosure for the purpose of servicing or adjusting the equipment when not in the company of someone who is capable of rendering aid in the event of accidental shock.

Personnel working with or near high voltage should remove watches, rings, or any jewelry that could accidentally make physical contact with circuits.

Personnel working with high or near high voltage should be familiar with modern methods of resuscitation. Such information may be obtained from the Bureau of Medicine and Surgerv.

HOT OIL HAZARD

Use caution when working around hot oils. Always allow lubricating and hydraulic. oil to cool before draining.

Burns can be severe.

FIRE PREVENTION

Hydraulic oil is flammable. Do not smoke when checking or filling the tank. Keep open flames and sparks away from the equipment.

Keep the equipment free of oil, grease and dirt accumulations. Regular steam cleaning is recommended for fire prevention and general safety.

Never overfill the hydraulic tank. Any overflow could contribute to a fire. Immediately repair any hydraulic leaks and clean up any spills.

COMPRESSED AIR SAFETY

Use extreme caution when using compressed air to blow parts dry' The pressure should not exceed 30 psi (208 kPa). Neverusecompressedairtoblowyourselfoff. Air pressure penetrating your skin can be fatal.

FALLING HAZARD

Always lower the equipment as far as possible before attempting to perform repairs or service. Due to the height of the upper lube points, it is essential to personnel safety that safe ladders, personnel lifts and/or scaffolding be used while servicing this equipment.

Always use safety tread walks and handholds where provided. The equipment can be dangerously slick under conditions of rain, frost or oil smears.

WARNINGS AND CAUTIONS

Generalized warnings and cautions applying to the equipment in this manual are summarized below and repeated throughout the manual.

CAUTION: Do Not Overfill. (Page 4-1)

CAUTION: To prevent overheating the element, the tank heater must be submerged whenever it is energized. Avoid energizing the heater whenever it is not submerged. The low oil level sensor interrupts power to the heater when the level is too low. (Page 4-1)

CAUTION: Disconnected hydraulic lines must be covered to prevent y rau c system contamination. Make sure open ports on hydraulic components including hoses, tubing, and fittings are either capped or plugged during installation, maintenance and repair procedures. (Page 4-3)

CAUTION: If any of the hydraulic components generates excessive heat (above 1800 F), discontinue operation immediately and determine the cause of the overheating. (Page 5-1)

SAFETY SUMMARY

Change 2 x

CAUTION: Disconnected hydraulic lines must be covered to prevent hydraulic system contamination. Make sure open ports on hydraulic components, including hoses, tubing, and fittings, are either capped, plugged, or taped-over during installation, maintenance and repair procedures.

(Page 6-2)

CAUTION: Do not use cleaning solvents on any hydraulic o-rings, seals, packing, etc.

(Page 6-2)

NEVER ADJUST HYDRAULIC COMPONENTS

TO SETTINGS HIGHER THAN THE VALUES

GIVEN IN THIS MANUAL. ANY ATTEMPT TO

GAIN "EXTRA" LIFTING CAPACITY COULD

CAUSE OVERLOADING, WHICH COULD

CAUSE DAMAGE, PERSONAL INJURY OR

DEATH. (Page 6-2)

CAUTION: The potentiometers are, limited to only 3/4 revolution. Forcing the potentiometers beyond internal stops will damage the unit. (Page 6-4)

CAUTION: If prying off sections becomes necessary, take extreme care not to mar or damage mating surfaces. Excessive force while prying can result in misalignment and seriously damage the pump. Gears are closely matched, and therefore must be kept together as sets when removed from a unit.

Avoid damaging journals or teeth. (Page 6- 10)

CAUTION: If parts are stubborn during assembly, do not force them and never employ an iron hammer.

Never hammer roller bearings into bores, use only an arbor press or other suitable tool instead. (Page 6-11)

CAUTION: Temporarily cover the splines of the integral gear and drive shaft with a protective sleeve and lightly grease the shaft and sleeve before inserting through shaft seal (3). Failure to do so will damage the seal. (Page 6-12)

SORS COLLECTION UNITS AND FRAME

ASSEMBLY OF FORWARD AND BUOY DECK

UNITS MUST HAVE SECONDARY SAFETY

ANCHORS ATTACHING THEM TO THE SHIP.

