Aft_A-frame_FRV40-227-133-010.pdf

FRV40-227-133-010

DESCRIPTION, OPERATION, INSTALLATION AND

MAINTENANCE INSTRUCTIONS

Aft A-Frame Model: HI-955

Halter Marine, Inc.

13085 Seaway Rd.

P.O. Box 3029 Gulfport, MS 39505

50-SPNA-1-00031

PUBLISHED BY DIRECTION OF NOAA

FRV40-227-133-010

DESCRIPTION, OPERATION, INSTALLATION AND

MAINTENANCE INSTRUCTIONS

Aft A-Frame Model: HI-955

Halter Marine, Inc.

13085 Seaway Rd.

P.O. Box 3029 Gulfport, MS 39505

50-SPNA-1-00031

PUBLISHED BY DIRECTION OF NOAA

20 SEPT 2007

RECORD OF CHANGES

Change No.

Date Title and/or Brief Description Signature of Validating Officer

APPROVAL AND PROCUREMENT RECORD PAGE

APPROVAL DATA FOR: FRV40-227-133-010

TITLE OF MANUAL: Aft A-Frame

APPROVAL AUTHORITY: NOAA

Contract Number

Ship Applicability

Qty Of Manuals

Building Yard

50-SPNA-1-00031 FRV40-227 2 EA Halter Marine Inc.

REMARKS:

CERTIFICATION: It is hereby certified that FRV40-227 to be provided under contract 50-SPNA-1-00031 has been approved by the approval data shown above.

Date:________________ Chand, LLC Mathews, LA 70375

CAGE CODE: 0D5X4

VALIDATION PERFORMANCE

Title of Publication

Aft A-Frame

Contractor Sub-Contractor (If Performing Validation)

Halter Marine, Inc.

Contract No.(s) and Purchase Orders, If Applicable

50-SPNA-1-00031

Chapter Section Paragraph Date Validation Completed

Check here if Not Validated

Contents of this manual have been validated and certified to be applicable to the equipment furnished under the above procurement as specified for Validation.

Name & Authority of Validating Officer: Signature of Validating Officer:

FOREWORD

This manual is intended to clearly and accurately reflect the actual configuration of the installed equipment described for the FRV40-227 Aft A-Frame. Users are urged to report instances noted wherein the manual does not achieve this objective.

This technical manual provides the instructions necessary to operate, to perform maintenance on and troubleshooting of the Aft A-Frame. The text is broken down as follows:

Section 1- General Information and Safety Precautions

Section 2- Operation

Section 3- Functional Description

Section 4- Scheduled Maintenance

Section 5- Troubleshooting

Section 6- Corrective Maintenance

Section 7- Drawings and Parts Listing

Section 8- Installation

INSTALLATION, OPERATION AND

SERVICE MANUAL FOR

HYDRAULICALLY OPERATED SIDE

AFT A-FRAME

VT HALTER MARINE INC.

NOAA Fisheries Research Vessel

FRV 40-2

M279-591-2

(Huber Doc. No. HI-955-4000-0)

Revision Description Date 0 Initial Release 5/7/03 A Changes made per Government’s Response to the FRV contractor’s DRL submittal 8/15/03.

2/9/04

Huber, Inc.

728 Hill Street

Jefferson, LA 70121

Prepared and Approved by Dominic Lorino

Table of Contents

Chapter/Paragraph Page Safety Summary 2

1. General Information and Safety Precautions 4 1-1 Safety Precautions 4 1-2 Introduction 4 1-3 Purpose 4 1-4 Scope 4 1-5 Applicability 4 1-6 Equipment Description 4 1-7 A-Frame Structure 4 1-8 Hydraulic Cylinders 4 1-9 System Capabilities 5 1-10 System Limitations 5

2. Operation 11 2-1 Introduction 11 2-2 Emergency Load Release 11

3. Functional Description 13

4. Scheduled Maintenance 15 4-1 Introduction 15 4-2 Scheduled Maintenance 15

5. TroubleShooting 17 5-1 Introduction 17 5-2Troubleshooting Procedures 17

6. Corrective Maintenance 19 6-1 Introduction 19 6-2 Counterbalance Valve Adjustment 19 6-3 Testing System Lines and Fittings 19 6-4 Testing Hydraulic Cylinder Operation 20 6-5 Cylinder Drift Test 20 6-6 Static and Dynamic Load Testing 21 6-7 General Repair Information 21 6-8 Tools and Repair Parts 21 6-9 Repairable Items 21 6-10 Hydraulic Equipment Removable and Reinstallation 21

