TECHNICAL MANUAL

DAVIT MODEL D5700CT

S/N 2050-2052

MANUFACTURED BY

2300 OREGON ST., SHERWOOD 97140, OR U.S.A. PHONE: 503.625.2560 FAX: 503.625.7980 E-MAIL: cranes@alliedsystems.com WEBSITE: http://www.alliedsystems.com

80-713

31 MARCH 2003

CHANGE LOG LIST OF PAGES AFFECTED

Page No. Cover 7-41

Change No. 1 1

Note: Date of issue for original manual is 31 March 03.

TABLE OF CONTENTS
CHAPTER/PARAGRAPH 1 PAGE CHAPTER/PARAGRAPH 4
4.1 4.2 4.3 4.3.1 4.3.2 4.3.3 4.4 4.4.1 4.4.2 4.4.3 4.5

PAGE

GENERAL INFORMATION AND SAFETY PRECAUTIONS

SCHEDULED MAINTENANCE
INTRODUCTION .............................................. 4-1 PREVENTIVE MAINTENANCE ....................... 4-1 SCHEDULED MAINTENANCE ....................... 4-1 Walk Around Inspection ........................... 4-1 Lubricant Specifications ........................... 4-1 Service Instructions .................................. 4-1 HYDRAULIC OIL MAINTENANCE ................... 4-4 Storage and Handling ............................. 4-4 In-Operation Care .................................... 4-5 Analysis .................................................... 4-5 EXTENDED STORAGE PROCEDURES ......... 4-5

1.1 SAFETY PRECAUTIONS ................................ 1-1 1.2 INTRODUCTION .............................................. 1-1 1.2.1 Scope ....................................................... 1-1 1.2.2 Applicability .............................................. 1-1 1.3 DAVIT DESCRIPTION ...................................... 1-1 1.3.1 Davit Installation ....................................... 1-1 1.3.2 Hydraulic Power Unit ............................... 1-1 1.3.3 Control Console ....................................... 1-1 1.3.4 Control Tension Winch ............................ 1-2 1.3.5 Swing Drive .............................................. 1-2 1.3.6 Hydraulic System ..................................... 1-2 1.3.6.1 Control Valve ............................................ 1-2 1.3.6.2 Boom System ........................................... 1-3 1.3.6.3 Swing System .......................................... 1-3 1.3.6.4 Winch System .......................................... 1-3 1.3.6.5 Emergency System .................................. 1-3 1.3.7 Electrical System ...................................... 1-3 1.3.7.1 Electric Motor ........................................... 1-3 1.3.7.2 Downstop Control .................................... 1-3 1.3.7.3 Anti-2-Block Control ................................. 1-3

5
5.1 5.1.1 5.1.2 5.2 5.2.1 5.2.2 5.2.3 5.3 5.3.1 5.3.2 5.3.3

TROUBLESHOOTING
INTRODUCTION .............................................. 5-1 Safety ........................................................ 5-1 Problem Area Isolation ............................ 5-1 PRELIMINARY TROUBLESHOOTING ............ 5-1 Pump Test ................................................. 5-1 Control Valve Test .................................... 5-1 Winch System Test ................................... 5-1 FAULT ISOLATION .......................................... 5-1 Probable Mechanical Causes ................. 5-1 Probable Hydraulic Causes .................... 5-2 Probable Electrical Causes ..................... 5-2 TROUBLESHOOTING .............................. 5-3

2
2.1 2.2 2.3 2.4 2.4.1 2.4.2 2.4.3 2.4.4

OPERATION
INTRODUCTION .............................................. 2-1 OPERATING CREW ........................................ 2-1 INSTRUMENTS AND CONTROLS .................. 2-1 OPERATING THE DAVIT ................................. 2-1 Pre-Operational Test ................................ 2-1 Launching Operation ............................... 2-1 Recovery Operation ................................. 2-2 Emergency Operation .............................. 2-2

6
6.1 6.1.1 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.3 6.3.1 6.3.1.1 6.3.1.2 6.3.1.3 6.3.1.4 6.3.1.5 6.3.1.6 6.3.1.7

CORRECTIVE MAINTENANCE
INTRODUCTION .............................................. 6-1 Maintenance Practices ............................ 6-2 HYDRAULIC AND ELECTRICAL SYSTEM ADJUSTMENTS ............................... 6-3 Main System Relief Pressure .................. 6-3 Swing Dual Counterbalance ................... 6-3 Constant Tension Winch Pressure .......... 6-4 Downstop Control Adjustment ................. 6-4 Anti-2-Block Control Adjustment ............. 6-5 Cable Tension Sensor Adjustment ......... 6-6 REPAIRS .......................................................... 6-6 Swing Drive .............................................. 6-6 Removal ................................................... 6-6 Disassembly ............................................. 6-7 Assembly .................................................. 6-7 Swing Motor Disassembly ....................... 6-7 Swing Motor Assembly ............................ 6-7 Swing Brake Disassembly ....................... 6-9 Swing Brake Assembly ............................ 6-9

3
3.1 3.2 3.2.1 3.2.2 3.2.3 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6

FUNCTIONAL DESCRIPTION
INTRODUCTION .............................................. 3-1 MECHANICAL SYSTEM .................................. 3-1 Davit .......................................................... 3-1 Winch ........................................................ 3-2 Swing Drive .............................................. 3-2 HYDRAULIC SYSTEM ..................................... 3-3 Boom System ........................................... 3-3 Swing System .......................................... 3-3 Winch System .......................................... 3-3 Emergency System ................................. 3-5 Downstop Control .................................... 3-5 Anti-2-Block Control ................................. 3-5

TABLE OF CONTENTS
CHAPTER/PARAGRAPH
6.3.1.8 6.3.1.8.1 6.3.1.8.2 6.3.1.8.3 6.3.1.8.4 6.3.1.9 6.3.1.10 6.3.1.10.1 6.3.1.10.2 6.3.1.10.3 6.3.1.11 6.3.2 6.3.2.1 6.3.2.2 6.3.2.2.1 6.3.2.3 6.3.2.4 6.3.3 6.3.3 6.3.3.1 6.3.3.2 6.3.3.2.1 6.3.3.2.2 6.3.3.2.3 6.3.3.2.4 6.3.3.2.5 6.3.3.3 6.3.3.3.1 6.3.3.3.2 6.3.3.3.3 6.3.3.3.4 6.3.3.3.5 6.3.3.4 6.3.3.4.1 6.3.3.4.2 6.3.3.4.3 6.3.3.5 6.3.3.5.1

PAGE

CHAPTER/PARAGRAPH
6.3.3.5.2 6.3.3.5.3 6.3.3.6 6.3.3.6.1 6.3.3.6.2 6.3.3.7 6.3.3.7.1 6.3.3.7.2 6.3.3.7.3 6.3.3.7.4 6.3.3.7.5 6.3.3.7.6 6.3.3.8 6.3.3.9

PAGE

Swing Gear Reducer Disassembly ....... 6-10 Primary Carrier Disassembly ................. 6-11 Secondary Carrier Disassembly ........... 6-11 Primary Carrier Assembly ..................... 6-11 Secondary Carrier Assembly ................ 6-12 Swing Gear Reducer Assembly ............ 6-12 Swing Bearing ........................................ 6-12 Wear Check ............................................ 6-12 Disassembly and Inspection .................. 6-13 Assembly ................................................ 6-14 Swing Drive Installation ......................... 6-14 Boom System ......................................... 6-14 Boom Lift Cylinder Removal .................. 6-14 Boom Lift Cylinder Disassembly ............ 6-14 Piston Seal Replacement ...................... 6-15 Boom Lift Cylinder Assembly ................. 6-15 Boom Lift Cylinder Installation ............... 6-16 Constant Tension Winch ........................ 6-16 Constant Tension Winch ........................ 6-16 Removal ................................................. 6-16 Disassembly ........................................... 6-16 Constant Tension End Disassembly ..... 6-16 Load Motor End Disassembly ................ 6-16 Spacer Removal .................................... 6-18 Piston and Housing Removal ................ 6-18 Drum and Brake Disassembly ............... 6-21 Assembly ................................................ 6-21 Drum and Brake Assembly .................... 6-22 Piston and Housing Installation ............ 6-22 Spacer Installation ................................. 6-22 Load Motor End Assembly ..................... 6-23 Constant Tension Motor End Assy ........ 6-23 Load Motor ............................................. 6-24 Disassembly ........................................... 6-24 Inspection ............................................... 6-25 Assembly ................................................ 6-25 Constant Tension Motor ......................... 6-26 Disassembly ........................................... 6-26

Inspection ............................................... 6-26 Assembly ................................................ 6-27 Winch Brake ........................................... 6-28 Disassembly ........................................... 6-28 Assembly ................................................ 6-28 Winch Gear Reducer ............................. 6-30 Gear Reducer Disassembly ................... 6-30 Primary Carrier Disassembly ................. 6-30 Secondary Carrier Disassembly ........... 6-30 Primary Carrier Assembly ..................... 6-30 Secondary Carrier Assembly ................ 6-30 Gear Reducer Assembly ........................ 6-31 Winch Installation ................................... 6-31 Winch Cable Installation ........................ 6-32

7
7.1 7.1.1 7.1.2 7.2 7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6

PARTS LIST
INTRODUCTION .............................................. 7-1 Major Subassemblies .............................. 7-1 Special Notes ........................................... 7-1 FORMAT .......................................................... 7-1 Item ........................................................... 7-1 Notes ........................................................ 7-1 ASC P/N ................................................... 7-1 Qty ............................................................. 7-1 Description ............................................... 7-1 Illustrations ............................................... 7-1

8
8.1 8.2 8.3 8.4

INSTALLATION
GENERAL ........................................................ 8-1 DAVIT INSTALLATION ..................................... 8-1 PREPARATION FOR OPERATION .................. 8-2 PREPARATION FOR RESHIPMENT ............... 8-2

ii

ABBREVIATIONS AND ACRONYMS

ABS .................... American Bureau of Shipping Adj .................................................. Adjustment amp ...................................................... Ampere API ....................... American Petroleum Institute APL ....................................Allowance Parts List A/R ................................................ As Required ASC .......................... Allied Systems Company Aux ...................................................... Auxiliary AWG ............................... American Wire Gauge bar ...................... 14.5 pounds per square inch Brg ....................................................... Bearing CAGE ................. Commercial And Government Entity cid ............................. cubic inch displacement CNTRL ................................................... Control CT .......................................... Constant Tension CTRL ..................................................... Control DIN ...................... Deutsche International Norm EIPS ..................... Extra Improved Plough Steel Elec .................................................... Electrical Ext ........................................................ External F ....................................................... Fahrenheit C ........................................ Celsius (centigrade) fpm ........................................... feet per minute FSCM ........................ Federal Supply Code for Manufacturers gal .......................................................... Gallon Galv ................................................. Galvanized Gnd ...................................................... Ground gpm .................................... Gallons Per Minute hp .................................................. Horsepower HPU ................................. Hydraulic Power Unit Hyd .................................................... Hydraulic Hz ............................ Hertz (cycles per second) ID .............................................. Inside Diameter IEEE ........................... Institute of Electrical and Electronic Engineers ISO ......... International Standards Organization IWRC ................. Independent Wire Rope Core kPa ................................................... kilopascal kw ......................................................... Kilowatt lb ............................................................ pound lbs ........................................................ pounds LH ...................................................... Left Hand lpm ......................................... Liters Per Minute LT ................................................................. Left Max .................................................... Maximum micron ..................................... 0.001 millimeter Min ..................................................... Minimum N.C. ........................................ Normally Closed N.O. .......................................... Normally Open NATO .......... North Atlantic Treaty Organization NC ........................................... National Coarse NEMA .......... National Electrical Manufacturers Association NF ............................................... National Fine NLGI ....... National Lubrication Grease Institute N-m ............................................. Newton-meter Nom .................................................... Nominal NPTF ................ National Pipe Tapered for Fuel NSS ............................ Not Serviced Separately NSTM ................... Naval Ship Technical Manual OD ......................................... Outside Diameter PC ................................ Pressure Compensator Pl ...............................................................Plate P/N ............................................... Part Number POS ...................................................... Position Pot .............................................. Potentiometer psi ............................... pounds per square inch PVB .................................... Pump Side Module PVE ...................... Proportional Valve Electrical Qty ...................................................... Quantity Ref .................................................... Reference RH .................................................. Right Hand rpm ............................... Revolutions Per Minute RT ............................................................. Right SAE ............... Society of Automotive Engineers SOL .................................................... Solenoid SOLAS .............................. Safety Of Life At Sea Spec ............................................. Specification SS .............................................. Stainless Steel SW .......................................................... Switch TEFC ................. Totally Enclosed, Fan-Cooled Thk ........................................................... Thick TMCR ..................... Technical Manual Contract Requirement TYP ........................................................ Typical v ................................................................. Volt vac .............................. Volts Alternating Current vdc ..................................... Volts Direct Current VOM ........................................ Volt-Ohm Meter