THIS IS TO PREVENT ANY MOVEMENT OF

EQUIPMENT SHOULD THE ISOLATORS

FAIL. (Page 8-1)

THIS EQUIPMENT IS POWERED BY 460 VAC

ELECTRICAL POWER. ALL ELECTRICAL

CONNECTIONS MUST COMPLY WITH

FEDERAL STANDARDS CODE AND/OR

REGULATIONS. IMPROPER OR INCORRECT

PROCEDURES COULD RESULT IN SERIOUS

INJURY OR DEATH. (Page 8-1)

CAUTION: When testing the pump(s) for rotation, do not allow the motor to run for more than a second or two. Prolonged running in the reverse direction can severely damage the pump(s). (Page 8-1)

BE SURE THAT THE POWER TO THE

EQUIPMENT IS OFF BEFORE ATTEMPTING

TO DISCONNECT THE CABLES. AN

ELECTRICAL SHOCK COULD BE FATAL.

(Page 8-2)

WHENEVER POTENTIAL PERSONAL INJURY OR

DEATH SITUATIONS EXIST REQUIRING

CORRECT PROCEDURES OR PRACTICES FOR

PREVENTION, THIS 'WARNING" SYMBOL IS

USED. THIS SAFETY ALERT SYMBOL

INDICATES IMPORTANT SAFETY MESSAGES IN

THIS MANUAL. WHEN YOU SEE THIS SYMBOL,

CAREFULLY READ THE MESSAGE THAT

FOLLOWS AND BE ALERT TO THE POSSIBILITY

OF PERSONAL INJURY OR DEATH.

All possible safety hazards cannot be foreseen so as to be included in this manual. Therefore, the operator must always be alert to possible hazards that could endanger personnel or damage the equipment.

CAUTION:

Whenever potential damage to equipment exists requiring correct procedures for prevention, the term "CAUTION" is used.

IMPORTANT:

Whenever information exists that requires special attention to procedures or to ensure proper operation of the crane, or to prevent its possible failure, the term "IMPORTANT" is used.

NOTE:

Whenever information exists that requires additional emphasis beyond the standard text, the term "NOTE" is used.

1-1 SAFETY PRECAUTIONS

1 -1.1 Warnings And Cautions Warnings and cautions appearing throughout this technical manual are of paramount importance to personnel and equipment safety. Prior to any attempt to operate, maintain, troubleshoot, or repair any part of this equipment, all warnings and cautions must be thoroughly reviewed and understood. Refer to the Safety Summary in the front of this manual for a complete listing of all warnings and cautions used throughout this manual.

1-1.2 General Safety Precautions Personnel responsible for the hydraulic power unit(s) shall become thoroughly familiar with and requenty review the following safety precautions. These precautions applyto both personnel and equipment, and should be considered supplemental to the specific warnings and cautions.

1. The hydraulic power unit(s), and all associated equipment shall be installed and grounded in accordance with applicable Coast Guard regulations and approved shipboard practices.

The following terms define the various precautions and 2. All maintenance operations shall comply with notices in this manual: applicable Coast Guard safety practices.

3. Proper installation and maintenance of protective guards and shutdown devices around rotating parts of machinery and high volfage sources shall be observed.

4. Special precautionary measures must be taken to prevent energizing the system at any time maintenance work is in progress.

1-1.3 General Rules The following rules are to be observed at all times:

1. Do not make any unauthorized alterations to the equipment.

2. Check the electrical system with voltmeter before working on system, to make sure it is not energized.

3. Always have a second person standing by while working on the electrical system, in case of emergency.

4. Do not wear loose clothing while working near rotating parts of machinery.

5. Protect against grounding before adjusting equipment or using measuring equipment.

6. De-energize all equipment before connecting or disconnecting meters or test leads. When "five" equipment must be serviced, observe the following precautions:

a. De-energize the equipment.

b. Discharge any stored voltage in capacitors by temporarily grounding terminals to be measured.