7. Drawings and Part Listings 25 7-1 Introduction 25 7-2 Manufacturer’s Information 25 7-3 Spare Parts Lists 25

8. Installation 55 8-1 Introduction 55 8-2 Safety Precautions 55 8-3 Installation Precautions 55 8-4 Tools For Installation 55 8-5 Preparation For Installation 55 8-6 A-Frame and Cylinder Installation 56 8-7 Post Installation Checks 56 8-8 Preparing the Equipment for Reshipment 56

Lists of Illustrations

Figure Title Page 1-1 General Arrangement 7 1-2 A-Frame General Assembly 8 1-3 A-Frame Performance Chart 9 1-4 Range of Pull Angles 10 2-1 Lubrication Chart 12 3-1 Hydraulic Schematic 14 7-1 Hydraulic Cylinder Drawing 28 7-2 STBD Counterbalance Manifold 29 7-3 Aft A-Frame Weldment 1 30 7-4 Aft A-Frame Weldment 2 31 7-5 Aft A-Frame Weldment 3 32 7-6 Pin Bracket 33 7-7 Lower Boom Weldment 1 34 7-8 Lower Boom Weldment 2 35 7-9 Lower Boom Weldment 3 36 7-10 STBD Upper Leg Weldment 37 7-11 Port Upper Leg Weldment 38 7-12 Port Leg Weldment 39 7-13 STBD Leg Weldment 40 7-14 Pin Bracket Weldment & Machine 1 41 7-15 Pin Bracket Weldment & Machine 2 42 7-16 Cross Member Weldment 1 43 7-17 Cross Member Weldment 2 44 7-18 Padeye Weldment 45 7-19 Aft A-Frame Stop Weldment 1 46 7-20 Aft A-Frame Stop Weldment 2 47 7-21 Aft A-Frame Stop Weldment 3 48 7-22 Aft A-Frame Stop Weldment 4 49 7-23 Lower Padeye 50 7-24 Cylinder Foundation Weldment 51 7-25 Sun Counterbalance Valve Cut Sheet 52 7-26 Phoenix MS 500 QH Floodlight Cut Sheet 53 8-1 A-Frame Installation 57

Lists of Tables

Table Title Page 1-1 Equipment Supplied 6 1-2 System Characteristics 6 4-1 Periodic Maintenance and Inspection Chart 16 5-1 Troubleshooting Chart 18 6-1 Torque Values 23 6-2 Repairable/Replaceable Components 24 7-1 Manufacturer’s Information 26 7-2 Recommended Spare Parts List 27

Safety Summary

The equipment described in this manual is a hydraulic controlled system, which uses flows up to 234.3 GPM and pressures up to 2500 psi. Observance of the following safety precautions is mandatory. All personnel associated with the operation and maintenance of the equipment must be familiar with the safe operation of the system and all safety devices must be maintained in proper working order.

Because the following safety precautions apply only to normal operating conditions, personnel in charge may find it necessary to issue supplementary or special precautions to cover local conditions in unusual circumstances. Furthermore, conditions not covered by these safety precautions may arise which, may render further operation of the equipment unsafe. Under these conditions, none of the following safety precautions are to be used as authority for further operation.

Attention is directed to the WARNING and CAUTION notices which appear in this manual.

WARNING notices are used to warn personnel about procedures, which must be followed for protection of personnel. Failure to comply may result in injury to personnel.

A CAUTION notice is an operating or maintenance procedure, practice, condition, statement, etc., which if not strictly observed could result in damage to or destruction of equipment or loss of effectiveness.

Electrical Safety Precautions

Personnel engaged in electrical work are to be fully informed of the hazards involved.

They shall receive proper instruction in accident prevention and first aid procedures.

They should be familiar with modern methods of resuscitation.

Do not tamper with electrical or mechanical interlocks and safety devices. Do not alter safety devices in any way without express authorization.

Do not service or adjust the electrical circuits alone. Always verify that a qualified person is present who can render aid in case of am accident and who is familiar with emergency shutdown procedures.

Deenergize the electrical power source at the main breaker before working on circuits.

Wear suitable protective clothing while working within four feet of exposed electrical equipment. Do not wear rings, wristwatches or clothing with exposed metal buttons, zippers or fasteners.

Metal handles of hand held tools should be insulated by an approved taping, coating or sleeve method.

Whenever it is necessary to work on electrical circuits or equipment in wet or damp locations, dry wooded (or similar non conductive material) platforms shall be provided so that there will be no possibility of contact between the wet floor and the workman’s shoes.

Hydraulic Safety Precautions

Always verify that line pressure is zero before disconnecting hydraulic lines.

Never tighten leaking connections or fittings while lines are pressurized. Application of torque to fittings or connections while lines are pressurized may rupture lines and result in injury to personnel.

Mop up spilled hydraulic fluid immediately. Investigate and correct the cause of any leakage of hydraulic fluid.

If clothing becomes drenched with hydraulic fluid, change immediately to dry clothing:

prolonged contact with hydraulic fluid is injurious to health.