iii

SAFETY SUMMARY
GENERAL SAFETY NOTICES Summarized on the following pages are general safety notices which supplement specific warnings and cautions appearing elsewhere in this manual. Since all electrical and hydraulic equipment is dangerous when operated or maintained incorrectly, you must thoroughly review and understand the Safety Summary before attempting to operate, troubleshoot or service this crane. The following symbols/terms are used to emphasize safety precautions and notices in this manual: OPERATING SAFETY Qualifications This crane must be operated and maintained by experienced, trained personnel. You must receive training prior to operating this crane. If you do not routinely operate this crane, refresher training is recommended. You must reacquaint yourself with this manual and the equipment before starting, then proceed slowly. Do Not Operate Alone It is essential that someone be on deck to watch clearances and give hand signals. Ensure that the director is clear of the crane and the load before you move it. Do not move the crane or load if you cannot see this person. Equipment Hazards Do not operate this crane if you know of malfunctions, missing parts, and/or misadjustments. Any one of these situations can cause or contribute to an accident or damage the crane. Lower the load and stop the crane immediately if problems arise after starting. Do not start the hydraulic power unit if the start switch has been tagged-out with a DO NOT START or other red tag. Never allow anyone under the load. Ensure the area is clear before moving the crane or the load. Never attempt any lifting operation with fewer than five wraps of cable on the winch drum. Cable clamps are not designed to hold loads. Never attempt to dismantle any of the safety devices built into the crane. When swinging the boom, always ensure that there is adequate clearance for both the boom and the load.

THE WARNING SYMBOL APPEARS WHEREVER INCORRECT OPERATING PROCEDURES OR PRACTICES COULD CAUSE SERIOUS INJURY OR DEATH. CAREFULLY READ THE MESSAGE THAT FOLLOWS TO PREVENT SERIOUS INJURY OR DEATH.

CAUTION
THE CAUTION SYMBOL APPEARS WHEREVER INCORRECT OPERATING PROCEDURES OR PRACTICES COULD CAUSE DAMAGE TO EQUIPMENT. CAREFULLY READ THE MESSAGE THAT FOLLOWS TO PREVENT EQUIPMENT DAMAGE. NOTE: The term NOTE highlights operating procedures or practices that may improve equipment reliability and/or personnel performance. NOTE: All possible safety hazards cannot be foreseen so as to be included in this manual. Therefore, you must always be alert to potential hazards that could endanger personnel and/or damage the equipment.

iv

SAFETY SUMMARY
Do not overload the crane. Always operate within the rated capacity of the crane and rigging. Refer to the load chart for this cranes lifting capacity. Inspect slings, chokers and other rigging devices frequently for cuts, abrasion, rust, kinks or other damage. Do not use suspected defective equipment to lift or move a load. Always wear appropriate safety clothing and use prescribed safety equipmenthead, foot, hand and eye protection, etc. Accurately place the load, keeping in mind how you expect the load to respond when released. Lower and remove the load before leaving the crane or securing hydraulic power. Maintain proper clearance from energized equipment. If the crane contacts energized equipmentstay clear of the crane and prevent anyone else from coming in contact with the crane. If you are on the crane, stand fastDo not jump off. MAINTENANCE SAFETY Unless properly serviced, this crane can be extremely dangerous. Qualifications In order to ensure safety, each person working on this crane must have the necessary skills, information, tools and equipment. Do not attempt to make adjustments, or perform repairs unless you are authorized and qualified to do so. Do Not Work Alone Never attempt to service energized equipment alone. Someone capable of rendering aid in the event of accidental shock must be present. Do not rely on the hydraulic system to support any part of the crane during maintenance or lubrication. Never stand under a crane component that is supported only by the hydraulic system. Ensure components are resting on their mechanical stops or supported with appropriate safety stands during maintenance or lubrication. Unless otherwise directed in this manual, never attempt servicing while power is applied. Tag the START switch and/or the disconnect switch with a DO NOT START sign when required. Never attempt servicing while the crane is moving or the hydraulic power unit is running. Lower the load and secure power. Equipment Safety Test Equipment. Ensure test equipment is in good condition. If an instrument must be held while taking measurements, ground the case of the instrument before energizing equipment. Do not touch live equipment or personnel working on live equipment while holding a multimeter. Some types of measuring devices should not be groundeddo not hold such devices while taking measurements. Heavy Equipment. Prevent personal injury or equipment damage by using a lifting device with a lifting capacity greater than twice the weight of any equipment to be lifted. Pressurized Equipment. Wear safety goggles when working on or near pressurized equipment. Lower all loads and relieve all hydraulic pressure before disconnecting hydraulic lines. Otherwise, the load could fall on you or pressurized hydraulic oil could cause severe personal injury. Never try to stop a hydraulic leak with any part of your body.

SAFETY SUMMARY
Electrical Hazards An electric shock could be fataltypically, the hydraulic power unit (HPU) is driven by a 440 vac, 3-phase, 60 Hz motor. Ensure power to the crane is OFF before opening electrical panels. Never attempt electrical testing or repairs while standing in water. Remove watches, rings, or any jewelry that may contact energized circuits. Hot Oil Hazards Burns from hot oil can be severeAlways allow lubricating and hydraulic oil to cool before draining. Fire Hazards Hydraulic oil is flammable. Do not smoke when checking or filling the tank. Keep open flames and sparks away from the crane. Regular steam cleaning is recommended for fire prevention and improves general safety by removing oil, and dirt accumulations. Never overfill the hydraulic tank because the overflow could contribute to a fire. Immediately repair any hydraulic leaks and clean up spills. Compressed Air Hazards When using compressed air to dry parts, pressure should not exceed 30 psi (200 kPa). Air pressure penetrating your skin can be fatal. Never direct compressed air at anyone. Falling Hazard Due to the height of some lubrication points, it is essential to personnel safety that approved ladders, personnel lifts and/or scaffolding be used while servicing this crane. Always lower the crane as far as possible before attempting to perform repairs or service. Always use safety treads and handholds where provided. The crane can be dangerously slick whenever oily surfaces are exposed to rain or frost.

vi

CHAPTER 1 GENERAL INFORMATION AND SAFETY PRECAUTIONS

1.1 SAFETY PRECAUTIONS Warnings and cautions appearing throughout this technical manual are of paramount importance to personnel and equipment safety. Before attempting to operate, troubleshoot, or service this equipment, you must thoroughly review and understand the Safety Summary that precedes this chapter. The following symbols/terms are used to emphasize safety precautions in this manual: 1.2.1 Scope This manual provides sufficient instructions to enable personnel to accomplish the following: 1. 2. 3. 4. 5. Install the crane. Prepare, operate, and secure the crane. Detect, isolate, and correct malfunctions. Remove, repair or replace, and reinstall parts. Perform scheduled maintenance.

Intermediate and depot level maintenance, specifically inspection, operability tests, fault isolation, and overhaul of items such as motors, brakes, and winches, will normally be accomplished at more extensive shop facilities. 1.2.2 Applicability This manual is applicable to the Model D5700CT Boat Davit. 1.3 DAVIT DESCRIPTION See Figure 1-1. The boat davit was developed for the launching and retrieving rigid inflatable boats (RIB's) in heavy seas. This davit is rated for a safe working load of 5,700 pounds at maximum extension of 14 ft - 6 in, and has the capability to raise and lower the hook approximately 58 feet on a 5/8 inch diameter (6 x 37) EIPS Type 1, Class 3 wire rope, rated for nominal breaking strength of 41,200 pounds. Winch hoisting speed is 85-100 feet per minute (fpm). Boom hoist speed is approximately 6 degrees per second. Swing rate is approximately 2 rpm. 1.3.1 Davit Installation The davit weldment and jib boom, the structural members which support the load, are constructed of ASTM A514B, 100,000 lb minimum yield steel with continuous welds. The winch is mounted to the jib boom assembly and a quick release hook is rigged for one-part reeving from the winch line, through a sheave. A shear ball type swing bearing is bolted to the underside of the davit to complete the davit and bearing assembly which is in turn bolted to a flanged pedestal welded to the deck. 1.3.2 Hydraulic Power Unit See specific Technical Manual for information pertaining to the hydraulic power unit and/or its components. Allied Systems did not supply the hydraulic power unit. 1.3.3 Control Console See Technical Manual TP2753A for information regarding the control console and/or its components. 1-1

THE WARNING SYMBOL APPEARS WHEREVER INCORRECT OPERATING PROCEDURES OR PRACTICES COULD CAUSE SERIOUS INJURY OR DEATH. CAREFULLY READ THE MESSAGE THAT FOLLOWS TO PREVENT SERIOUS INJURY OR DEATH.

CAUTION
THE CAUTION SYMBOL APPEARS WHEREVER INCORRECT OPERATING PROCEDURES OR PRACTICES COULD CAUSE DAMAGE TO EQUIPMENT. CAREFULLY READ THE MESSAGE THAT FOLLOWS TO PREVENT EQUIPMENT DAMAGE. NOTE: The term NOTE highlights operating procedures or practices that may improve equipment reliability and/or personnel performance. NOTE: All possible safety hazards cannot be foreseen so as to be included in this manual. Therefore, you must always be alert to potential hazards that could endanger personnel and/or damage the equipment. 1.2 INTRODUCTION This manual has been prepared to assist personnel operating and servicing the D5700CT Low Profile DAVIT. Chapters 1 through 6 comprise the operating and servicing instructions, Chapter 7 contains parts lists for all components of the crane and Chapter 8 provides installation procedures.

