2685 REFERENCE DRAWINGS.pdf

REV. DATE APRD.

□ Accepted

□ Accepted with Comments

□ Not Accepted

Refer to Notations On:

□ Drawing

□ Return Document

Resubmission: □ Required □ Not Required

Approved Subj. to Approv. Reg. Agcy. Apprvl.

Reviewer:

Date Returned:

Return Document No.:

REVISIONS

DESCRIPTION

MDC REVIEW

A 9/11/2013 ___

EM LIGHTING AND BATTERY

DURATION ADDED

General Notes:

DR. BY DES. BY CHK'D BY

IGS IGS SNT

APRD. FOR THE DIR. - CH. DES. BR. SIZE REV.

DATE

SHEET: COVERJuly 11, 2013 SCALE: NTS

LITTLE ROCK DISTRICT - TOWBOAT

95' x 39' x 10'

ELECTRICAL

LOAD ANALYSIS (DC)

RECOMMENDED

/ / TIM KEYSER

PROJECT NO. DRAWING NO.

/ / GREG LEE

A 2885 793-B710-02 A

MARINE DESIGN CENTER

100 PENN SQUARE EAST PHILADELPHIA,

PA 19107

DEPARTMENT OF THE ARMY

MARINE DESIGN CENTER

CORPS OF ENGINEERS

CIRCUIT FULL LOAD

LOAD GROUP NUMBER AMPS D.F. AMP D.F. AMP D.F. AMP

PANEL-D1 24VDC (PILOT HOUSE)

RADAR #1 D1-1 5.0 0.5 2.50 0.5 2.50 0.5 2.50

RADAR #2 D1-2 3.8 0.5 1.90 0.5 1.90 0.5 1.90

AIS D1-3 3.0 1.0 3.00 1.0 3.00 1.0 3.00

GPS UNIT D1-4 1.0 1.0 1.00 1.0 1.00 1.0 1.00

NAV. LIGHT CONTROL PANEL D1-5 10.0 1.0 10.00 1.0 10.00 1.0 10.00

NIGHT VISION CAMERA D1-6 2.0 0.0 0.00 1.0 2.00 1.0 2.00

SWING METER D1-7 6.0 0.3 1.80 0.3 1.80 0.3 1.80

P.H. WIPER #1, 2 D1-8 3.6 0.1 0.36 0.1 0.36 0.3 1.08

FWD P.H. WINDOW FANS D1-9 9.8 0.3 2.94 0.3 2.94 0.3 2.94

P.H. WIPER #3, 4 D1-10 3.6 0.1 0.36 0.1 0.36 0.3 1.08

AFT P.H. WINDOW FANS D1-11 6.0 0.3 1.80 0.3 1.80 0.3 1.80

P.H. WIPER #5, 6 D1-12 3.6 0.1 0.36 0.1 0.36 0.3 1.08

TOTAL: 57.40 26.02 28.02 30.18

PANEL-D2 12VDC (PILOT HOUSE)

DEPTH SOUNDER #1 D2-1 2.0 1.0 2.00 1.0 2.00 1.0 2.00

DEPTH SOUNDER #2 D2-2 2.0 1.0 2.00 1.0 2.00 1.0 2.00

WEATHER STATION D2-3 1.0 1.0 1.00 1.0 1.00 1.0 1.00

VHF RADIO #1 D2-4 5.5 0.3 1.65 0.3 1.65 0.8 4.40

INTERNAL TELEPHONE SYSTEM D2-5 2.0 0.2 0.40 0.2 0.40 0.2 0.40

VHF RADIO #2 D2-6 5.5 0.3 1.65 0.3 1.65 0.8 4.40

INSTRUMENT PANEL LIGHTS D2-7 2.0 0.5 1.00 0.5 1.00 0.5 1.00

LOUDHAILER D2-8 5.0 0.3 1.50 0.3 1.50 0.5 2.50

SATELLITE COMPASS D2-9 1.0 1.0 1.00 1.0 1.00 1.0 1.00

SAT TV SYSTEM D2-10 4.2 0.5 2.10 0.5 2.10 0.5 2.10

P.H. RED LIGHT D2-11 1.0 0.9 0.90 0.9 0.90 0.9 0.90

TOTAL: 31.20 15.20 15.20 21.70

ELECTRICAL LOAD ANALYSIS (DC)

Summer Day Winter Night EMERGENCY

Est. Est. Est.

CIRCUIT FULL LOAD

LOAD GROUP NUMBER AMPS D.F. AMP D.F. AMP D.F. AMP

ELECTRICAL LOAD ANALYSIS (DC)

Summer Day Winter Night EMERGENCY

Est. Est. Est.