If clothing is to be discarded, comply with own ship/station procedure for handling/disposal of hazardous material/waste.

Specific WARINGS and CAUTIONS

The following warnings and cautions appear in the text of this manual and are repeated here for emphasis:

WARNING

To prevent accidental application of power to the system while performing maintenance, the circuit breaker must be turned to the OFF position and tagged “OUT OF SERVICE – DO NOT ENERGIZE”. Energizing equipment during maintenance procedures may result in injury to personnel.

WARNING

Always insure that line pressure is zero before attempting any removal or repair procedure. Never tighten fittings or connections while lines are pressurized.

Application of torque to fittings or connections while lines are pressurized may rupture lines and result in injury to personnel.

WARNING

Loose fittings and connections are dangerous to personnel during operation.

WARNING

Do not attempt to adjust the counterbalance valve installed in the hydraulic cylinder. The adjusting screw serves as an emergency load release when screwed all the way in. Failure to observe this warning may result in injury to personnel and/or damage to equipment.

CAUTION

Do not mark the cylinder rod with an instrument that might scratch the surface.

CAUTION

Strict adherence to the installation procedures must be observed. Failure to comply may results in damage to equipment.

SECTION 1

GENERAL INFORMATION AND SAFETY

PRECAUTIONS

Chapter 1

General Information and Safety Precautions

1-1.Safety Precautions.

Personnel operating or working on the equipment discussed in the following chapters should read and understand all safety precautions summarized in the Safety Summary section.

1-2. Introduction This chapter provides a general description of the major component of the hydraulically operated A-Frame in stalled on the NOAA Fisheries Research Vessel FRV 40-1.

The system, which powers the A-Frame, consists of hydraulic, electrical and electronic components. This Technical Manual ONLY covers the A-Frame and hydraulic cylinders.

All other components whether hydraulic or electrical is supplied by others.

1-3. Purpose.

This manual provides the necessary information for the installation, Maintenance, and repair of the A-Frame.

1-4. Scope.

This manual presents general and detailed descriptions of the A-Frame. In addition, sufficient information is presented to operate, maintain, troubleshoot, and repair the system

1-5. Applicability.

The information contained in this manual is applicable to the A-Frame.

1-6. Equipment Description.

The purpose of the A-Frame is raise and lower objects into and out of the water .

1-7. A-Frame Structure.

The A-Frame weldments consist mainly of A36 steel while the foundation is ABS EH36 steel. (See drawings in the Chapter 7)

1-8. Hydraulic Cylinders.

The two cylinders to rotate the A-Frame are 12” bore 7” rod and 80” stroke chrome plated rod. The cylinders are designed to operate at a working pressure of 2500 psi. The two hydraulic cylinders on each frame are mounted such that when they are fully retracted(operating and stowage position) the center of the A-Frame is 12’-8” outboard.

When the cylinder are fully extended the center of the A-frame is 30’-9” inboard.

Counter balance valves are installed in a manifold block that is bolted to the cylinder mounting plate. These valves allow the A-Frame to be stopped at any position between fully retracted and fully extended. The valves also ensure that the A-Frame will not free-fall, even if there is a break in the hydraulic piping between the hydraulic power source and the cylinders.

1-9.System Capabilities.

The A-Frame with a maximum flow of 234.3 GPM is capable of fully extending or fully retracting the A-Frame in 15-30 seconds. The A-Frame may be stopped and held at any position between fully extended or fully retracted even if there is a loss of electrical and/or hydraulic power. See Table 1-2 for System Characteristics.

The performance chart for the A-frame can be found in Chapter 1.

1-10. System Limitations.

The A-Frame is designed to support objects in and out of the water within in its full range of motion.

Table 1-1 Equipment Supplied

Qty Description Weight

1 Aft A-Frame 28913 lbs ( Including Cylinders)

Table 1-2 System Characteristics

A-Frame Working Capacity 8050 lb (3652kg)

Maximum Time to Rotate A-Frame From stop to stop fully loaded 30 seconds

Minimum Time to Rotate A-Frame From stop to stop fully loaded 15 seconds

A-Frame Cylinders 12” Bore 7” Rod 80” Stroke

Counterbalance valve settings 2600 psi

Maximum operating pressure 2500 psi

SECTION 2

OPERATION

Chapter 2

Operation

2-1. Introduction.

The step-by-step procedures for operating the A-Frame are not included in the technical manual. A couple of notes are included in this section for the counterbalance vales.

2-2. Emergency Load Release. Two cartridge counterbalance valves are installed in each hydraulic cylinder used on the A-Frame. They are designed to prevent over running load control and hydraulic load locking.

The counterbalance valves restrain flow to and from the hydraulic cylinders such that positive pressure must be applied to move the A-Frame, even if they are in a position, which would normally allow movement by the force of gravity.