CABLE ANCHOR CABLE DRUM

DOUBLE PLANETARY GEAR REDUCER

MAIN WINCH HYDRAULIC MOTOR

CONSTANT TENSION VANE TYPE HYDRAULIC MOTOR CONSTANT TENSION CLUTCHES WINCH FRAME

AMC128

MAIN WINCH BRAKE

SPRING BRAKE

Figure 1-2 Constant Tension Winch

1.3.4 Constant Tension Winch See Figure 1-2. A constant tension type winch is mounted to the jib boom. The winch consists of a load hydraulic motor, constant tension hydraulic motor, planetary gear reducer, spring applied/hydraulically released friction brakes, frame, cable drum and shaft. Bare drum line pull is 8,000 pounds, and bare drum speed is approximately 85 fpm. A sprague clutch in the main winch brake allows the load to be lifted without brake drag. 1.3.5 Swing Drive See Figure 1-3. Two swing drives bolted to the davit base provide swinging at approximately 2 rpm. Each drive consists of a roller stator type hydraulic motor, spring applied/ hydraulically released brake, gear reducer and pinion. The pinion engages external gear teeth in the outer race of the swing bearing to drive the davit left or right. Adjustable swing stops are designed to limit the swing arc to 135 degrees in either direction from center. 1.3.6 Hydraulic System

LEGEND 1. HYDRAULIC MOTOR 2. BRAKE 3. GEAR REDUCER 4. PINION

2 3

1.3.6.1 Control Valve See Technical Manual TP2753A for information regarding the control console and/or its components.

Figure 1-3 Swing Drive

1-2

AMC 083

1.3.6.2 Boom System The boom system controls hydraulic power to extend and retract the jib boom. Hydraulic pressure from the control valve applied to the double acting boom lift cylinder extends the boom. 1.3.6.3 Swing System The swing system controls hydraulic power to swing the davit. Hydraulic pressure from the control valve releases the swing brakes and turns the swing motors. A lever operated swing stop valve, mounted to the underside of the davit, automatically limits swing arc. Dual counterbalance valves at the swing motor ports hydraulically lock the swing motors until activated. 1.3.6.4 Winch System The winch system controls hydraulic power to the winch for either normal hoisting and lowering, or constant tension functions. Hydraulic power is applied to either a load or constant tension hydraulic motor. A counterbalance valve hydraulically locks the winch and keeps the load from dropping. A spring applied hydraulic release brake acts as a parking brake. 1.3.6.5 Emergency System The emergency operating system is designed to allow limited use of the hydraulically controlled functions of the davit (hoist, slew and lowering) in the event of a loss of power. The system components are located on the control console. See Technical Manual TP2753A for information regarding the control console and/or its components. 1.3.7 Electrical System Both power distribution and control functions are served by the electrical system. For this reason, the electrical system is divided into Primary Crane Control and HPU subsystems.

1.3.7.1 Electric Motor The hydraulic pump is driven by a 50 hp 460 vac 3-phase, 60 Hz electric motor. This motor is energized by a solid state soft start system. 1.3.7.2 Downstop Control The Downstop Control is designed to prevent the operator from paying out the winch cable beyond the last three wraps on the drum. The Downstop Control consists of a springloaded drum roller, a proximity switch and a cam. 1.3.7.3 Anti-2-Block Control The Anti-2-Block Control is designed to prevent the operator from 2-blocking the davit (hoisting the hook into the sheave). The Anti-2-Block Control consists of a proximity switch, a spring and a weight and cable.

1-3

Characteristics Ratings: Safety Factor, Structural Safety Factor, Wire Rope Load Hoist Speed Swing Speed Swing Arc Wire Rope Hook Test Weights: Dynamic (150% of Rated Load) Static (200% of Rated Load) Electrical Power Requirements: Hydraulic System: Operating Pressure Relief Pressure Required Pump Output Temperature Range Hydraulic Fluid Hydraulic Power Unit: Control Valve Boom: Externally Applied Forces Maximum Shock Pressure Winch: Maximum Rated Load Normal Hoisting Speed Constant Tension Speed Resistance (Constant Tension Mode) Gear Ratio (Normal Hoisting) Drum Torque Drum Speed Drum Capacity Maximum CT Pressure Load Hydraulic Motor Constant Tension Hydraulic Motor Winch Brake

Description 6:1 5:1 5,700 lbs 85 fpm nominal (Bare Drum Speed) 2 rpm nominal 135 in each direction from center 5/8" 6 x 37 EIPS RR-W-410 Type 1 Class 3 Nominal Strength 41,200 lbs 5,700 lb Capacity, Quick Release 8,550 lbs 11,400 lbs 460 vac, 3-phase, 60 Hz 2,500 psi 2,750 psi 34 gpm 0 F to 180 F (-17 C to 82 C) Mobil DTE 13M (MIL-H-17672, 2110-T-H) See TP2754 See TP2753A Double Acting Column Loading Only 3000 psi Constant Tension Type 5,700 lbs 85-100 fpm 550 fpm 25-300 lbs 40 : 1 38,590 lb-in 32 rpm 75 feet, 5/8" cable 1200 psi 4.5 cid Gear Type 7.0 cid Vane Type Spring applied/hydraulically released multiple disc type with oneway sprag clutch

Table 1-1 Reference Data 1-4

Characteristics Hydraulic System: (continued) Swing: Swing Bearing Number of Teeth Maximum Torque Hydraulic Motor Gear Ratio Maximum Intermittent Output Torque Maximum Input Speed Swing Brake Environmental: Atmospheric Temperature Humidity Stability

Description

Shear Ball Roller Type 84 102,500 lb-ft Maximum Moment 6.8 cid each - Roller Stator Type x 2 40.96 :1 100,000 lb-in 3,000 rpm Spring applied/hydraulically released multiple disc type

Davit and equipment will withstand frequent soaking by salt spray and ambient atmospheric conditions Davit and equipment will operate within ambient temperature range of -40 to 120 F Davit and equipment will withstand effects of relative humidity ranging from 0 to 100% under operating and stowage conditions Davit is capable of lifting and swinging its rated load at maximum boom extension of 14 feet - 6 inches at 10 degrees adverse list

Table 1-1 Reference Data - Continued 1-5

Model ........................................................... D5700CT Nomenclature ............................................. Boat Davit Rated Capacity ............................................ 5,700 lbs Overturn Moment .......................................93,150 lb-ft Swing Moment ....................................... 542,041 lb-in Davit Gross Weight ....................................... 4,750 lbs Winch Gross Weight ........................................ 950 lbs

NOTE: Capacities shown in this manual make no allowances for freely suspended loads, operating speeds, or weights of any accessories.

25" SWING RADIUS (635 mm)

Note: For information regarding HPU or control console , consult Technical Manuals Tp2754 and TP2753A respectively

BEARING INSTALLATION: SEE TABLE 7-2, PAGE 7-5 AND TABLE 7-4, PAGE 7-7

34" (864 mm)

SINGLE PART REEVING WITH TOTAL SIDE TO SIDE SWING MOTION OF 60 STORAGE HEIGHT

113.25" (2877 mm)

153.50" MAX (3899 mm)

TO DECK 6" BORE (152 mm) TO DECK

137.50" MAX (3493 mm) 37.50" (952 mm)

DECK

168" (4267 mm) DAVIT INSTALLATION

AMC443

Figure 1-4 Dimensional Data 1-6

CHAPTER 2 OPERATION
2.1 INTRODUCTION This chapter provides detailed information and step-by-step instructions for safely and effectively operating the Boat Davit, model D5700CT. Use extreme care when operating this equipment for the first time. Inexperienced operators should perform the various functions with no load to become familiar with the davit and its controls. 2.2 OPERATING CREW The full operating crew will be specified by the ships manning document. Normally the davit will be controlled by one (1) crew member, the operator. Additional crew members will be required to tend the hook, give signals to the operator, and handle rigging. 3. Ensure the Emergency Valve is in the charge (closed) position. 4. Press the Start Pushbutton and ensure the HPU starts. Allow the system to warm up, and ensure that the Accumulator Pressure Gauge reads approximately 2500 psi. 2.4.2 Launching Operation The following procedure is used for lowering a boat into the sea during rough weather. 1. Perform the Pre-Operational Test specified in paragraph 2.4.1. 2. Use the boom, swing and winch controls to position the boat for launching. Boom Control Lever - Pulling the lever rearward raises the boom. Pushing the lever forward lowers the boom. 2.3 INSTRUMENTS AND CONTROLS The davit was designed to interface an array of existing consoles that are current onboard equipment. Though the functions of different consoles are very similiar, there may be differences in physical layouts of the components such as indicator lights, push bottons and control valve handles. Reference the instruments and controls section of the manual supplied with your original crane for specific control locations. The operator should become thoroughly familiar with the location and function of all instruments and controls before operating the davit. Check all instruments immediately upon starting, and at frequent intervals during operation to ensure proper care through prompt detection of irregularities. If any instrument or control does not register or operate properly, secure power, and locate and correct the cause before resuming operation. 2.4 2.4.1 OPERATING THE DAVIT Pre-Operational Test Swing Control Lever - Pulling the lever rearward swings the davit to the right. Pushing the lever forward swings the davit to the left. Winch Joystick - Pulling the lever rearward raises the load. Pushing the lever forward lowers the load. NOTE: If the Constant Tension Select pushbutton is pressed while the boat is suspended by the winch, the winch cannot go into constant tension mode. As soon as the boat is supported by the water and the cable becomes slack, the boom cylinder pressure switch activates the selector valve solenoid and puts the system into constant tension mode. 3. As the boat approaches the water, the operator depresses the Constant Tension Select pushbutton which turns on the amber light in the switch. When the boat enters the water, the system shifts into constant tension mode and the yellow Constant Tension Engaged indicator light comes on. Move winch joystick back for maximum tension. 4. In order to release the hook from the boat, the winch joystick must be returned to the MIN TENSION position. This will allow the crew and the seas to pay out cable from the drum.

1. Check the reservoir fluid level on the hydraulic power unit (HPU) sight gauge, if one exists. 2. Cycle Swing and Boom Control Levers respectively, and ensure that they return to neutral position when released.

2-1

and then move the winch joystick to MIN TENSION so that cable tension will be zero. IF A DELAY OCCURS IN THE BOAT OR IF WEATHER CONDITIONS ARE EXTREME, THE WINCH JOYSTICK MAY BE EASED BACK INTO MAXIMUM TENSION POSITION (PULLED REARWARD) TO STABILIZE THE BOAT AND PREVENT SLACK FROM ENDANGERING THE CREW MEMBERS. THE WINCH JOYSTICK MUST BE RETURNED TO MINIMUM TENSION POSITION (NEUTRAL) BEFORE ANY AT TEMPT AT RELEASING THE HOOK FROM THE BOAT. 5. When the hook has been released from the boat and the operator, is ready to retrieve the cable, quickly move the winch joystick to the right and return it to the neutral position to cancel the constant tension mode. The yellow Constant Tension Engaged indicator light will go out, and the winch will be in normal hoisting mode.

IF A DELAY OCCURS IN THE BOAT OR IF WEATHER CONDITIONS ARE EXTREME, THE WINCH JOYSTICK MAY BE EASED BACK INTO MAXIMUM TENSION POSITION (PULLED REARWARD) TO STABILIZE THE BOAT AND PREVENT SLACK FROM ENDANGERING THE CREW MEMBERS. THE WINCH JOYSTICK MUST BE RETURNED TO THE MINIMUM TENSION POSITION (NEUTRAL) BEFORE ANY ATTEMPT AT CONNECTING THE HOOK TO THE BOAT. 4. When the crew has connected the hook to the boat, slowly move the winch joystick rearward. This gradually increases tension so the boat can rise and fall on a taut cable. 5. As the boat reaches the crest of a wave, cancel constant tension by moving the winch joystick quickly to the right and immediately returning it to hoist position. At this time the winch will be in normal hoisting mode, and will begin hoisting the boat at a speed which corresponds to the winch joystick position. (Sometimes it is easier to watch the drum paying out and taking in cable to determine the best point to hoist the boat.)