EM LIGHTING PANEL (ELECTRONICS RM)

PILOT HOUSE EM LIGHTS EL-1 10.0 0.0 0.00 0.0 0.00 0.8 8.00

TEXAS DECK EM LIGHTS EL-2 14.0 0.0 0.00 0.0 0.00 0.8 11.20

UPPER DECK EM LIGHTS EL-3 16.0 0.0 0.00 0.0 0.00 0.8 12.80

MAIN DECK-ENGINE RM EM LIGHTS (PORT) EL-4 14.0 0.0 0.00 0.0 0.00 0.8 11.20

MAIN DECK-ENGINE RM EM LIGHTS (STBD) EL-5 14.0 0.0 0.00 0.0 0.00 0.8 11.20

MAIN DECK-PASSAGEWAY EM LIGHTS EL-6 16.0 0.0 0.00 0.0 0.00 0.8 12.80

HOLD EM LIGHTS EL-7 14.0 0.0 0.00 0.0 0.00 0.8 11.20

TOTAL: 98.00 0.00 0.00 78.40

Nominal Voltage System Voltage 24 Volts Battery Type and Rating (2) - 12VDC Deep Cycle Marine Battery (255 Amp-Hr each)

Summer Day Current Draw 26.02 Amps Winter Night Current Draw 28.02 Amps Emergency Current Draw 30.18 Amps

Time Required for Back-up Power 3 Hours Battery Back-up Time Estimate - Summer Day 9.8 Hours Battery Back-up Time Estimate - Winter Night 9.1 Hours Battery Back-up Time Estimate - Emergency 8.4 Hours

Nominal Voltage System Voltage 12 Volts Battery Type and Rating (1) - 12VDC Deep Cycle Marine Battery (255 Amp-Hr)

Summer Day Current Draw 15.20 Amps Winter Night Current Draw 15.20 Amps Emergency Current Draw 21.70 Amps

Time Required for Back-up Power 3 Hours Battery Back-up Time Estimate - Summer Day 16.8 Hours Battery Back-up Time Estimate - Winter Night 16.8 Hours Battery Back-up Time Estimate - Emergency 11.8 Hours

Nominal Voltage System Voltage 12 Volts Battery Type and Rating (1) - 12VDC Deep Cycle Marine Battery (255 Amp-Hr)

Summer Day Current Draw 0 Amps Winter Night Current Draw 0 Amps Emergency Current Draw 78.40 Amps

Time Required for Back-up Power 3 Hours Battery Back-up Time Estimate - Summer Day - Hours Battery Back-up Time Estimate - Winter Night - Hours Battery Back-up Time Estimate - Emergency 3.3 Hours

Evaluation of Pilot House 24VDC System Battery Bank

Evaluation of Pilot House 12VDC System Battery Bank

Evaluation of EM Lighting 12VDC System Battery Bank

REV. DATE APRD.

□ Accepted

□ Accepted with Comments

□ Not Accepted Refer to Notations On:

□ Drawing

□ Return Document Resubmission: □ Required □ Not Required Approved Subj. to Approv. Reg. Agcy. Apprvl.

Reviewer:

Date Returned:

Return Document No.:

General Notes:

REVISIONS

DESCRIPTION

Original Issue

MDC REVIEW

DR. BY DES. BY CHK'D BY

IGS IGS SNT

APRD. FOR THE DIR. - CH. DES. BR. SIZE REV.

DATE

SHEET: COVER

MARINE DESIGN CENTER

100 PENN SQUARE EAST

PHILADELPHIA PA 19107

DEPARTMENT OF THE ARMY

MARINE DESIGN CENTER

CORPS OF ENGINEERS

LITTLE ROCK DISTRICT - TOWBOAT

95' x 39' x 10'

CABLE SCHEDULE &

VOLTAGE DROP (DC)

RECOMMENDED

/ / TIM KEYSER

PROJECT NO. DRAWING NO.