The counter balance valve must be set to 2600 psi prior to operation of the A-Frame under any type of loading. To set the counterbalance valve to 2600 psi turn the adjustment screw clockwise to lower the pressure and counter-clockwise to raise the pressure. The setting pressure should be read on the backpressure gage.

These valves also serve as a safety device, which locks the frames in case of hydraulic line breakage.

WARNING

Do not attempt to adjust the counterbalance valves installed in the hydraulic cylinders. The adjusting screw serves as an emergency load release when screwed all the way in. Failure to observe this warning may result in injury to personnel and/or damage to equipment.

In an emergency situation, such as loss of power, the A-Frame may be rotated, only in the direction caused by the force of gravity, by turning the counterbalance valve adjusting screws all the way in. (Clockwise)

SECTION 3

FUNCTIONAL DESCRIPTION

Chapter 3

Functional Description

The hydraulics and the controls are not supplied by Huber, Inc. so therefore are not part of this technical manual.

SECTION 4

SCHEDULED MAINTENANCE

Chapter 4

Scheduled Maintenance

4-1 Introduction.

This chapter contains information of a general nature for the maintenance of the A-Frame and cylinders only. The hydraulics and the controls are supplied by others.

WARNING

Always insure that line pressure is zero before attempting any removal or repair procedure. Never tighten fittings or connections while lines are pressurized. Application of torque to fittings or connections while lines are pressurized may rupture lines and result in injury to personnel.

WARNING

To prevent accidental application of power to the system while performing maintenance, the circuit breaker must be turned to the OFF position and tagged “ OUT OF SERVICE – DO NOT ENERGIZE”. Energizing equipment during maintenance procedures may result in injury to personnel.

4-2 Scheduled Maintenance.

Become familiar with the system configuration before attempting any maintenance.

Study the hydraulic schematic in chapter 3 of this technical manual and any other hydraulic drawing that go with the system. Also review the electrical schematic, which are not included in this manual. When a hydraulic component must be removed for repair or replacement, the open lines must be capped to prevent contamination of the hydraulic fluid.

Hydraulic system fittings and connections must be leak tight at system pressure.

CAUTION

Loose fittings and connections are dangerous to operating personnel during operation.

During nonoperating periods, loose fittings will allow air to enter the lines. Investigate any abnormal leakage of hydraulic fluid and correct the cause before further operation is attempted.

Periodic preventive maintenance procedures are presented in Table 4-1. Periods given are for normal operating conditions. More frequent maintenance will be required in dusty, dirty or humid environments.

Establish a schedule for performing the maintenance tasks listed. It is usual to maintain equipment records as a guide for modifying the intervals of specific maintenance procedures based upon usage experience.

Periodic lubrication of the A-Frame should be accomplished with the lubrication chart in chapter 2.

Table 4-1 Periodic Maintenance and Inspection Chart.

Part Maintenance Function Period Cylinders Check mounting for loosening or shifting Monthly

Check condition of piston rod surface for damage or scoring

Monthly

Lubricate Hinge pins. See lubrication Chart in chapter

Monthly

Check connections for loosening

Monthly

A-Frame Lubricate Pivot pin in lower A-Frame leg. See lubrication chart in chapter

Monthly

Counterbalance valve Set counterbalance valve to 2600 psi.

Prior to start-up

SECTION 5

TROUBLESHOOTING

Chapter 5

Troubleshooting

5-1 Introduction.

This chapter provides instructions for troubleshooting the possible malfunctions of the A- Frame.

The basic cause for hydraulic system failures are electrical malfunctions and hydraulic. In general, it is preferable to eliminate the electrical faults first, since these can be corrected without opening the hydraulic lines and exposing the system to contaminates. Electrical troubleshooting for this A-Frame is not part of this report. This report only contains troubleshooting for the A-Frame itself.

When a hydraulic component is removed for repair or replacement, the open lines must be capped to prevent contamination of the hydraulic fluid. Become familiar with circuit functions before attempting any repairs.

The attention of operating and maintenance personnel is specifically directed to the warnings below and to the warning and caution notices at the front of the manual.

Compliance with warnings and cautions will protect personnel from injury and equipment from damage.

WARNING

Always insure that line pressure is zero before attempting any removal or repair procedure. Never tighten fittings or connections while lines are pressurized. Application of torque to fittings or connections while lines are pressurized may rupture lines and result in injury to personnel.

WARNING

To prevent accidental application of power to the system while performing maintenance, the circuit breaker must be turned to the OFF position and tagged “ OUT OF SERVICE – DO NOT ENERGIZE”. Energizing equipment during maintenance procedures may result in injury to personnel.

5-2 Troubleshooting Procedures.

Troubleshooting procedures fro the A-Frame only are presented in table 5-1. No special test equipment is required for troubleshooting the hydraulic system and the flood lights..