IF THE WINCH JOYSTICK IS MOVED SLOWLY FROM MAX TENSION POSITION TO CANCEL CONSTANT TENSION, OR IS ALLOWED TO REST IN MAX TENSION POSITION, THE HOOK WILL BE RETRIEVED AT A SPEED IN EXCESS OF 500 FPM. 6. Move the winch joystick back to WINCH UP to retrieve the hook. 2.4.3 Recovery Operation The following procedure is used for recovering a boat from the sea during rough weather. 1. Perform the Pre-Operational Test specified in paragraph 2.4.1. 2. Use the boom, swing and winch controls to position the boat for recovery. Boom Control Lever - Pulling the lever rearward raises the boom. Pushing the lever forward lowers the boom. Swing Control Lever - Pulling the lever rearward swings the davit to the right. Pushing the lever forward swings the davit to the left. Winch Joystick - Pulling the lever rearward raises the load. Pushing the lever forward lowers the load. 3. Lower the hook and depress the Constant Tension Select pushbutton (9) until the indicator light in the switch comes on 2-2

IF CONSTANT TENSION MODE IS CANCELLED WHILE THE BOAT IS TENDING DOWN A SWELL, THE DAVIT WILL SHOCK THE LOAD, CREATING THE POTENTIAL FOR DAVIT FAILURE. 6. When the boat is clear of the water, slow hoisting and when the boat clears the deck edge, position the boat over its cradle so it can be lowered and secured.

2.4.4 Emergency Operation Should an electrical power failure occur which prevents starting the hydraulic power unit, the davit is equipped with a backup hydraulic/mechanical system to launch. Operators should practice using the emergency systems to reduce confusion in the event of an actual emergency. All emergency lowering components with exception to the winch lowering tee handle are located on the console. See Technical Manual TP2753A for information pertaining to the use of the emergency operation components.

CHAPTER 3 FUNCTIONAL DESCRIPTION

3.1 INTRODUCTION The model D5700CT Boat Davit provides the capability to launch and retrieve rigid inflatable boats (RIB's) in uneven seas by use of a constant tension winch. When placed in Constant Tension mode, this winch reels the cable in and out automatically, maintaining cable tension, in response to rising and falling seas. The functions and capabilities of the davit are the result of several systems working together: Davit; Winch; Swing Drive(s); Operator Controls; Hydraulic System; Electrical System; and the Hydraulic Power Unit. Note: The control console and power unit were not supplied with the davit. Consult TP2754 for information regarding the hydraulic power unit and 2753A for information regarding the control console. 3.2 MECHANICAL SYSTEM

3.2.1 Davit The davit weldment and jib boom are the structural members which support the load, and the winch is mounted to the jib

JIB BOOM

ANTI-2-BLOCK CONTROL

DAVIT

SHEAVE CASE

LIFT CYLINDER HYDRAULIC LID SWING DRIVES

DOWNSTOP CONTROL QUICK RELEASE HOOK

SWING BEARING

DAVIT INSTALLATION

Figure 3-1 Component Identification 3-1

CABLE ANCHOR CABLE DRUM

DOUBLE PLANETARY GEAR REDUCER

MAIN WINCH HYDRAULIC MOTOR

CONSTANT TENSION VANE TYPE HYDRAULIC MOTOR CONSTANT TENSION CLUTCHES WINCH FRAME

AMC128

MAIN WINCH BRAKE

SPRING BRAKE

Figure 3-2 Constant Tension Winch

boom. An automatic release hook is rigged for one-part reeving from the winch line, through a sheave at the tip of the jib boom. A shear-ball type swing bearing is bolted to the underside of the davit weldment. The davit and bearing assembly is in turn bolted to the pedestal, which is welded to the deck. 3.2.2 Winch See Figure 3-2. The Constant Tension Clutches freewheel in WINCH UP, but prevent the Cable Drum from turning in the opposite direction unless the Spring Brake is released by WINCH DN selection. In Constant Tension Mode, the Constant Tension Clutches disconnect the Load Hydraulic Motor from the drivetrain and valves installed in manifolds bolted to the Constant Tension Hydraulic Motor control winch operation. 3.2.3 Swing Drive See Figure 3-3. Two Swing Drives are required to operate the davit. A dual counterbalance valve is used to release the Swing Brakes as fluid is directed to the Swing Hydraulic Motors. Pinions engage external gear teeth on the outer race of the swing bearing.

LEGEND 1. HYDRAULIC MOTOR 2. BRAKE 3. GEAR REDUCER 4. PINION

2 3

Figure 3-3 Swing Drive 3-2

AMC 083

3.3

HYDRAULIC SYSTEM counterbalance valve traps fluid inside the swing motors, preventing them from rotating, and the swing brakes are also engaged. Hydraulic pressure applied to the swing dual counterbalance valve is directed first through an internal shuttle valve to release the swing brakes. Then the swing dual counterbalance valve begins to open at 500 psi (3,447 kPa), and relieves at 2000 psi (13,789 kPa) allowing fluid to return to tank. A lever actuated swing stop valve vents pressure to tank whenever the davit swings into the mechanical swing stop, to prevent abrupt stops. 3.3.3 Winch System See Figure 3-4. The winch system distributes hydraulic fluid to the winch for either normal hoisting, or constant tension functions. Hydraulic power is applied to either the load or constant tension hydraulic motor in the winch. A counterbalance valve controls return oil flow in the lowering direction during normal hoisting. Normal hoisting is controlled by directing oil to the load hydraulic motor, which drives the cable drum through double planetary reduction gears, then through a spring applied/ hydraulically released brake equipped with an integral one-way roller clutch. The one-way roller clutch freewheels in the up direction, but prevents the shaft from rotating in the down direction unless the brake is released by hydraulic pressure from WINCH DN selection. Ultimately, the drum is driven

3.3.1 Boom System See Figure 3-7. In order to prevent free fall, the boom system is designed to be powered down as well as up. When the boom control lever is actuated, fluid passes through the boom control valve section to the boom lift cylinder junction block. The boom lift cylinder junction block is mounted directly to the base end of the boom lift cylinder and it houses the load lock valve. The load lock valve allows free flow to the base (lifting) end of the boom lift cylinder and a check valve built into the cartridge prevents reverse flow to the control valve. Then the load lock valve prevents the boom from lowering until sufficient back pressure, 850 psi, accumulates in the stem (lowering) end of the boom lift cylinder. Finally, the load lock valve discharges to tank at 3400 psi to protect the davit from hydraulic shock loading and pressure spikes. 3.3.2 Swing System See Figure 3-7. When the swing control lever is actuated, fluid passes through the swing dual counterbalance valve to release the spring applied/hydraulically released swing brakes and drive the swing hydraulic motors. The swing hydraulic motors are mounted in line with the swing brakes and the swing gear reducers. The swing dual counterbalance valves lock the swing drives hydraulically until rotation is directed by the control valve. When the swing lever is not actuated, the swing dual

LEGEND 1. Winch Electrically Operated Relief Valve 2. CT Hydraulic Motor 3. Winch Check Valve 4. Main Hydraulic Motor 5. Winch Counterbalance Valve 6. Winch Solenoid Valve 7. Winch Pressure Reducing Valve 8. CT Winch Sequence Valve

1 5 8

EMERGENCY LOWER

CT RETURN

CT PRESSURE

WINCH UP

WINCH DOWN

Figure 3-4 Constant Tension Winch 3-3

AMC476

through a spring clutch which locks the shaft (hub) to the drum. In constant tension mode, the load hydraulic motor is disconnected from the drivetrain when the spring clutch is hydraulically released allowing the constant tension hydraulic motor to drive the cable drum directly. Manifolds bolted to the constant tension motor contain valves that control the constant tension winch: The electrically operated proportional relief valve (1) controls the pilot pressure to the constant tension relief valve. It is factory set and should not require adjustment. The sequence valve is set to 1200 psi to ensure that there is enough pressure to release the clutch which sets line tension. The pressure reducing valve is set at 800 psi to limit the pressure applied to the clutch piston. An electrical solenoid valve connects the constant tension clutch directly to tank when the winch is in normal hoisting mode. This allows faster transition from constant tension mode to normal hoisting mode. When the solenoid valve is shifted to constant tension position, hydraulic pressure releases the spring applied /hydraulically released clutch, disconnecting the shaft (hub) from the normal hoisting drivetrain.

3.3.4 Emergency System See Figure 3-7. The emergency system consists of the emergency valve, hand pump, accumulator, emergency winch control lever and the accumulator pressure gauge. During normal operation hydraulic pressure passing through a parallel check valve is stored in the accumulator. The hand pump is used to recharge the accumulator during emergency operation. The boom and swing control levers function as in normal operation, but are powered by the accumulator through the emergency valve.

IF THE SWING JUNCTION BLOCK NEEDLE VALVE IS ROTATED EXCESSIVELY, THE BOAT CAN FREE FALL RESULTING IN PERSONAL INJURY OR DEATH.

6 LEGEND 1. PROXIMITY SWITCH 2. DOWNSTOP WELDMENT 3. ARM 4. ROLLER 5. BEARING 6. SPRING 7. PLATE 4,5 1 7 2 3

1/16" Figure 3-5 Downstop Control 3-4

AMC 222

CAUTION
CAUTION: IF THE ELECTRICAL DISCONNECT SWITCH IS NOT IN THE OFF POSITION PRIOR TO EMERGENCY WINCH OPERATION, THE WINCH SOLENOID WILL BE DAMAGED. Emergency lowering is best accomplished by rotating the swing junction block needle valve slowly counterclockwise which vents the accumulated fluid in the boom lift cylinder through a restrictor to the swing section of the main control valve and then to tank. Simultaneously, pressure vented to the swing junction block releases the winch brake. Lowering speed is controlled by the swing junction block needle valve. The emergency winch control lever is behind the front console cover, under the left end of the control valve. Pull the lever toward you for WINCH UP and push away for WINCH DN. 3.3.5 Downstop Control

Normally, the drum roller rides against the spooled cable on the drum. When only three wraps of cable remain on the drum, the roller drops down and by riding directly on the surface of the drum, moves the sensor arm adjacent to the proximity switch. The proximity switch triggers the downstop inhibit circuit which stops the WINCH DN operation. 3.3.6 Anti-2-Block Control

See Figure 3-6. The Anti-2-Block Control consists of a proximity switch, sensor arm, spring, and a weight and cable, and is designed to prevent the operator from 2-blocking the davit (hoisting the hook into the sheave). The weight hanging freely maintains tension on the cable to hold the sensor arm away from the proximity switch. As the hook approaches the upper travel limit, it lifts the weight and the spring draws the sensor arm toward the proximity switch which closes, triggering the anti-2-block inhibit circuitto stop WINCH UP operation.

See Figure 3-5. The Downstop Control, consisting of a spring-loaded drum roller, a proximity switch, and a sensor arm, is designed to prevent the operator from paying out cable beyond the last three wraps on the drum.