/ / GREG LEE A 2885 793-B725-02 -

July 11, 2013 SCALE: NTS

CIRCUIT CABLE Cm L A V VD VD% VD%

LOAD GROUP NUBMER SIZE TOTAL

MAIN FEED PANEL-D1 24VDC (PILOT HOUSE) D1 T-250 250000 60 80.0 24 0.495 2.06 2.06

RADAR #1 D1-1 T-6 6530 20 5.0 24 0.395 1.65 3.71

RADAR #2 D1-2 T-6 6530 20 3.8 24 0.300 1.25 3.32

AIS D1-3 T-6 6530 20 3.0 24 0.237 0.99 3.05

GPS UNIT D1-4 T-6 6530 20 1.0 24 0.079 0.33 2.39

NAV. LIGHT CONTROL PANEL D1-5 T-10 10380 20 10.0 24 0.497 2.07 4.14

NIGHT VISION CAMERA D1-6 T-6 6530 20 2.0 24 0.158 0.66 2.72

SWING METER D1-7 T-6 6530 20 6.0 24 0.474 1.98 4.04

P.H. WIPER #1, 2 D1-8 T-6 6530 20 3.6 24 0.284 1.19 3.25

FWD P.H. WINDOW FANS D1-9 T-10 10380 20 9.8 24 0.487 2.03 4.09

P.H. WIPER #3, 4 D1-10 T-6 6530 20 3.6 24 0.284 1.19 3.25

AFT P.H. WINDOW FANS D1-11 T-6 6530 20 6.0 24 0.474 1.98 4.04

P.H. WIPER #5, 6 D1-12 T-6 6530 20 3.6 24 0.284 1.19 3.25

MAIN FEED PANEL-D2 12VDC (PILOT HOUSE) D2 T-250 250000 60 60.0 12 0.372 3.10 3.10

DEPTH SOUNDER #1 D2-1 T-6 6530 20 2.0 12 0.158 1.32 4.41

DEPTH SOUNDER #2 D2-2 T-6 6530 20 2.0 12 0.158 1.32 4.41

WEATHER STATION D2-3 T-6 6530 20 1.0 12 0.079 0.66 3.75

VHF RADIO #1 D2-4 T-16 16510 20 5.5 12 0.172 1.43 4.53

INTERNAL TELEPHONE SYSTEM D2-5 T-6 6530 20 2.0 12 0.158 1.32 4.41

VHF RADIO #2 D2-6 T-16 16510 20 5.5 12 0.172 1.43 4.53

INSTRUMENT PANEL LIGHTS D2-7 T-6 6530 20 2.0 12 0.158 1.32 4.41

LOUDHAILER D2-8 T-16 16510 20 5.0 12 0.156 1.30 4.40

SATELLITE COMPASS D2-9 T-6 6530 20 1.0 12 0.079 0.66 3.75

SAT TV SYSTEM D2-10 T-10 10380 20 4.2 12 0.209 1.74 4.84

P.H. RED LIGHT D2-11 T-6 6530 20 1.0 12 0.079 0.66 3.75

VOLTAGE DROP & CABLE SELECTIONSVOLTAGE DROP & CABLE SELECTIONS

VD=(2KxLxI)/Cm K=12.9 FOR Cu

FROM BATTERY BANK TO PILOT HOUSE

P.O. Box 840687, Houston, Texas 77284 Phone: 713 896 6500 Fax: 713 896 6611

Form No. STDFM-43 Rev. 0 07/21/98

Level 2 Installtion & Assembly.doc

Crane Installation & Assembly / Inspections & Tests (Level 2) For

Army Corps of Engineering

Project: CELRP Monallo llI Solicitation No. DACW61-98-R-0028 Document No. P-006-1 Solicitation code: E05 SeaTrax Serial No.4252 Series 126, Model 12632

Concept:

The SeaTrax 12632 crane is a Kingpost mounted marine crane. There is no slew ring bearing for the crane to mount on. The Kingpost extends up through the center of the crane with bushings at the bottom of the crane and up in the gantry structure.

The Kingpost has been designed to mount and weld into the barge hull structure. The lower section of the Kingpost is designed to extend through the deck to the hull bottom. SeaTrax will supply the Kingpost with the extension to fit in the barge hull. After the barge is completed, with the Kingpost installed, the crane can be installed. No part of the crane attaches to or touches the barge. The bottom of the crane upper works is located about 2' above the barge deck. No protrusions can extend up above the barge deck under the swing circle of the crane upper works that may interfere with the crane.

The bottom of the boom, when horizontal, will extend almost to the barge deck. Also, no protrusions may extend through the deck anywhere the boom may be at a low boom angle and near to the barge deck.

The crane will be delivered in multiple packages. It will be necessary to assemble the crane on the Kingpost. All the components will bolt or pin together. There is no welding necessary to assemble the crane. The enclosed instructions, with attachments, describe the method of assembly.

Enclosed:

Kingpost installation instructions, with attachments

Crane assembly instructions, with attachments

Kingpost Mounting in Barge

The deck of the barge is to have an opening to allow the insertion of the lower section of the Kingpost.

The opening is to extend to the bottom of the barge. The barge contractor, in the design of the interface of the barge to the Kingpost shall use proper design considerations so stress concentrations are kept to a minimum.