Table 5-1 Troubleshooting Chart

Symptom Probable Cause Remedy A-Frame fails to hold stationary

1. Counterbalance Valve 1. Adjust, repair or replace counterbalance valve

2. Internal hydraulic system leak

1. See chapter 6, cylinder drift test.

Flood Lights don’t work 1. Electrical Wiring 1. Check for correct wiring

2. Check to see if light bulb works.

SECTION 6

CORRECTIVE MAINTENANCE

Chapter 6

Corrective Maintenance

6-1. Introduction.

This chapter contains instructions for the alignment and adjustment of the repairable parts of the A-Frame. This chapter also included reference tables containing engineering data to assist in corrective maintenance. Chapter 7 contains the bill of materials.

6-2 Counterbalance Valve Adjustment.

Two cartridge counterbalance valves are installed in each hydraulic cylinder used on the A-Frame. They are designed to prevent overrunning load control and hydraulic load locking.

The counterbalance valves restrain flow to and from the hydraulic cylinders such that positive pressure must be applied to move the A-Frame, even if they are in a position, which would normally allow movement by the force of gravity.

These valves also serve as a safety device, which locks the frames in case of hydraulic line breakage.

WARNING

Do not attempt to adjust the counterbalance valves installed in the hydraulic cylinders. The adjusting screw serves as an emergency load release when screwed all the way in. Failure to observe this warning may result in injury to personnel and/or damage to equipment.

The pressure setting of the counterbalance valves must be adjusted at the factory or, after installation, only by an authorized and qualified factory service representative. These valves may be removed for inspection and cleaning without changing the pressure setting. These valves are not repairable; therefore, spares should be on hand with the correct pressure setting.

The installation and test engineer will first set the counterbalance valves for minimal pressure, and then gradually increase the pressure setting until the A-Frame moves smoothly with no erratic jerking. There is no specified pressure setting for these valves.

After the set pressure of each pair of valves is determined, spares may be ordered as factory set and adjustable or factory set and “tamper proof”.

6-3 Testing System Lines and Fittings.

Examine all visible hydraulic lines and fittings on the A-Frame for evidence of leaks while operating the A-Frame at normal system pressure.

Always insure that line pressure is zero before attempting any removal or repair procedure. Never tighten fittings or connections while lines are pressurized. Application of torque to fittings or connections while lines are pressurized may rupture lines and result in injury to personnel.

If leaks are detected, trace the visible fluid to the leaking fitting. Shut down the system and reduce the pressure to zero. Tighten the leaking fitting(s) as required. Turn the system on and operate to determine if tightening has corrected the leak(s). If leaking continues, repair or replace fitting.

6-4 Testing Hydraulic Cylinder Operation.

Test the operation of the hydraulic cylinders on the A-Frame as follows:

A. Verify smooth, steady movement of the cylinders and the A-Frame to which they are attached.

B. Verify that the cylinders and A-Frame can be stopped at any intermediate position between fully extended and fully retracted.

C. Verify that the A-Frame can be fully retracted or fully extended in 15-30 seconds.

6-5 Cylinder Drift Test.

Perform the following steps to determine if there is excessive leakage through the counterbalance valves or cylinder seals.

A. Place the A-Frame in a position approximately half way between vertical and fully extended.

B. Turn off power to the system, either electrical, hydraulic, or both.

C. Mark the position of the cylinder rods or the frame to a reference point using a felt tip pen.

CAUTION

Do not mark the cylinder rod with an instrument that might scratch the surface.

D. Allow the A-Frame to remain unpowered for a period of one hour, and then measure the amount of drift from the mark in step C above.

E. If this distance is more than ¼”, either the cylinder seals or at least one of the counterbalance valves are leaking.

F. Repair or replace as necessary and repeat steps A through D until test results are acceptable.

G. Repeat steps A through F above with the A- Frame stopped approximately half way between vertical and fully retracted.

6-6 Static and Dynamic Load Testing The static and Dynamic test was will completed by the shipyard after all equipment is installed and commissioned.

6-7 General Repair Information The main cause of malfunction of the components of any hydraulic system is contamination particles that collect and lodge in moving parts and cause these parts to stick. Often, such sticking parts can be disassembled, cleaned and reassembled with the use of original parts. During the inspections of items removed for repair or replacement, a determination should be made of which. Action to take based on the condition of the item and a study of the drawings for the item. Personnel are cautioned not to perform repairs on equipment that is operating satisfactorily.

Before attempting any repairs, study the hydraulic schematic and become familiar with circuit functions and component configurations.

When a hydraulic component must be removed for repair or replacement, the open lines must be capped to prevent contamination of the fluid. All o-rings that are removed during disassembly should be discarded and replaced with new ones.