LEGEND 1. PROXIMITY SWITCH 2. SENSOR ARM 3. SPRING 4. CABLE 5. WEIGHT 6. CABLE CLIP

1 3

1/16"

6 4 2

6 5
AMC 263

Figure 3-6 Anti-2-Block Control 3-5

THIS PAGE INTENTIONALLY LEFT BLANK

3-6

LEGEND 1. Winch, CT 2. Cylinder 3. Manifold 4. Valve, Deceleration 5. Swing Drive Assy 6. Valve, Counterbalance 7. Manifold

Figure 3-7 Hydraulic Schematic Diagram 3-7 / (3-8 blank)

Figure 3-8 Electrical Control Diagram 3-9 / (3-10 blank)

Figure 3-9 Electrical Schematic Diagram 3-11 / (3-12 blank)

CHAPTER 4 SCHEDULED MAINTENANCE

4.1 INTRODUCTION Periodic maintenance and lubrication is necessary to ensure long life and proper function of the davits components. To obtain the best performance and prevent unnecessary wear, it is essential that the maintenance and lubrication schedules in this chapter be followed. If the davit is operated extensively, or in severe conditions, service intervals should be shortened. 4.2 PREVENTIVE MAINTENANCE A sensible, conscientiously applied preventive maintenance program can greatly reduce the chance of equipment failure and increase the service life of the davit. A preventive maintenance program should be based on the maintenance and lubrication charts, and the amount of anticipated use of the davit. 4.3 SCHEDULED MAINTENANCE

. WINCH GEAR REDUCER OIL (MIL SPEC not available)

Use only Exxon Torque Fluid 56.

. HYDRAULIC SYSTEM OIL (MIL-H-17672, 2110-T-H) Use

only premium grade, anti-wear hydraulic oil. The manufacturer recommends Mobil DTE 13M. NOTE: Failure to use the recommended oil during the warranty period may void warranty (expressed or implied) on related hydraulic components, if inspection indicates lubrication related cause. Oil samples will be required with submission of all hydraulic components for warranty consideration. 4.3.3 Service Instructions The Maintenance and Lubrication Chart (Table 4-1) shows maintenance and lubrication points. Boxed items indicate maintenance check points. Circled numbers indicate lubrication points. Numbers in the REF column correspond to Figure 4-2 and/ or the following paragraph numbers. 1. SWING BEARING Lubricate the swing bearing through the lube fitting located on the davit. Rotate the davit in 30 degree increments between applications. Rotate the davit through its entire swing arc after lubrication to distribute the lubricant.
30 TYP

4.3.1 Walk Around Inspection Operators shall perform a walk around inspection before each operating session, looking for loose fasteners, leaking connections, worn or damaged hoses, or any other defects or dangerous conditions. Promptly report any defects to proper authority. 4.3.2 Lubricant Specifications All lubricants and oils used on the equipment shall conform to the following specifications. The numbers in the Frequency of Maintenance fields of the Maintenance and Lubrication Chart (Table 4-1) correspond to the lubricant specification item numbers below.

. GREASE (MIL-G-24139) Use only EP1 or EP2,

multipurpose grease containing molybdenum disulfide (MoS2) and a suitable corrosion inhibitor. For ambient temperatures below 10 F (-12 C) use EP1. For ambient temperatures above 10 F (-12 C) use EP2.

. GEAR LUBRICANT (MIL-G-18548) Formulated for

lubricating exposed gears.

. WINCH CABLE LUBRICANT (MIL-G-18458).

HD 80W-90 multipurpose gear oil. Figure 4-1 Swing Bearing Lubrication 4-1
AMC477

. SWING GEAR REDUCER OIL (MIL-L-2105E) Use only

10

6 9 4 13 5 3 1,2 11
CONSTANT TENSION WINCH

5 5 8

DAVIT INSTALLATION

Figure 4-2 Maintenance and Lubrication Diagram

SHUT OFF THE ELECTRICAL SUPPLY TO THE HYDRAULIC POWER UNIT BEFORE PERFORMING MAINTENANCE OR SERVICE ON THE PINIONS AND RING GEAR. FAILURE TO DO SO COULD CAUSE SERIOUS INJURY OR DEATH. 2. PINIONS AND RING GEAR Distribute lubricant around the outside face of the gear. Visually inspect the gear and pinions for excessive wear or damage. Also, check that the pinion retaining caps and capscrews are secure. 4-2

3. SWING DRIVE Add approved gear oil as required. To check the oil level, clean the area around the plug on the top of the swing gear reducer. Then remove the plug and ensure the oil level is visible through the hole. Check the swing drive for leaks. NOTE: Drain and refill with fresh oil every 2000 hours or every 12 months , whichever occurs first.

AMC532

4. LIFT CYLINDER See Fig. 4-3. Check the hydraulic cylinder every 30 days for leakage around the stem and packing gland. If leakage is present, refer to Chapter 6, Corrective Maintenance. 5. CONSTANT TENSION WINCH To check the oil level, clean the area around the plug in the center of the end housing on the constant tension end of the winch, and then remove the plug. The oil level should be at the bottom of this port. Add approved oil as required. Drain and refill annually, capacity is approximately 1 U.S. gallon (3.8 liters). Check the winch assembly for leaks. NOTE: Disassemble the winch, inspect all wear items, and change oil every 2,000 operating hours or 12 months, whichever occurs first. See Chapter 6 for winch disassembly and inspection procedures.

Packing Gland

Stem
AMC182

Figure 4-3 Boom Lift Cylinder

MAINTENANCE POINT DESCRIPTION

FREQUENCY OF MAINTENANCE

REF

NOTE: Numbers in FREQUENCY OF MAINTENANCE column correspond to LUBRICANT SPECIFICATIONS in Section 4.3.2. An X in this position indicates that DAILY WEEKLY MONTHLY inspection only is required. Numbers in REF column 10 HRS 50 HRS 200 HRS correspond to Fig. 4-2 and/or paragraph 4.3.3.
SWING BEARING PINIONS AND RING GEAR SWING DRIVE LIFT CYLINDER WINCH WINCH CABLE SHEAVE PIN & BUSHING HOOK DAVIT INSTALLATION PIVOT BEARINGS DAVIT MOUNTING BOLTS FASTENERS HYDRAULIC LINES AND FITTINGS

AS REQUIRED

1 2 3 4 5 6 7 8 9 10 11 12 13

Table 4-1 Maintenance and Lubrication Chart 4-3

6. WINCH CABLE Lubricate to prevent rust and internal friction. One excellent method of application is to apply lubricant to the cable while it passes through a sheave, working it into the valleys between the strands and coating the outer wires and lubricating the wire rope at the base of the end fittings. Remove excess grease from the wire rope. See NSTM Chapter 613 for appropriate cleaning instructions to remove new wire rope shipping preservative. Periodically inspect the entire length of the winch cable. Look for fraying, severe kinks, broken strands or rust. If any damage is found or if the wire rope has stretched to a diameter smaller than that listed in Table 4-2, the entire cable must be replaced. NOTE: The inspection, care, and maintenance of the winch cable should comply with current safety rules.
Nominal Diameter of Rope in Inches 0-3/4 13/16 - 1-1/8 1-3/16 - 1-1/2 1-9/16 - 2-1/4 2-5/16 and larger Undersized Inches 0 0 0 0 0 Oversized Inches 1/32 3/64 1/16 3/32 1/8

Return the davit to readiness condition. 10. PIVOT BEARINGS Check cylinder, boom and cable sheave bearings for wear every 90 days. Wear must not extend beyond the fabric lining of the bearings, approximately 0.012" (0.030 mm), nor exceed a total wear of 0.024" (0.060 mm). 11. DAVIT MOUNTING BOLTS Check the davit mounting bolts for security after the first three to four hours of operation. Thereafter, check security every 500 hours of operation. Ensure all hardware is in place and of the correct grade. Tighten the davit mounting bolts as indicated in Figure 8-1 Davit Installation. 12. FASTENERS See Figure 4-4. Unless otherwise specified, check all fasteners for security every six months. Note: See Figure 8-1 for Davit, Pedistal and Ring Gear installation fasteners. 13. HYDRAULIC LINES AND FITTINGS Inspect all hydraulic lines and fittings for damage or leakage and tighten or replace as required. Replace any hose, fitting or O-ring that is damaged or leaking during operation and cannot be corrected by proper tightening. Never attempt to stop a leak by overtightening. 4.4 HYDRAULIC OIL MAINTENANCE The presence of dirt, water and other contaminants in hydraulic oil will adversely affect its condition and lead to premature breakdown due to high operating temperatures and/or an increased oxidation rate. As hydraulic oil oxidizes, sludge and varnish forming materials accumulating in pumps, valves, cylinders, tank and lines will increase wear.

Table 4-2 Wire Rope Tolerances 7. SHEAVE PIN & BUSHING No lubrication is necessary. Check sheave groove, pin and bushing for excessive wear or damage. Replace any parts as required. 8. HOOK Inspect the hook for excessive wear, distortion, or cracks. Make sure that the latching device is working properly. Replace the hook if required. 9. DAVIT ASSEMBLY

CAUTION
DISCONNECTED HYDRAULIC LINES MUST BE COVERED TO PREVENT HYDRAULIC SYSTEM CONTAMINATION. ENSURE OPEN PORTS ON HYDRAULIC COMPONENTS INCLUDING HOSES, TUBING, AND FITTINGS ARE EITHER CAPPED, OR PLUGGED DURING INSTALLATION, SERVICE AND REPAIR PROCEDURES. 4.4.1 Storage and Handling

Give the davit a fresh water washdown weekly. On a monthly basis, thoroughly clean davit assembly and associated components with detergent and fresh water. Rinse with fresh water.

CAUTION
WEAR GLOVES WHEN HANDLING WIRE ROPE. Inspect davit structure and associated components for cracks, corrosion and physical damage. Prepare and paint chipped or damaged surfaces. Apply a thin coat of silicone compound to bare metal surfaces. 4-4 1. Store drums on their sides. If possible, keep them indoors or under a roof. Keep the drums sealed tightly.

2. Before opening a drum, clean the top of the drum thoroughly to prevent dirt from entering. 3. Use only clean containers, hoses, etc. to transfer oil from the drum to the hydraulic tank. An oil transfer pump equipped with a 10 micron filter is recommended. Keeping the oil clean and moisture-free will help it last much longer and prevent contamination damage to close-fitting parts. 4.4.2 In-Operation Care

4.5 EXTENDED STORAGE PROCEDURES If the davit will be stored or inactive for more than 60 days, the following procedures are recommended: 1. Visually check the davit to ensure that packings, seals, plugs, etc., are all in place and that there is no unusual leakage or damage. Repair or correct any leakage or damage found. 2. Perform all maintenance and lubrication procedures as outlined previously in this chapter. 3. Preserve the winch and cable, bearings, bushings, swing gear and other unpainted surfaces with a non-running grease. 4. Cover electrical power equipment and unpainted surfaces with a moisture barrier material that will not cause condensation. 5. 6. Store in a dry, enclosed building if possible. Inspect all items every 6 months.

NOTE: Replace the return filter element after the first 50 hours of operation on new or rebuilt winches. 1. Prevent contamination by keeping the system tight and using proper filtration. 2. Prevent hydraulic system overheating. If any component is hotter than 180 F (82 C), shutdown the davit and allow the system to cool. If the overheating problem persists, isolate and correct the problem. 3. Establish oil change intervals in accordance with manufacturer's recommendations and actual operating conditions so oil is replaced before it breaks down. NOTE: Change oil annually or every 2,000 operating hours, whichever occurs first. 4. Keep the tank properly filled to prevent moisture from condensing on inside walls. 5. Repair all leaks immediately.

7. Restore paint that has been damaged in transit or handling. Procedures are available upon request from the manufacturer.