The horizontal loads from the crane are transmitted through the deck and hull bottom, as such the Kingpost should be supported at the top and bottom of the barge properly. [The maximum design Moment is 53000 Kip-ft] The vertical loads are to be transmitted through hull bulkheads. [The maximum Vertical design load is 960 Kip] It is the responsibility of the barge designer to provide the structure to accept the loads imposed by the crane.

The material of the Kingpost is either API 2H gr. 50 or ANSI A572 gr. 50. Both are low carbon medium strength steels that can be welded by most welding procedures. The exact length of the Kingpost is to be determined by the barge designer. The bottom of the Kingpost can be trimmed for proper fit.

There will be a lateral outlet on the lower section of the Kingpost. This outlet will be below deck. The outlet will be an 8" pipe that extends from the side of the Kingpost up through the center and out the top. This pipe will carry possible cables and hoses to the swivel located on the crane. The final orientation of the lateral outlet will be determined best by the barge manufacturer.

Installation of Kingpost:

The barge contractor is responsible to supply a crane sufficient to lift and reach to install the Kingpost complete with rigging.

The details and order of how the Kingpost is attached to the barge, are per the barge manufacturer.

The following is a set of instructions to insure that the Kingpost is located properly in the barge.

Protect the machined surface on the top of the Kingpost and the gear from damage.

The Kingpost is to be vertically located with the distance from the bottom of the Kingpost gear to the barge deck to be 16” plus or minus 1" (reference 4252B)

The outlet, below deck, is to be oriented to the correct position for future access.

The Kingpost is to be held vertical within plus or minus ½ degree.

The Kingpost is to be welded in place by the barge manufactures drawings and welding procedures.

Non destructive testing as required by barge manufacturers requirements.

Attachments:

1. 3 D view of Kingpost in barge. (4252Y)

2. Basic dimensions of Kingpost. (4252B)

Crane Assembly SeaTrax model 12632

The personnel responsible for installation of the crane will need to review the documents provided, and look over the crane components supplied.

The barge contractor is responsible to supply a crane (s) sufficient to lift and reach to install the upper works, gantry and boom complete with rigging. The weights of major components listed are approximate at this time. The actual weights should be close to these.

Major components will come with lifting eyes for either two or four part lifts, depending on the component. Note: The pictorial attachments do not show lifting eye positions.

Proper rigging procedures are to be followed to protect the load and boom hoist cables from damage.

Replacement of damaged cables is the responsibility of the barge contractor.

Cleanliness must be adhered to when working with the hydraulic components. Care must be taken to protect the fittings, hose ends, or hydraulic oil from contamination and damage. If the system is contaminated, the parts or system will have to be cleaned. This could include changing the hydraulic oil, which will be the responsibility of the barge contractor.

All bolts installed are to be torqued to specifications provided by SeaTrax. A listing of the approximate number and size of bolts to be installed is attached.

All electrical installations that can be completed at the factory will have been installed. Wiring and fixtures on the decks, gantry, and boom have been removed for shipment and will have to be installed by the barge contractor on the barge. See attached: Wiring diagram (Sheet 1 for reference only) and Cabling completion listing.

Basic Assembly Steps:

The following are the basic assembly steps required to assemble the crane. These steps should be reviewed / revised if necessary to suit the barge contractor’s requirements during the assembly.

Initial Box Barge / SeaTrax

1. Set several (minimum of 6) 8" x 8" x 3' minimum wooden beams around top of swing gear on Kingpost.

2. Rig, and set upper works onto Kingpost and rest on wooden beams, maintaining weight on slings.

3. With crane holding most of weight of upper works, shift and install the lower bearing pads. (Reference drawing 4252LB)

4. Install both boom hoists to back of upper works.

5. Install upper radial bearing onto top of Kingpost. (Reference drawing 4252UB)

6. Install radial bearing keeper ring.

7. Rig and lift gantry structure onto Kingpost and align mounting bolt holes with matching upper works boltholes.

8. Install gantry-mounting bolts and torque. (22 per side) Reference bolt Installation procedure for torque values.

9. Install rear walkway between engine and generator house. (roof level, upperworks)

10. Install ladder to rear of generator house.

11. Install railings around top of upper works.

12. Install the vent hood (complete with muffler) on top of engine house.

13. Install ladder to gantry upper bearing area.

14. Install upper thrust bearing. (Reference drawing 4252UB)

Page Completion Signature:

Barge Contractor. Date:

SeaTrax Technician: Date:

15. Install bearing cap plate.

16. Install bearing cap plate bolts and torque. Reference bolt Installation procedure for torque values.

17. Install grease lines for upper bearing.

18. Grease upper and lower bearings. Use no. 2 ep grease. This may have to be repeated a few times during assembly and initial operation of crane. Repeat as necessary.