6-8 Tools and Repair Parts.

No special tools are required for repair of the A-Frame. Standard tools, such as socket and wrench sets, torque wrenches, screwdrivers, pliers, and a bench vise, are typical tools needed for repairs. Refer to chapter 7 for specific item to be repaired and make certain that the proper tools and repair parts are on hand prior to starting repairs. Torque values for fasteners and cartridge valves are listed in Table 6-1.

6-9 Repairable Items This part specifies the items of equipment, which are considered to be repairable. Other items should be replaced if found to be defective.

6-10 Hydraulic Equipment Removable and Reinstallation.

Always insure that line pressure is zero before attempting any removal or repair procedure. Never tighten fittings or connections while lines are pressurized. Application of torque to fittings or connections while lines are pressurized may rupture lines and result in injury to personnel.

WARNING

To prevent accidental application of power to the system while performing maintenance, the circuit breaker must be turned to the OFF position and tagged “ OUT OF SERVICE – DO NOT ENERGIZE”. Energizing equipment during maintenance procedures may result in injury to personnel.

Prior to any removal of any item for replacement, isolate the item from the rest of the hydraulic system by closing stop valves, if available. Place a container under the flange or joint to catch fluid, and then remove the bolts or fittings. Remove the item to be repaired or replaced to the work area for inspection only after capping all exposed hydraulic connections to prevent entrance of foreign matter into the hydraulic lines.

Install repaired or replacement items in their original position. Use new o-rings on hydraulic joints. Tighten flange bolts evenly to prevent cocking. Torque all fasteners in accordance with Table 6-1

Open any stop valves, which may have been used to isolate the item for repair/replacement. Test for proper operation of A-Frame as described in sections 6-2 through 6-5 above.

Table 6-1 Torque Values

Counter Balance Valve CWIA-LHN 350-375 ft-lb

¼” Zerk Fitting ½ turn past finger tight

Keeper Plate Bolts SHCS UNC ½-12 1 ¾” long 110 ft-lb

Floodlight mounting Bolts M8x1.25x30 25 ft-lb

Table 6-2 Repairable/Replaceable Components

Assembly/Item Action Required Repair Parts

Boom Arm Weldment Repair by Welding N/A

Hydraulic Cylinder Repair Figure 7-1

Crossmember Repair by Welding N/A

Base Weldment Repair by Welding N/A

Floodlight Replace Light Bulb or Replace

N/A

Counterbalance Valve Replace Valve N/A

Pad Eyes Repair by Welding N/A

SECTION 7

DRAWINGS AND PARTS LISTS

Chapter 7

Drawings and Parts Listings

7-1 Introduction.

This chapter contains drawings and parts listings for all repairable assemblies and components in the A-Frame. It also contains a listing of manufacture’s names and complete addresses. A spare parts list can also be found in this chapter.

7-2 Manufacturer’s Information Table 7-1 provides manufacturer’s names and complete addresses for all A-Frame related items.

7-3 Spare Parts List Table 7-2 contains the recommended spare parts list.

Table 7-1 Manufacturer’s Information

Name Address

Phoenix Products Company, Inc. 6161 North 64th Street Milwaukee, WI 53218-1543

Sun Hydraulics 1500 West University Parkway Sarasota, FL 34243

Huber, Inc. 728 Hill Street Jefferson, LA 70121

Table 7-2 Recommended Spare Parts List

Quantity Description Part # Material

2 Sun Counterbalance Valves CWIA-LHN

2 Hinge Pin Keeper Plates HI-955-6024 A36

4 Lock Washer ½” 316L SS

4 Socket Head Cap Screw UNC ½ -12 x 1 ¾” long

316L SS

2 Hinge Pin Bushing HI-955-4018 SAE 660 Bronze

8 Zerk Fitting ¼” NPT 304 SS

1 Hinge Pin Weldment HI-955-4090 17-4 PH H1150

1 Phoenix Halogen Floodlight MS 500 QH

10 4 11/16” Recessed Single Contact Lamps Up to 240 Volts and 500 Watts

10 Phoenix Halogen Floodlight Mounting bolts

M8x1.25x30 316L SS

2 Cylinder Seal Kit SK 7478 Urethane Seals

3:1 pilot ratio, Vented, Counterbalance valve Capacity:

15 gpm(60 L/min.)

Functional Group:

Products : Cartridges : Counterbalance : 4-Port Vented : 3:1 Pilot Ratio

Model:

CWCA

Product Description

Vented counterbalance valves with pilot assist are meant to control an overrunning load. The check valve allows free flow from the directional valve (port 2) to the load (port 1) while a direct-acting, pilot-assisted relief valve controls flow from port 1 to port 2. Pilot assist at port 3 lowers the effective setting of the relief valve at a rate determined by the pilot ratio. Backpressure at port 2 does not affect the valve setting because the spring chamber references the vent (port 4). Other names for this valve include motion control valve and over center valve.