SAE & SBC IDENTIFICATION

B S C
S.A.E. GRADE 5 (General purpose bolts) S.A.E. GRADE 8 (General purpose bolts)

6. Watch filter indicators and replace filter elements when required. 4.4.3 Analysis

1. Obtain a sample from the hydraulic system while the oil is hot to ensure an accurate analysis. 2. If water appears at the bottom of the sample after it has stood for several minutes, there is either an opening for water to enter the system or the system has been subjected to severe temperature fluctuations which caused condensation. 3. Maintain ISO 4406 cleanliness standard of 17/14 or better.

FX

316

Figure 4-4 Bolt Identification

AMC276

S.A.E. GRADE 9 (Used for load carrying bolts)

STAINLESS STEEL (Used for corrosion resistant applications)

4-5

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4-6

CHAPTER 5 TROUBLESHOOTING
5.1 INTRODUCTION The purpose of this chapter is to aid shipboard personnel in the isolation and correction of problems that can occur during operation of the davit and related equipment. This chapter provides general instructions for the inspection and isolation of mechanical, hydraulic and electrical problems as well as corrective maintenance procedures for restoring the davit to normal operation as soon as possible. 5.1.1 Safety The safety summary in the front of this manual lists general precautions. In addition, any warnings and cautions provided in this chapter and throughout this manual shall be observed. 5.1.2 Problem Area Isolation This chapter contains provisions for isolating malfunctions in the davits mechanical, hydraulic, and electrical systems. You may isolate a malfunction by operating the davit and observing performance in sequential order. Additionally, listening for unusual noises and vibrations aids in isolating a malfunction to a specific component. 5.2 PRELIMINARY TROUBLESHOOTING To recognize malfunctions of either electrical, hydraulic or mechanical systems and to isolate and identify the most common or probable causes of system malfunctions, the following preliminary checks should be made: 1. Verify that electrical power is available. Check all fuses and visually inspect all external electrical circuits for bare or broken wire. 2. Verify that hydraulic power is available and that hoses are correctly connected. Should the davit fail to operate properly, perform the following tests using a 0-3000 psi pressure gauge and a 0-50 gpm (0-200 lpm) flow meter. 5.2.1 Pump Test See specific manual for information regarding the pump and/ or HPU. Allied Systems did not supply the HPU. 5.2.2 Control Valve Test See TP2753A for information regarding the control valve and/ or console. 5.2.3 Winch System Test Verify hydraulic oil delivery to the winch by connecting a 03000 psi pressure gauge to the inlet line of the load hydraulic motor. 2. 1. If the load hydraulic motor is receiving adequate pressure and flow, but is not operating properly, repair or replace the motor. 2. If the winch lifts properly, but chatters when starting or stopping, check the overcenter valve on the load motor junction block because this valve controls winch brake release and may cause intermittent brake application. 5.2.4 Swing System Test Verify hydraulic oil delivery to the swing drives by connecting a 0-3000 psi pressure gauge to the inlet line of the swing hydraulic motors. If the swing drives are receiving adequate pressure and flow, but are not operating properly, repair or replace the motor(s). 5.2.5 Boom System Test Verify adequate hydraulic oil delivery to the boom lift cylinder. If the boom lift cylinder is not lifting the load and/ or creeps down when it should be locked, it may be caused by hydraulic oil seeping around the cylinder seal, or a defective or cross-connected load lock valve. 1. Place a load on the davit and then carefully disconnect the hydraulic line between the stem end of the boom lift cylinder and the load lock valve. If fluid continues to run out of the fitting on the stem of the cylinder, replace the cylinder seal because it is leaking. Otherwise, the load lock valve is defective.

REMOVE ANY LOAD FROM THE BOOM LIFT CYLINDER, INCLUDING THE WEIGHT OF THE BOOM, BEFORE REMOVING THE LOAD LOCK CARTRIDGE OR MANIFOLD. FAILURE TO DO THIS WILL CAUSE THE LOAD TO FALL RESULTING IN PERSONAL INJURY OR DEATH. Repair or replace the defective load lock valve.

5-1

5.3

FAULT ISOLATION

5.3.1 Probable Mechanical Causes Mechanical malfunction or failure can be attributed to any or all of the following: 1. Poor lubrication techniques and failure to perform preventive maintenance on a scheduled basis as outlined in Chapter 4. 2. Loosely mounted control components due to mechanical vibration. 3. Dirt and accumulations of other foreign matter on moveable parts. 4. Worn and/or broken parts. Such parts shall be repaired or replaced in accordance with the applicable procedure in Chapter 6. a. Unusual noise or vibration may indicate bearing or gear problems. b. Brake slippage may indicate worn friction discs.

5.3.3 Probable Electrical Causes The most common electrical problems are open circuits, partial grounds and short circuits.

ONLY QUALIFIED PERSONNEL SHOULD TROUBLESHOOT AND PERFORM REPAIRS AND ADJUSTMENTS TO ELECTRICAL SYSTEMS. 1. Open Circuit. An open circuit is caused by a broken wire or connection. 2. Partial Ground. A partial ground is caused by damaged insulation permitting excessive current leakage. 3. Short Circuit. A short circuit is caused by two bare wires or connectors contacting each other.

5. Overloaded or physically damaged components including the davit structure, wire rope, hooks, sheaves and mounting hardware. 5.3.2 Probable Hydraulic Causes Hydraulic malfunction or failure can be attributed to any or all of the following: 1. Incorrect adjustment of relief valves, pressure switches, load holding valves, etc. 2. Inadequate hydraulic system pressure or flow, or contaminated hydraulic oil. 3. Internal leaks in components or component overheating.

CAUTION
IF ANY OF THE HYDRAULIC COMPONENTS GENERATES EXCESSIVE HEAT, DISCONTINUE OPERATION IMMEDIATELY AND DETERMINE THE CAUSE OF OVERHEATING. OPERATING TEMPERATURE MUST NOT EXCEED 180 F (82 C). 4. Sticking valve spools, damaged motors/pumps, restrictions in lines, or faulty relief/load holding valves. 5. 5-2 Incorrect pipe/hose connections.

Symptom / Malfunction
No davit functions.

Probable Cause
No power to hydraulic power unit. Tripped circuit breaker. Defective control circuit wiring. Broken or incorrectly connected hydraulic lines or fittings. Restricted hydraulic filter. Low hydraulic oil level. Defective pump or motor.

Corrective Action
Restore power. Locate cause, reset breaker. Locate fault and correct. Repair or replace. Replace filter element. Examine hydraulic system for contamination. Replenish hydraulic oil. Repair or replace. Replenish hydraulic oil. Repair or replace. Replace oil with correct grade. Repair or replace. Locate and correct (check hydraulic filter element). Repair or replace. Repair or replace. Replenish hydraulic oil. Replace filter element. Repair all leaks. Locate and correct (check filter element). Repair or replace. Repair or replace. Repair or replace. Repair or replace. Repair or replace valve.

Excessive heat (above 180 F).

Low hydraulic oil level. Malfunctioning relief valve. Wrong grade of hydraulic oil. Defective pump or motor. Restriction in circuit. Main control valve leaking internally. Hydraulic motor(s) leaking internally.

Sluggish functions.

Low hydraulic oil level. Restricted filters. Leaking suction lines. Restriction in circuit. Defective pump or motor. Defective hydraulic motor.

Erratic functions. Davit function continues after control handle is released.

Defective pump or motor. Defective control valve actuators (PVE). Valve spool or handle binding.

Table 5-1 General Troubleshooting Table 5-3

Symptom / Malfunction
No Swing function.

Probable Cause
Defective swing dual counterbalance valve. Defective control valve. No pressure to brake. Swing brake(s) not releasing or binding. Defective swing drive motor(s). Defective pump or motor.

Corrective Action
Adjust, repair or replace. See valve troubleshooting. Repair or replace. Repair or replace. Check for plugged lines to brake. Repair or replace. Repair or replace. Repair or replace. Adjust, repair or replace. Check return filter, hose size, restrictions in other hydraulic components. Check disc stack thickness. Replace worn discs. Check release pressure. Replace springs if required. Place pressure gauge in bleed port and check pressure with system on. Pressure should be a minimum of 20 psi over the full release pressure. Replace bearing. Place pressure gauge in bleed port, check for adequate pressure. Replace defective line or component. Replace.

Swing function "jerky".

Defective swing brake(s). Misadjusted or defective swing dual counterbalance valve.

Swing brake slips.

Excessive back pressure in the actuation line of the brake, reducing holding torque. Disc plates worn. Springs broken or have taken a permanent set.

Swing brake drags or runs hot.

Low release pressure.

Bearing failure, causing excessive drag. Brake will not release. Stuck or clogged valve.

Defective O-rings. Discs frozen, due to severe emergency stop or prolonged reduced release pressure operation. Noise or looseness in swing mechanism. Dry or defective swing bearing. Excessive gear backlash. pinions and/or bearing if required. Defective gear reducer or brake.

Replace disc stack. Lubricate or replace. Check backlash. Replace swing drive Repair or replace.

Table 5-2 Swing Troubleshooting Table 5-4

Symptom / Malfunction
No "boom up" function.

Probable Cause
Cylinder leaking internally. Defective control valve. Defective pump.

Corrective Action
Repair or replace. Repair or replace. Repair or replace. Repair or replace. Repair or replace. Correct hose/pipe connections. Replace seal. Repair or replace. Correct hose/pipe connections.

No "boom down" function.

Defective load lock valve. Defective pump. Improper hose/pipe connections.

Cylinder will not hold a load, or boom drops when control handle is in neutral.

Cylinder seal worn or damaged. Defective load lock valve. Improper hose/pipe connections.

Table 5-3 Boom Troubleshooting Table 5-5

Symptom / Malfunction
Sluggish winch functions.

Probable Cause
Low hydraulic oil level. Blocked hydraulic filter element. Leaking suction lines. Restriction in circuit. Defective pump or motor. Defective hydraulic motor or control valve.

Corrective Action
Fill tank to correct level. Replace filter element. Repair or replace. Locate and correct. Check filter element. Repair or replace. Repair or replace. Reduce load. Repair or replace. Repair or replace. Lower load. Adjust or repair anti-2-block control. Repair or replace. Repair or replace. Locate and eliminate restriction in return line (check return filter). Adjust, repair or replace. Repair or replace. Repair or replace. Repair or replace.

Winch will not lift a load.

Davit overloaded. Defective pump or motor. Defective winch motor. Davit 2-blocked, or anti-2-block control defective or improperly adjusted.

Winch will not hold load.

Defective winch counterbalance valve. Defective winch brake. High back pressure affecting winch brake or winch counterbalance valve.

Winch will not lower load.

Defective or improperly adjusted downstop control. Defective winch counterbalance valve. Defective winch counterbalance valve. Defective winch brake.

Winch jerks when lowering load.

IF THE CONSTANT TENSION SYSTEM EXHIBITS ANY SIGN OF ERRATIC OPERATION, OR TENSION CONTROL DIFFICULTIES, APPROPRIATE TROUBLESHOOTING TESTS AND REPAIRS MUST BE PERFORMED IMMEDIATELY. CONTINUED OPERATION IN THIS MANNER COULD RESULT IN EQUIPMENT DAMAGE, PERSONAL INJURY, OR DEATH.
CT SELECT or ENGAGE light not working. Bulb failed. Relay defective. Pushbutton defective. CT mode will not engage.