19. Lift crane slightly and remove wooden beams. Lower crane, positioning Kingpost top into upper bearing assembly.

20. Install and lock swivel extension pipe into top of cap plate.

21. Attach ground wire to swivel and drop ground wire through extension pipe and Kingpost center pipe. Pull end of ground wire outside of Kingpost below deck.

22. Install swivel assembly on top of swivel extension pipe.

23. Connect ground wiring from crane to swivel

24. Complete ground wiring to barge structure below deck.

25. Install cab access ladder.

26. Install vibration isolators to top of cab support house.

27. Set cab support house and bolt in place.

28. Install search light to top of cab.

29. Install windspeed unit to top of cab.

30. Install cab on top of cab support house.

31. Install walkway around cab.

32. Install boom stops.

33. Install gantry sheave access platform.

34. Install ladder from rear walkway to gantry sheave platform.

35. Hook up hydraulic hoses to boom hoists. (Reference Completion of Hydraulic Hose Listing attached attached).

36. Run Eng. Throttle, kill cables & control hoses up from valve house to cab. Connect all hoses. (Approximate quantity of 15 (sizes range 3/8" to ¾”) (Reference Completion of Hydraulic Hose Listing attached).

37. Install engine exhaust to muffler. Flex pipe bolts to engine and clamps to under side of vent hood.

38. Install generator exhaust extension pipe to exhaust pipe rear of cab. Flex pipe bolts to generator and clamps to bottom of hard pipe.

39. Run all electric cables up from generator house to cab. Reference cable schedule (4252F sheets 3-5) and completion sheet attached for numbers 41 - 46)

40. Run cable from cab support house to cab.

41. Install rear cab light to cab support handrails.

42. Install gantry light to upper bearing area.

43. Install light to gantry sheave access platform.

44. Install rear deck lights, on walkway between engine house and generator house.

45. Connect battery cables to batteries.

46. Block up and connect boom sections together. Reference bolt Installation procedure for torque values.

Barge / SeaTrax

Note: Prior to installing the assembled boom, the crane maybe required to be rotated. If the crane needs to be rotated, the following steps (47-55) shall be completed. On completion of these steps the SeaTrax technician will be available to operate and rotate the crane to its required position.

Operating the crane is solely the responsibility of SeaTrax, all other activities such as checking / greasing / rigging shall be for the account of the barge contractor.

47. Check oil level in swing gearbox holding tank. Add oil if necessary. (For levels, see lubrication information attached).

48. Check oil level in boom hoist gearboxes. Add oil if necessary.

49. Grease bearing on outside end of boom hoists. Grease zerk on brake band end of hoist drum. (For type, see lubrication information attached).

50. Check hydraulic oil condition and oil level in engine. Add oil if necessary.

51. Check oil level in pump drive gearbox. Add oil if necessary.

52. Check engine oil and coolant. Add as necessary.

53. Upon engine start, rotate and align slew box shafts to Install swing pinions and retainers. Check / repair leaks as necessary and verify direction of pinions. Switch hoses as necessary.

54. Check / repair leaks as necessary and verify direction of boom hoist drums. Switch hoses as necessary.

55. Check hydraulic system for leaks.

56. Shut engine down.

57. Rig boom and lift into position with upper works.

58. Install boom foot pins, spacers and retainer bolts. Grease boom foot pins. (For type, see lubrication information attached).

59. Connect hydraulic hoses from upper to load hoists in boom. (Reference Completion of Hydraulic Hose Listing attached).

Barge / SeaTrax

Note: To complete the boom suspension reeving, it will be necessary to run the crane.

Operating the crane is solely the responsibility of SeaTrax, all other activities such as checking / greasing / rigging shall be for the account of the barge contractor.

60. Check “gantry” sheaves for freedom of movement. Grease sheaves. (For type, see lubrication information attached)

61. Check “boom” sheaves for freedom of movement. Grease sheaves. (For type, see

62. Lock out one boom hoist by removing and capping brake release line.

63. Rig one boom suspension side with synthetic line (1/2” or larger).

64. Set up boom hoist cable off end of boom. Hook to synthetic line. Use boom hoist to pull line and cable through sheaves.

65. Make sure cable lays on drum correctly and is tight.

66. Anchor cable to boom hoist drum and gantry dead end.

67. Uncap brake release hose and reattach to hoist brake.

68. Repeat instructions 62 through 67 for other hoist.

Note: Note: To complete the fast line and main line reeving, it will be necessary to run the crane. Operating the crane is solely the responsibility of SeaTrax, all other activities such as checking / greasing / rigging shall be for the account of the barge contractor.