1 _ 1

CHAPTER 1.-

GENERAL INFORMATION AND SAFETY PRECAUTIONS

1- Change 2 2

c. Set meter to a range higher than the expected voltage and connect meter to the terminals being measured.

d. Be sure to protect against grounding.

e. Without touching the meter or test leads, energize the equipment and read the meter.

f. De-energize the equipment and remove the test leads.

7. Make sure frames of all motors and starter panels have been securely grounded before operating equipment or performing any tests or measurements.

8. Inspect surrounding area above and below deck carefully, and remove any foreign material which could interfere with proper operation.

9. Do not attempt to start, operate, or make any repairs to the system without first reading and understanding the appropriate portions of this manual.

10. Always take special precautionary measures to prevent anyone from applying power and attempting to use the system while maintenance work is in progress.

11. Do not jumper out or bypass any electrical safety interlock circuits.

12. All circuits not known to be "dead" must be considered "live" and dangerous at all times.

13. When working near electricity, do not use metal rulers, flashlights, metallic pencils, or any other objects having exposed conductive surfaces.

14. Do not use test equipment known to be in poor condition.

15. Make sure personnel are clear of operating area.

16. Make sure electrical power is off, and tagged "out of service" before any repair or adjustment is made to equipment.

1-2 INTRODUCTION

1-2.1 Purpose This manual has been prepared to assist personnel in operating, maintaining, and repairing the Model HPU Hydraulic Power Units, HPU-1, 2, 3, & 4.

1-2.2 Scope This manual provides a complete source of information about the equipment. Sufficient information is presented to enable personnel to operate, maintain, troubleshoot, and repair the equipment and its associated systems. Chapter 7 contains parts lists for all components and associated systems.

1-2.3 Applicability This manual is applicable to Hydraulic Power Units Model HPU, HPU-1, 2, 3, & 4.

1-3 SHIPBOARD MAINTENANCE

1-3.1 Scope Maintenance procedures in this manual enable personnel to accomplish the following:

1. Install the equipment.

2. Prepare, operate, and shut down the equipment.

3. Detect, isolate, and correct faults.

4. Remove, repair or replace, and reinstall parts.

5. Perform scheduled maintenance.

1-4 INTERMEDIATE AND DEPOT MAINTENANCE

Intermediate and depot level maintenance as described in Chapter 6 is performed at more extensive shop facilities. Such maintenance normally consists of repair, modification, modernization, overhaul, reclamation, or rebuilding of parts assemblies, and items. Specific intermediate and depot level maintenance for the equipment will consist of inspection, operability tests, fault isolation, and overhaul of items such as hydraulic pumps.

1-5 EQUIPMENT DESCRIPTION

1-5.1 Overall Capabilities Figure 1-1 illustrates the major components and equipment relationships. The Hydraulic Power Units are capable of providing hydraulic power for operation of the TB 90-60 shipboard crane and the SORS collection systems. Two 300 hp Hydraulic Power Units (HPU-1 and HPU-2) supply hydraulic power for operation of the TB 90-60 crane. One 150 hp Hydraulic Power Unit (HPU-4) supplies power for SORS collection system.

1-5.2 Physical Data Fig. 1-2 illustrates the four Hydraulic Power Units.

Table 1-1 lists the basic components and capacities of each HPU.

Change 2 1- 3

Fig. 1-1 Component Identification

Description Characteristics

Electric Motor, HPU-1 & HPU-2 . . . . . . . . . 150 hp, 460 VAC, 3 phase, 60 Hz.

Electric Motor, HPU-3 & HPU-4 . . . . . . . . . 75 hp, 460 VAC, 3 phase, 60 Hz.

Hydraulic Pumps, HPU-1 & HPU-2

Type 1 (V40-140) . . . . . . . . . . . . . . . Pressure compensated, variable displacement, axial piston.