Page 1 of 4Sun Hydraulics : CWCA

2/9/04http://www.sunhydraulics.com/cmsnet/cbcppprint.aspx?Cat_Level_0=1&Cat_Level_1=2&Cat_Level...

Technical Features

Counterbalance valves should be set at least

1.3 times the maximum load induced pressure.

Turn adjustment clockwise to decrease setting and release load.

Full clockwise setting is 0 psi (0 bar). All 4-port counterbalance, load control, and pilot-to-open check cartridges are physically interchangeable (i.e. same flow path, same cavity for a given frame size).

Reseat exceeds 85% of set pressure when the valve is standard set. Settings lower than the standard set pressure may result in lower reseat percentages.

Sun counterbalance cartridges can be installed directly into a cavity machined in an actuator housing for added protection and improved stiffness in the circuit.

This valve has positive seals between all ports.

With vented valves, a lower pilot ratio may be required to achieve machine stability compared to non-vented valves.

Incorporates the Sun floating style construction to eliminate the effects of internal parts binding due to excessive installation torque and/or cavity/cartridge machining variations.

Technical Data US Units Metric Units

Cavity T-21A Series 1 Reseat >85% of Set Pressure >85% of Set Pressure U.S. Patent # 4,834,135 4,834,135 Model Weight .45 lb 0,20 kg Adjustment Nut Torque 108 lbf in. 12 Nm Capacity 15 gpm 60 L/min.

Factory Pressure Settings Established at 2 in³/min. 32,8 cc/min.

Pilot Ratio 3:1 3:1 Valve Installation Torque 30 - 35 lbf ft 45 - 50 Nm Load Holding to 3075 psi with 4000 psi valve setting 215 bar with 280 bar valve setting Free Flow Check Cracking Pressure 40 psi 2,8 bar Maximum Valve Leakage at Reseat 5 drops/min. 0,4 cc/min.

Allen Wrench Hex Size 5/32 in. 4 mm Valve Hex Size 7/8 in. 22,2 mm Adjustment Nut Hex Size 9/16 in. 15 mm

Seal Kits Buna 990-021-007 Viton 990-021-006

Page 2 of 4Sun Hydraulics : CWCA

Option Selection

CWCA - L H N

$ 67.00 U.S. Dollar Recommended List Price

Preferred Options

Control Functional Setting Range Seal

L Standard Screw Adjustment

+0.00 H 1000 - 4000 psi (70 - 280 bar), 3000 psi (210 bar) Standard Setting

+0.00 N Buna-N +0.00

Additional Options C* Tamper Resistant - Factory

Set +4.10 I 400 - 1500 psi (30

- 105 bar), 1000 psi (70 bar) Standard Setting

+0.00 V Viton +4.00

* Special setting required, specify at time of order. No charge.

Related Information Explanation of Sun cartridge control options - US units.

Explanation of Sun cartridge control options - metric units.

Model Code : CWCA Print Date : 9 February 2004

Page 3 of 4Sun Hydraulics : CWCA

Copyright © 2003 Sun Hydraulics Corporation.

All rights reserved.

Terms and Conditions - Statement of Privacy

Page 4 of 4Sun Hydraulics : CWCA

SECTION 8

INSTALLATION

Chapter 8

Installation

8-1 Introduction This chapter describes the installation procedures for the A-Frame and cylinders. These procedures are keyed to applicable figures contained in this manual. The personnel performing these installations should read these procedures before attempting any work.

Post-installation checks and adjustments are described in the following paragraphs.

6-2, Counterbalance Valve Adjustment

6-3, Testing System Lines and Fittings

6-4, Testing Hydraulic Cylinder Operation

6-5, Cylinder Drift Test

CAUTION

Strict adherence to the following installation procedures must be observed.

Failure to comply may result in damage to equipment.

8-2 Safety Precautions.

Personnel installing the A-Frame and Cylinders should read and understand all safety precautions described in the front section of this manual.

8-3 Installation Precautions If the A-Frame and cylinders are installed in accordance with these instructions, operation should be trouble free.

Hydraulic lines from the hydraulic power unit, which is supplied by others, must be flushed to shipyard and pump manufacturer standards before connection to the A-Frame cylinders.

8-4 Tools For Installation No special tools are required to install the A-Frame and cylinders. Standard tools, such as socket sets, torque wrenches, screwdrivers, welding torch and pliers are typical tools needed to complete installation.

8-5 Preparation For Installation Clean the working area to insure that no foreign matter enters the hydraulic lines and hydraulic cylinders.

Ensure that proper tools and hardware are available before attempting to install any components.