69. Slowly pull in on boom hoists. In conjunction with this operation, the barge contractor should ensure the cable remains in tension whilst spooling onto the drum tightly. Check cable on drums and in system.

70. Raise the boom a little and stop. Check that hoists and system is operating properly.

Lower and raise a little several times before raising very high. Watch boom hoist drums to insure rope is kept tight and is spooling correctly. Do not allow rope to go slack on drum.

71. Raise boom close to boom stops to check for alignment. Shift and align booms stops as necessary.

72. Install boom limit assembly. Set boom high and low limits. High limit should be set about two feet from boom stops. Low limit should be set above horizontal well clear of deck but sufficiently low enough to set in rest. These can be easily reset later if desired.

73. Set boom in rest. Do not let boom cables go slack. Maintain some tension to keep cables tight on drum.

74. Install all ground connection cables. There are about eight cables. These connect all major sections of the crane together and through the swivel to barge ground.

Using an ohm meter check all sections of the crane to have earth continuity.

75. Note: To complete the fast line and main line reeving, it will be necessary to run the crane. Operating the crane is solely the responsibility of SeaTrax, all other activities such as checking / greasing / rigging shall be for the account of the barge contractor.

76. Upon engine start, check / repair leaks as necessary and verify direction of load hoists. Switch hoses as necessary.

77. Check “Load Sheaves” for freedom of movement. Grease sheaves. . (For type, see

78. Grease bearing on end of both load hoists, Grease zerk on inside of brake band end of hoist drums. . (For type, see lubrication information attached)

79. Set fast line load block (single sheave block) near tip of boom. Grease sheave and thrust bearing. (For type, see lubrication information attached)

80. Set fast line spool off end of boom with cable coming off of the top of the spool toward the boom.

81. Run cable through boom and anchor to front hoist drum. Make sure cable layers on drum correctly and spools on tightly.

Barge / SeaTrax

82. Using rigging diagrams, run cable through sheaves and rig to Auxiliary load block, prior to dead ending the cable install anti-two-block switch device and anchor back to boom point. Do not forget to install load cell between the dead end and cable wedge socket.

83. Set main load block (multi sheave block) near tip of boom. Grease sheaves and thrust bearing. (For type, see lubrication information attached)

84. Set main line spool off end of boom with cable coming off of the top of the spool toward the boom.

85. Run cable through boom and anchor to the back hoist drum. Make sure cable layers on drum correctly and spools on tightly.

86. Using rigging diagram, run cable through sheaves and rig to main load block. Rig for 8 part of lines. Prior to dead ending the cable install anti-two block switch. Do not forget to install load cell between the dead end and cable wedge Socket.

87. Lower and raise load blocks as necessary to insure cables are set properly on load drums.

88. Lower boom to a low position and install boom walkways. Start at butt section, but do not tighten bolts until all sections are installed and any adjustments are made.

89. When all sections are installed, tighten all mounting bolts.

90. Set boom back in rest. Do not allow load blocks to lay down and cables to go slack.

91. Install light fixtures and lights on boom. (Reference cable schedule (4252F sheets 3-

5) and completion sheet attached).

92. Install Mipeg load indicator cables from load cells in boom tip to cab.

93. Install Mipeg boom angle indicator cable from box in boom butt to cab.

94. Perform a continuity check of each circuit to verify no shorts and circuit appears to be working properly.

95. Check engine oil and coolant in generator. Add if any needed.

96. Turn off all switches and breakers. Start generator. Check that generator is running properly and run for a few minutes to warm up.

97. Step by step turn on and check out each section of the wiring circuit. Fix any problems before moving to another section of circuit. Turn off each previous circuit before turning on any new circuit.

98. After all individual circuits have been tested and verified, turn on all circuits to verify full load condition. Leave all circuits on for at least 30 minutes and check for any overheating of any part of the circuit and capacity of generator to carry full load.

99. Check to see if Load indicator appears to be working properly.

100. Operate all secondary component functions, ref. Wipers, air conditioner, lights, etc. to verify all are functioning properly.

101. Grease all sheaves, pins, upper bearings, lower bearing shoes and swing gear at this time.

102. Upon completion of the above instructions, the crane will require a run in period to prove the integrity of all the systems. SeaTrax will perform this.

Only to the satisfaction of the SeaTrax technician will this be deemed complete.

103. During the run in period the barge contractor should make the necessary arrangements to carryout the noise survey. Please refer to Solicitation No.

DACW61-98-R-0012 for complete details.