Rating . . . . . . 4 . . . . . . . . . . . . 63 gpm max. � 1800 rpm, 2500 psi, 8.54 cid, cw rotation.

Type 2 (V40-1 1 0) . . . . . . . . . . . . . . . Pressure compensated, variable displacement , axial piston.

Rating . . . . . . . . . . . . . . . . . . . . 45 gpm max. � 1800 rpm, 2500 psi, 6.71 cid, cw rotation.

Type 3 (P30) . . . . . . . . . . . . . . . . . . Gear Pump (one inch gear width).

Rating . . . . . . . . . . . . . . . . . . . . 14 gpm max. g 1800 rpm, 2500 psi, cw rotation.

Hydraulic Pump, HPU-3 & HPU-4

Type 2 (V40-1 1 0) . . . . . . . . . . . . . . . Pressure compensated, variable displacement, axial piston.

Rating . . . . . . . . . . . . . . . . . . . . 45 gpm max. � 1800 rpm, 2500 psi, 6.71 cid, cw rotation.

Hydraulic Suction Strainer . . . . . . . . . . . . 67 gpm, 200 mesh (74 micron).

Hydraulic Pressure Filter . . . . . . . . . . . . 50 gpm, 3 micron.

Hydraulic Return Filter . . . . . . . . . . . . . . 75 gpm, 1 0 micron.

Hydraulic Oil Cooler . . . . . . . . . . . . . . . Thermal Transfer.

Hydraulic Tank, HPU-1 & HPU-2 . . . . . . 800 gal, stainless steel, with level indicator.

Hydraulic Tank, HPU-3 . . . . . . . . . . . . . 600 gal, stainless steel, with level indicator.

Hydraulic Tank, HPU-4 . . . � . . I . . . . . . 400 gal, stainless steel, with level indicator.

Electric Motor Starter . . . . . . . . . . . . . . Wye-Delta reduced voltage type, NEMA 12 enclosures.

Monitor, Temp & Alarm . . . . . . . . . . . . . 0'- 1000'F, Programmable.

1-5.6 Hydraulic Reservoir (Tank) Each HPU is equipped with a stainless steel Oil Reservoir, Sight Level Indicator, and Level and Temperature Sensors.

1-5.3 Electric Motors Electric motors are 460 VAC, 3 phase, 60 Hz totally enclosed, fan cooled, 1800 rpm, TEFC, NEMA Design B Severe Duty meeting IEEE-45 and USCG 259 specifications. Rated Power for each motor is 150 hp (HPU-1 and HPU-2) and 75 hp (HPU-3 and HPU-4). See Fig. 1-1.

1-5.4 Hydraulic Pumps Main Hydraulic Pumps are pressure compensated, variable displacement axial piston type, delivering 63 gpm (HPU-1 and HPU-2) or 45 gpm (HPU-3 and HPU-4) at 1800 rpm, with an operating pressure up to 2500 psi.

Auxiliary Hydraulic Cooling Pumps are gear type pumps mounted in tandem to the main pumps (HPU-1 and HPU-2), delivering 14 gpm at 1800 rpm at 2500 psi.

1-5.5 Control Panel Each Hydraulic Power unit is operated through a Control Panel, mounted to the starter assembly frame. This box includes local/remote control selection, indicators, and status alarms.

1-5.7 Oil Temperature Control Hydraulic oil temperature is maintained by use of thermostatically controlled immersion Tank Heaters, and sea water cooled Oil Coolers. An alarm/temperature control system monitors oil temperature, and gives audio/visual warning in case of excessive temperature.

1-5.8 Filtration Filtration consists of 200 mesh Suction Strainers, 3 micron Pressure Filters, and 10 micron Return Filters.

Filter element condition is monitored, and indicator lights located in Control Panel warn of restricted condition.

Visual indicators (gauges) are also provided, 1-5.9 Motor Starters Electric Motors are started by Wye-Delta electronic "soft start" reduced voltage motor controllers. Starters are housed in NEMA 12 stainless steel, watertight enclosures. -is

Table 1-1. Reference Data, HPU-1,2,3 & 4

1-4

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