NOTE: If constant tension winch performance decreases significantly after a change in climate, verify that the winch is serviced with the correct oil. See Chapter 4, Scheduled Maintenance, for lubricant specifications.

Replace bulb. Replace relay. Replace. Adjust, repair or replace. Replace. Correct hose/pipe connections. Check pressure, repair or replace clutch solenoid valve. Ensure joystick is unobstructed. Adjust Minimum Tension (Max. Out). Adjust pressure reducing valve (800 psi). Adjust sequence valve (1200 psi). Adjust, repair or replace. Repair or replace.

Downstop control or anti-2-block control defective or improperly adjusted. Tension switch proximity failure. Improper hose/pipe connection. Clutch not releasing. Winch joystick not in MAX position. Minimum Tension set too low or too high. Insufficient clutch release pressure. Insufficient CT pressure. Malfunctioning main control valve. Malfunctioning electrically operated relief valve.

CT mode will engage, but will not function. The drum locks up when Constant Tension mode is selected. Winch does not maintain constant tension on cable while in CT mode.

Table 5-4 Winch Troubleshooting Table 5-6

Symptom / Malfunction
Main spool moves but pump fails to come on stroke (manual activation only). Main spool moves with no resultant oil from working ports (manual activation only).

Probable Cause
Worn or damaged ball and seat in PVB shuttle valve. Damaged or faulty compensator. Maximum load pressure matched with PVB load setting. PVB load sense relief valve damaged. Working pressure has exceeded main relief valve setting.

Corrective Action
Replace PVB and contact manufacturer. Inspect for oil contamination and contact manufacturer. Adjust PVB load sense relief. If load sense relief not adjustable, contact manufacturer. Reduce working load pressure. Increase PVP relief setting and contact manufacturer.

Table 5-5 Control Valve Troubleshooting Table 5 - 7 / (blank)

CHAPTER 6 CORRECTIVE MAINTENANCE

6.1 INTRODUCTION This chapter provides maintenance personnel with procedures necessary to perform corrective maintenance on the equipment. This chapter identifies the specific corrective maintenance procedures for shipboard, intermediate, and depot level maintenance of the equipment. Detailed instructions, with illustrations, explain how to perform required maintenance. Maintenance procedures are presented in two sections. Section 6.2 describes required adjustment procedures and Section 6.3 describes the procedures necessary to remove, disassemble, clean, inspect, repair, replace, assemble, and reinstall the equipment. Table 6-1 lists tools and supplies recommended for maintenance. Most repairs can be performed with ordinary hand tools although some specialized tools will be required.

Tool / Supply
Open end/box end combination wrench set and socket wrench set Screwdrivers

Application / Description
Sized from 1/4 inch to 1-5/8 inches for removal and reinstallation of components. Various standard sizes for removal reinstallation, and adjustment of components. Various sizes for removal and reinstallation of components. Various sizes for removal and reinstallation of components. Sized from 1/16 inch to 9/16 inch for removal and reinstallation of components. For removal and reinstallation of components without marring machined surfaces. Scaled from 0 to 2000 lb-ft. Scaled from 0 to 200 lb-in. Various sizes for removal of components. To make alignment and end play checks. To measure diameters and thickness with precision. Scaled from 0 to 3000 psi. Scaled from 0 to 50 gpm. To make voltage, current and resistance checks. Various sizes for removal of components. For handling smaller heavy components such as the winch, the swing drives or the control valve. To remove anchor pins.

Retaining ring pliers Adjustable pliers Allen wrench set

Leather mallet

Torque wrench Torque wrench Gear and bearing pullers Dial indicator Micrometer Hydraulic pressure gauge (with JIC and CPV fittings) Hydraulic flow meter Multimeter (VOM) Drift pin set Chain fall or hand operated cable hoist

Slide hammer and/or 20 lb machinist's hammer

Table 6-1 Tools and Supplies 6-1

Tool/Supply
Crane Mineral-base cleaning solvent (FED SPEC P-D-680, Type II) Gasket cement (NSN 8040 00 664 4134) Grease gun Crocus cloth, 400 grit Machinist's vise, equipped with jaw protectors

Application/Description
Sufficient capacity for lifting heavy components. For cleaning parts. For replacing gaskets. For component lubrication. For polishing and corrosion removal. For holding components in place. Jaw protectors prevent marring of machined surfaces. For assembling the accumulator. For winch assembly and disassembly. For removing main winch hub from drum. For aligning winch brake and hub during assembly. For spacer removal. For winch brake removal. For winch service. For centering drum in winch frame. For installing winch drum oil seal. For use with Spring Compressor (P/N: 41729). For removing gears and bearings from shafts. For installation of specific fasteners. For installation of specific fasteners. For installation of components. For sealing of mating surfaces. For installation of O-rings and seals. To prevent corrosion of bare metal surfaces.

Bladder Pull Rod (P/N: 11-503) Winch Repair Tool Kit (P/N: 42383) Main Winch Hub Retainer (P/N: 41721) Brake Ring Retainer (P/N: 41726) CT Winch Hub Retainer (P/N: 41727) Spring Compressor (P/N: 41729) Drivers (P/N: 41732, 41734, 41735) Spacers, set of 3 (P/N: 41733) Seal Driver (P/N: 41737) Port-A-Power (P/N: P39/RCH202) Press Anti-seize compound (MIL-A-907A) Thread Locking Compound (MIL-S-22473E) Sealing compound (Permatex No. 2, MIL-S-45180) Sealing Compound, Loctite "Ultra Blue" Sealant Petroleum Jelly Cosmoline

Table 6-1 Tools and Supplies - Continued 6.1.1 Maintenance Practices

CAUTION
ENSURE OPEN PORTS ON HYDRAULIC COMPONENTS, INCLUDING HOSES, TUBING, AND FIT TINGS, ARE EITHER CAPPED OR PLUGGED DURING SERVICE OR REPAIR TO PREVENT HYDRAULIC SYSTEM CONTAMINATION.

1. Cleanliness is of the utmost importance when servicing any hydraulic equipment. Cap any open hydraulic lines to prevent dirt from entering the system. Use clean tools and lint-free rags. 2. Inspect all parts prior to reassembly to detect any wear or damage which may have occurred in operation or shipping. 6-2

3. Use only authorized replacement parts. Never reuse expendable parts such as oil seals, backup rings, gaskets, etc. Although they may appear to be in good condition, they can be defective. 4. Clean all metal parts with approved cleaning solvent.

NEVER ADJUST HYDRAULIC COMPONENTS TO SETTINGS HIGHER THAN THE VALUES GIVEN IN THIS MANUAL. ANY ATTEMPT TO GAIN EXTRA LIFTING CAPACITY WILL CAUSE OVERLOADING WHICH MAY RESULT IN EQUIPMENT DAMAGE,PERSONAL INJURY OR DEATH. NOTE: The hydraulic system must be at operating temperature before accurate adjustments can be made. 6.2.1 Main System Relief Pressure See TP2753A for information regarding the control valve and setting the main relief. 6.2.2 Swing Dual Counterbalance Valve Adjustment See Figure 6-1. 1. The swing dual counterbalance valve cartridges are factory set to open at 450 psi pilot pressure and relieve to tank at 2000 psi. NOTE: If the swing dual counterbalance valves require adjustment for any reason, remember that the Swing LH and Swing RH functions must be adjusted separately. 2. Connect a 0 - 3000 psi pressure gauge at the unused swing brake port on one of the swing drive motors. 3. The swing dual counterbalance valve controls only return flow from the motor back to the tank and should begin to open at 450 psi. 4. With the HPU running and at operating temperature, slew the davit right or left while observing the gauge. One cartridge of the counterbalance valve controls return flow while swinging in one direction, and the other controls return flow in the opposite direction. Slew the davit in the opposite direction while observing the gauge. 5. To adjust the cracking pressure, loosen the jamnut on the cartridge and turn the stem in or out with a hex wrench until the gauge reads 450 psi. If the pressure cannot be adjusted, replace the cartridge.

CAUTION
DO NOT USE ORGANIC SOLVENTS TO CLEAN O-RINGS, SEALS OR PACKINGS. 5. Lubricate all O-rings with petroleum jelly or clean hydraulic oil prior to installation. 6. Secure the hydraulic power unit (HPU) before performing electrical tests on the control valves. 7. Prevent metal tools from coming into contact with sensitive electronic components. 8. Turn power off before connecting or disconnecting valve coils or other electrical loads. 6.2 HYDRAULIC AND ELECTRICAL SYSTEM ADJUSTMENTS See Table 6-2. This section describes procedures for adjusting hydraulic and electrical components. Hydraulic system settings should not require adjustment unless components are changed. Relief Pressure
Main System Relief Valve Winch Sequence Valve Winch Counterbalance Valve Swing Dual Counterbalance Valve Constant Tension Motor Pressure Constant Tension Clutch Pressure

Setting
2750 psi 1000 psi 3000 psi 2000 psi 1200 psi 800 psi

Reference
Para. 6-2.1 Figure 3-13 Figure 3-13 Para. 6-2.2 Para. 6-2.3 Para. 6-2.3

Table 6-2 Pressure Settings 6-3

6. After adjustment/replacement has been accomplished and the gauge has been removed, cycle the davit several times to purge air from the system and check for leaks. 6.2.3 Constant Tension Winch Pressure Adjustments See Figure 6-2. 1. Secure the HPU and connect one 0-3000 psi gauge with a tee fitting in the line at port P and another at the clutch pressure port as shown. 2. Start the HPU and allow the system to reach operating temperature. 3. Loosen the locknut on the sequence valve and slowly adjust the valve until the gauge at port P reads 1200 psi. Tighten locknut. 4. Loosen the locknut on the pressure reducing valve and slowly adjust the valve until the gauge at the clutch pressure port reads 800 psi. Tighten locknut. 5. Secure the HPU and remove gauges and tee fitting. Connect lines and replace clutch pressure port plug.

6.2.4 Downstop Control Adjustment See Figure 6-3. This is a limiting device designed to prevent the operator from paying out cable beyond the last three wraps on the drum.

IT IS CRITICAL THAT THIS CONTROL BE PROPERLY ADJUSTED. FAILURE TO DO SO COULD CAUSE A SERIOUS ACCIDENT RESULTING IN EQUIPMENT DAMAGE, PERSONAL INJURY OR DEATH. NEVER OPERATE THE DAVIT WITH FEWER THAN THREE COMPLETE WRAPS OF CABLE ON THE DRUM BECAUSE CABLE CLAMPS ARE NOT DESIGNED TO HOLD RATED LOADS. 1. Winch down until three complete wraps of cable remain on the drum. Maintain at least 100 lbs tension on the cable while lowering. Secure the HPU. The roller (4) must drop down from the first layer of cable and ride directly on the drums surface. 2. Adjust the arm (3) until it is centered over the face of the proximity switch (1).

ADJUSTMENT SCREW

LOCK NUT

Figure 6-1 Swing Dual Counterbalance Valve Adjustment 6-4

AMC 106

GAUGE PORT (ON OPPOSITE SIDE)

TEMPORARY TEE - FITTING

CLUTCH PRESSURE ADJUSTMENT (PRESSURE REDUCING VALVE) SET TO 800 PSI

HOIST MOTOR END T P R

CT MOTOR END

CLUTCH PRESSURE (800 PSI)

CONSTANT TENSION PRESSURE (1000 PSI)

CONSTANT TENSION ADJUSTMENT (SEQUENCE VALVE) SET TO 1000 PSI

Figure 6-2 Constant Tension Winch Pressure Adjustment 3. Loosen the locknut on the proximity switch (1) and adjust the switch by screwing it in or out until there is 1/16" clearance between the switch face and the arm (3). Tighten the locknut. 4. Start the HPU and carefully operate the davit to ensure that the winch stops immediately after the roller contacts the bare drum with three complete wraps of cable remaining. Readjust if necessary. 6.2.5 Anti-2-Block Control Adjustment See Figure 6-4. This is a limiting device designed to prevent the operator from hoisting the hook into the sheave.