104. During the run in period SeaTrax will calibrate the Load Indicator system. This will require test weights of approximately 30 tons, 60 tons, 130 tons and 260 tons. The barge contractor will provide these and personnel to assist in positioning and rigging these weights.

The barge contractor should perform any paint repairs that may have occurred during shipment, handling and installation. Repair all damaged areas in accordance with SeaTrax paint procedure attached.

Level 2 installation and assembly / testing of the crane will only be complete on approval from the COR, and before level 3 can proceed.

Witnessed and Accepted

COR Representative: Date:

Attachments:

1. General arrangement drawing. (4252A)

2. Exploded assembly views of crane. (4252Z sheets 1-6)

3. Upper bearing assembly. (4252UB)

4. Lower bearing assembly. (4252LB)

5. Cable schedule (4252F sheets 3-5)

6. Site Run / completion of Electrical Cables Listing.

7. Completion of Hydraulic Hose Listing.

8. Lubrication Information.

9. Preliminary Bolt list.

10. SeaTrax bolt specifications and torque’s.

11. SeaTrax Paint Procedure.

Site Run / completion of Electrical Cables Listing Reference cable schedule (4252F sheets 3-7), Rev1, DGC, Feb.23.2001

The below cable listing is desired to give the crane barge manufacturer an overview of the electrical tasks to be completed prior to client handover. As a general rule; there shall be no cables or equipment installed on the boom, gantry or kingpost (load monitor sensors are installed on the boom).

The cable tray installation will be complete.

Connecting cables between the engine, generator, cab support rooms to the drivers cab is done through a junction box in the cab support room. All cables going to the cab shall be connected at both ends in this junction box enclosure.

Cable no’s A, From B, To Reinstall

AC Cables

P13 J.box,kingpost base Collector ring enclosure A & B PE13 Kingpost base ground Collector ring enclosure A & B P15 Collector ring enclosure Transfer switch,gen.house A P19 Transfer switch,gen.house Cab Control Enclosure A P21 Cab Control Enclosure Boom Light#1 A & B P22 Boom Light#1 Boom Light#2 A & B P31 Cab Control Enclosure Boom Light#3 A & B P32 Boom Light#3 Boom Light#4 A & B P41 Cab Control Enclosure Boom Light#5 A & B P42 Boom Light#5 Boom Light#6 A & B P51 Cab Control Enclosure Switch,light,Gen.Room A & B P71 Cab Control Enclosure Switch,light,Eng.Room A P102 Deck Lights,Sw.#1,cab Deck Lights,Sw.#2 B P104 Deck Lights JB101 Deck light cab/gen A P105 Deck Lights JB101 Light, upper bearing B P106 Light, upper bearing Light, upper sheaves A & B P107 Deck Lights JB101 Light#1, back w-way B P108 Light#1, back w-way Light#2, back w-way A & B P109 Deck Light sw.,emerg.,cab Deck Light,emerg. B P161 Cab Control Enclosure Battery charger,eng.Room A P191 Cab Control Enclosure Receptacle, gen.room A

Cable no’s A, From B, To Reinstall

DC Cables

C3 Cab Control Enclosure Battery charger enclosure A C5 Cab Instrument panel Generator controls A J12 Annunciator Enclosure,cab Diesel engine,eng.room A J13 Annunciator Enclosure,cab Flame detector,gen.room A J14 Annunciator Enclosure,cab Flame detector,engine room A J15 Annunciator Enclosure,cab Generator controls A C16 Cab Control Enclosure J.box16,Anti 2 block A J18-1 Load Monitor Load Sensor Main A & B J18-2 Load Monitor Load Sensor Aux A & B J18-3 Load Monitor Angle Sensor A & B C262 Main,drum rot.driver Main,drum rot.transmitter B connector C265 Aux.,drum rot.driver Aux.,drum rot.transmitter B connector C268 Boom,drum rot.driver Boom,drum rot.transmitter B connector

Grounding:

The ground cable must installed between all the barge (earth boss) and slipring, located at the top of the gantry, slipring to gantry, gantry to turntable, turntable to 1st boom section, turntable to store room, and store room to drivers cab, and drivers cab to cab control enclosure. All cable tray runs must be electrically bonded together, also the end of each tray run the tray must be grounded to the main structure.

Completion of Hydraulic Hose Listing

All connections are SAE J514, 37deg. Flared Hydraulic Tube Fitting (JIC).

Hose sizes are in 1/16th of an inch.