Refer to the following illustration before starting installation:

Figure 3-1 Hydraulic Schematic

Figure 8-1 A-Frame Installations

8-6 A-Frame and Hydraulic Cylinder Installation.

1. The area where the A-Frame will be welded to needs to be prepared for welding.

2. Weld A-Frame into place using footprint on drawing number HI-955-6000 sheet 1 through 4.

3. Lower A-Frame into place on foundation base.

4. Insert mounting pin into lower boom arm through the foundation base.

5. Install keeper plate on the outside of the foundation base by using the required ½’ socket head cap screws. Torque ½” SHCS to 110 ft-lbs.

6. Install cylinder into to place with the blind end closest to the deck. Note the manifold with the counterbalance valves mounted in it is already mounted to the cylinder and therefore does not required any kind of installation. Make sure that the manifold block faces inboard.

7. Insert pins into cylinder and mounting lugs.

8. Connect hydraulic lines by reviewing the hydraulic diagram 3-1.

8-7 Post Installation Checks.

After the installations are completed, the adjustments and test described in chapter 6 may be completed.

8-8 Preparing the Equipment for Reshipment Prepare the equipment for reshipment by performing the following steps:

A. Turn off all circuit breakers supplying power to the lights on the A-frame and tag “OUT OF SERVICE – DO NOT ENERGIZE”.

B. Dissconnect all electrical wiring from the lights.

C. Disconnect the hydraulic lines from the A-frame cylinders. Plug or cap all openings to prevent entrance of foreign matter into the cylinders and hydraulic lines.

D. Where possible, crate each piece of equipment. Preserve and mark the crates for reshipment.

The Metric System and Equivalents

Linear Measure Liquid Measure

1 centiliter = 10 milliters = .34 fl. ounce 1 centimeter = 10 millimeters = .39 inch 1 deciliter = 10 centiliters = 3.38 fl. ounces 1 decimeter = 10 centimeters = 3.94 inches 1 liter = 10 deciliters = 33.81 fl. ounces 1 meter = 10 decimeters = 39.37 inches 1 dekaliter = 10 liters = 2.64 gallons 1 dekameter = 10 meters = 32.8 feet 1 hectoliter = 10 dekaliters = 26.42 gallons 1 hectometer = 10 dekameters = 328.08 feet 1 kiloliter = 10 hectoliters = 264.18 gallons 1 kilometer = 10 hectometers = 3,280.8 feet

Square Measure Weights

1 sq. centimeter = 100 sq. millimeters = .155 sq. inch 1 centigram = 10 milligrams = .15 grain 1 sq. decimeter = 100 sq. centimeters = 15.5 sq. inches 1 decigram = 10 centigrams = 1.54 grains 1 sq. meter (centare) = 100 sq. decimeters = 10.76 sq. feet 1 gram = 10 decigram = .035 ounce 1 sq. dekameter (are) = 100 sq. meters = 1,076.4 sq. feet 1 dekagram = 10 grams = .35 ounce 1 sq. hectometer (hectare) = 100 sq. dekameters = 2.47 acres 1 hectogram = 10 dekagrams = 3.52 ounces 1 sq. kilometer = 100 sq. hectometers = .386 sq. mile 1 kilogram = 10 hectograms = 2.2 pounds 1 quintal = 100 kilograms = 220.46 pounds Cubic Measure 1 metric ton = 10 quintals = 1.1 short tons

1 cu. centimeter = 1000 cu. millimeters = .06 cu. inch 1 cu. decimeter = 1000 cu. centimeters = 61.02 cu. inches 1 cu. meter = 1000 cu. decimeters = 35.31 cu. feet

Approximate Conversion Factors

To change To Multiply by To change To Multiply by inches centimeters 2.540 ounce-inches newton-meters .007062 feet meters .305 centimeters inches .394 yards meters .914 meters feet 3.280 miles kilometers 1.609 meters yards 1.094 square inches square centimeters 6.451 kilometers miles .621 square feet square meters .093 square centimeters square inches .155 square yards square meters .836 square meters square feet 10.764 square miles square kilometers 2.590 square meters square yards 1.196 acres square hectometers .405 square kilometers square miles .386 cubic feet cubic meters .028 square hectometers acres 2.471 cubic yards cubic meters .765 cubic meters cubic feet 35.315 fluid ounces milliliters 29,573 cubic meters cubic yards 1.308 pints liters .473 milliliters fluid ounces .034 quarts liters .946 liters pints 2.113 gallons liters 3.785 liters quarts 1.057 ounces grams 28.349 liters gallons .264 pounds kilograms .454 grams ounces .035 short tons metric tons .907 kilograms pounds 2.205 pound-feet newton-meters 1.356 metric tons short tons 1.102 pound-inches newton-meters .11296

Temperature (Exact)

°F Fahrenheit 5/9 (after Celsius °C temperature subtracting 32) temperature