Conn. Hose Size From To

01 6 Slew Brake Slew Brake Valve - Cab floor Bulkhead 02 6 Slew Brake Slew Brake Pedal - Cab floor Bulkhead 03 8 Control Circuit Filter System Shutdown Valve - Cab floor Bulkhead 04 12 Return Manifold Return Manifold in Cab - Cab floor Bulkhead 05 6 Aux. Hoist Control Valve Aux. Hoist Joystick (DN) - Cab floor Bulkhead 06 6 Aux. Hoist Control Valve Aux. Hoist Joystick (UP) - Cab floor Bulkhead 07 6 Main. Hoist Control Valve Main. Hoist Joystick (UP) - Cab floor Bulkhead 08 6 Main. Hoist Control Valve Main. Hoist Joystick (DN) - Cab floor Bulkhead 09 6 Slew Control Valve Slew Joystick (L) - Cab floor Bulkhead 10 6 Slew Control Valve Slew Joystick (R) - Cab floor Bulkhead 11 6 Boom Limit Valve Boom Hoist Joystick (UP) - Cab floor Bulkhead 12 6 Boom Limit Valve Boom Hoist Joystick (DN) - Cab floor Bulkhead 13 6 Boom Hoist Control Valve Boom Hoist Pressure Gage - Cab floor Bulkhead 14 6 Load Hoist Control Valve Load Hoist Pressure Gage - Cab floor Bulkhead 15 4 Slew Control Valve Slew Pressure Gage - Cab floor Bulkhead 16 16 Return Manifold Load Hoist Return Manifold - In Boom Butt 17 16 Main Hoist Control Valve Main Hoist Motor (DN) - In Boom Butt 18 16 Main Hoist Control Valve Main Hoist Motor (DN) - In Boom Butt 19 16 Main Hoist Control Valve Main Hoist Motor (DN) - In Boom Butt 20 16 Main Hoist Control Valve Main Hoist Motor (DN) - In Boom Butt 21 8 Main Hoist Brake Valve Main Hoist Brake Actuator - In Boom Butt 22 6 Motor Cooling Valve Main Hoist Motor - In Boom Butt 23 16 Aux. Hoist Control Valve Aux. Hoist Motor (DN) - In Boom Butt 24 16 Aux. Hoist Control Valve Aux. Hoist Motor (DN) - In Boom Butt 25 16 Aux. Hoist Control Valve Aux. Hoist Motor (UP) - In Boom Butt 26 16 Aux. Hoist Control Valve Aux. Hoist Motor (UP) - In Boom Butt 27 8 Aux. Hoist Brake Valve Aux. Hoist Brake Actuator - In Boom Butt 28 6 Aux. Cooling Valve Main Hoist Motor - In Boom Butt 29 20 Boom Hoist Control Valve Left Boom Hoist Motor (DN) 30 20 Boom Hoist Control Valve Left Boom Hoist Motor (DN) 31 20 Boom Hoist Control Valve Left Boom Hoist Motor (UP) 32 20 Boom Hoist Control Valve Left Boom Hoist Motor (UP) 33 6 Motor Cooling Valve Left Boom Hoist Motor 34 8 Brake Release Valve Left Boom Hoist Brake Actuator 35 20 Boom Hoist Control Valve Right Boom Hoist Motor (DN) 36 20 Boom Hoist Control Valve Right Boom Hoist Motor (DN) 37 20 Boom Hoist Control Valve Right Boom Hoist Motor (UP) 38 20 Boom Hoist Control Valve Right Boom Hoist Motor (UP) 39 6 Motor Cooling Valve Right Boom Hoist Motor 40 8 Brake Release Valve Right Boom Hoist Brake Actuator 41 16 Return Manifold - left boom hoist Return Manifold -in return pipe 42 16 Return Manifold - right boom hoist Return Manifold -in return pipe

Preliminary Bolt list Serial No. 4252

No Size

Gantry connection 44 2" Boom connection 32 1 1/2" Upper platform 12 3/4" Bearing access platform 8 3/4" Cab walk-around 12 3/4" Cab support connection 24 1/2" Cab support handrails 16 5/8" Generator house handrails 16 5/8" Machinery house handrails 20 5/8" Upper bearing connection 24 1 1/2" Engine hood 18 5/8" Cab connection bolts 8 5/16"

4 10mm Generator house ladder 8 5/8" Machinery house ladder 8 5/8" Bearing access ladder 8 5/8' Sheave access ladder 8 5/8" Boom hoist connection 8 2" Boom butt access 4 3/4" U-bolts.

8 3/4" Boom straight access 8 3/4" U-bolts Boom point access 6 3/4" U-bolts Fly jib walk- around 12 1/2" Jib ladder 6 5/8" Boom hoist guards 12 1/2" Sheave guards 4 5/8" U-bolt