CAUTION
IT IS IMPORTANT THAT THIS CONTROL BE PROPERLY ADJUSTED. FAILURE TO DO SO COULD CAUSE EQUIPMENT DAMAGE.

AMC161

6-5

1. Winch up until the hook ball begins to lift the weight (5). Secure the HPU. 2. With the weight just lifted by the hook ball, ensure that the spring (3) is able to move the sensor arm (2) near the proximity switch (1). Also inspect the cable for fraying or dragging as this would prevent the arm from moving when the weight is lifted. 3. Loosen the locknut on the proximity switch (1) and adjust the switch by screwing it in or out until there is 1/16" clearance between the switch face and the sensor arm (2). Tighten the locknut. 4. Start the HPU and winch down until the weight (5) is hanging freely. Ensure that the weight pulls the sensor arm (2) away from the proximity switch (1). 5. Carefully operate the davit to ensure that the winch stops before the hook ball contacts the sheave case. Adjust the length of cable (4) if necessary. 6.2.6 Cable Tension Sensor Adjustment See Fig. 6-5. The cable tension sensor senses tension in the winch cable inhibiting constant tension mode while there is a load on the cable. 1. Inspect the assembly for excessive wear on the roller which might prevent correct operation or adjustment. Replace any components as required. 2. With slack in the cable, manually move the arm (2) until it obstructs the proximity switch (1). Loosen the locknut on

the proximity switch (1) and adjust the switch by screwing it in or out until there is 1/16" clearance between the switch face and the arm (2). Tighten the locknut. 6.3 6.3.1 REPAIRS Swing Drive

6.3.1.1 Removal See Figure 6-6. 1. Secure the HPU and ensure that all pressure in hydraulic lines is relieved. 2. Disconnect all hydraulic hoses from the swing motor and brake. Tag all hoses to ensure correct connections at installation. Cap or plug all lines and ports to prevent contamination.

CAUTION
IF BOTH SWING DRIVES ARE TO BE REMOVED, SECURE THE DAVIT FROM ROTATING BEFORE REMOVING THE DRIVES. 3. Remove the eight capscrews (7) securing the swing drive to the davit. 4. Install lifting eyes in the gear reducer (3) housing and remove the swing drive using an overhead hoist. Place the unit in a clean work area for disassembly.

6 LEGEND 1. PROXIMITY SWITCH 2. DOWNSTOP WELDMENT 3. ARM 4. ROLLER 5. BEARING 6. SPRING 7. PLATE 4,5 1 7 2 3

1/16"

Figure 6-3 Downstop Control Adjustment 6-6

AMC 222

6.3.1.2 Disassembly See Figure 6-6. Prior to disassembly, clean off all dirt. 1. Remove two capscrews (9) and withdraw hydraulic motor (1) from brake (2). Discard gasket (10) from under motor. After removal of motor, wash exterior in solvent to remove any traces of dirt. 2. Remove two capscrews (9A) and withdraw the brake (2) from gear reducer (3). Discard gasket (11) from between brake and reducer. 3. Remove two capscrews (8) from pinion cap (5), and remove pinion (4). 6.3.1.3 Assembly See Figure 6-6. Assembly is basically the reverse of disassembly. Install new gaskets (10) and (11) under the hydraulic motor (1) and brake (2). Tighten capscrews (7) to 85 lb-ft; tighten capscrews (8) to 35 lb-ft; and tighten capscrews (9) and (9A) to 125 lb-ft. 6.3.1.4 Swing Motor Disassembly See Figure 6-7. After removing hydraulic lines, cap or plug all lines and ports to prevent contamination and ensure workbench surface is absolutely clean.

1. Place the motor in a vise with end cover (17) facing up, taking care to clamp at the port area, but not with the ports facing the jaws. 2. Remove four bolts (19) and end cover (17).

3. Shift wear plate (13) to clear end of drive link (12) and lift group [rotor assembly (14) and wear plate (13)] from housing (9). 4. Remove shaft (10) and drive link (12) from housing by pushing up on shaft end with palm of one hand and lifting shaft with the other hand. Items (6), (7), (8), (10), (12), (15) and (16) will usually come out together. 5. If not, remove housing (9) from vise and place upside down (mounting flange up) on workbench. This allows thrust bearings (7) and (8) to fall free. Next insert fingers through dust seal (1) and push seal carrier (6) out the opposite end of the housing. Avoid marring the housing bore with the seal carrier. 6. Mount housing assembly (9) in a vise, and using the grip end of a large screwdriver, tap dust seal (1) until it falls free. 7. With small screwdriver, carefully remove retaining ring (2), seal (4) and shim (3). 6.3.1.5 Swing Motor Assembly See Figure 6-7. 1. Wash all parts in clean solvent and discard seals.

LEGEND 1. PROXIMITY SWITCH 2. SENSOR ARM 3. SPRING 4. CABLE 5. WEIGHT 6. CABLE CLIP

1 3

1/16"

6 4 2

6 5
AMC 263

Figure 6-4 Anti-2-Block Control Adjustment 6-7

LEGEND 1. PROXIMITY SWITCH 2. TENSION ARM 3. ROLLER 4. ROD 5. SPRING 6. BASE

4 3 2 5 5

Figure 6-5 Cable Tension Sensor Adjustment 2. Position housing with mounting flange up, and install a new seal (4) in groove. 3. 4. Install shim (3) into groove next to seal (4). Push retaining ring (2) into position.

5. Place housing in vise as in Disassembly step 1, clamped at port area with groove side up. 6. Place thrust bearings (7) and (8) on shaft (10) followed by the seal carrier assembly (6) with large diameter facing the thrust bearings.

6-8

AMC485

7. Install the drive link (12) into shaft (10). Align mark at root of drive link tooth with mark on cupped end of shaft. Fill end of drive link with grease. NOTE: If markings are indistinguishable, the root of the drive link tooth should be placed with the deeper slot of the output shaft to the right and 1/4" through hole to the left. Mark alignment as described on end of drive link with soft pencil if no marks appear. 8. Slide assembled shaft into housing (9). Shaft must be flush or slightly below housing. 9. Insert a lightly oiled O-ring (5) in groove of housing.

LEGEND 1. HYDRAULIC MOTOR 2. BRAKE 3. GEAR REDUCER 4. PINION 10 5. PINION CAP 6. SHEAR BLOCK 7. CAPSCREW 9A 8. CAPSCREW 9. CAPSCREW 9A. CAPSCREW 6 10. GASKET 11. GASKET 7

1 9 2 11 3

10. Place wear plate (13) on top of drilled end of housing, ensuring alignment of seven feed holes. Ensure alignment groove of wear plate is in direction of ports. 11. Insert a lightly oiled O-ring (5) in groove of rotor (14). With seal side down, place rotor (14) over drive link and align mark on drive link root with rotor valley (minimum diameter). Align mark on stator with slot in wear plate and verify alignment of seven feed holes with wear plate and housing. Align four bolt holes with housing and ensure that seal stays in place. NOTE: Counterbore on rotor faces away from housing. 12. Insert a lightly oiled O-ring (5) in end cover (17). 13. Press grease into recess in center of end cover face. If recess is filled with oil, wipe clean before loading with grease. Press steel ball (16) into greased recess and install pin (15) by inserting concave end into the end cover (17). 14. Carefully invert end cover assembly (15), (16), (17) and (5) and place on top of rotor assembly (14). Avoid dislodging O-ring or pin from end cover. NOTE: Ensure all O-rings are in place. 15. Insert four bolts (19) and torque to 50 lb-ft. 16. Place assembly on side (ports facing up) in vise and rotate shaft to ensure the suction port is in the same direction of rotation. 6.3.1.6 Swing Brake Disassembly See Figure 6-8.
4 5 8
AMC 112

Figure 6-6 Swing Drive 1. Loosen the four 12-point capscrews (7) from the input end of the brake. Alternately unscrew the bolts 1/2 turn at a time until all the internal spring force is relieved. Remove the cover (2).

CAUTION
DO NOT CLAMP OR OTHERWISE RESTRAIN COVER (2) WHILE REMOVING CAPSCREWS (7) SINCE THE BRAKE IS UNDER A HIGH COMPRESSIVE LOAD. 2. Apply low air pressure, 20-30 psi, to the brake release port while holding one hand on top of the piston (3) and springs (9). The air will force the piston out of the case (1). 3. Remove the brake shaft (4).

4. Remove friction discs (10), and separator plates (11) from the case. 6.3.1.7 Swing Brake Assembly See Figure 6-8. Assemble in reverse order of disassembly with the following additional instructions:

6-9

5 12 11 10 13 4 6 1 9 3 7 8 14 15 17 16

18

19

LEGEND 1. DUST SEAL 2. RETAINING RING 3. SHIM 4. SEAL 5. O-RING 6. SEAL CARRIER 7. THRUST BEARING 8. THRUST BEARING 9. HOUSING 10. SHAFT 11. COOLING PLUG 12. DRIVE LINK 13. WEAR PLATE 14. ROTOR ASSEMBLY 15. PIN 16. BALL 17. END COVER 18. NAMEPLATE
AMC 113

Figure 6-7 Swing Motor 1. Install the shaft (4) by pushing shaft downward through the bearing (5) and seal (17) until shoulder on shaft is seated against bearing. NOTE: Soak new friction discs (10) in hydraulic oil for ten minutes before installation. 2. Install friction discs (10) and separator plates (11) in exactly the same order as they were removed with a friction disc (10) on each end. Avoid contaminating the friction surfaces with dirt, grease, or fluid other than that specified for the hydraulic system. NOTE: If a separator plate (11) is placed next to the piston (3) the brake will overheat and seize up. 3. Pour hydraulic oil over the stack until the fluid level is even with the top friction disc. 4. Replace the piston O-rings and backup rings (14, 15, 12 and 13), ensuring the two O-rings (14) and (15) are nearest each other and the two backup rings (12) and (13) are outside of them. Gently slide the piston (3) into the case until the large O-ring (15) touches the case. Now press down firmly on the piston with the heel of both hands to squeeze the O-rings into the case and seat the piston against the friction discs. 6 - 10

5. 6.

Insert the springs (9) into the piston (3). Place O-ring (16) around the lip on the case (1).

7. Set the cover (2) on the input end of the shaft (4). Ensure the bearing (6) starts over the shaft before the cover touches the springs. 8. Start the four capscrews (7) through the cover and into the case by hand. Alternately tighten 1/2 turn at a time until the cover is seated against the case and then torque the four capscrews (7) to 80 lb-ft. 6.3.1.8 Swing Gear Reducer Disassembly See Figure 6-9. 1. Remove capscrews (36) from cover (32). Remove cover and thrust washer (31). NOTE: Bolts assembled with Loctite may require heating before removal. 2. 3. 4. Remove sun gear (30). Remove primary carrier assembly (20). Remove secondary carrier assembly (11).

5.

Lift ring gear (10) from remaining assembly.

6. Remove retaining ring (9) and thrust washer (8) from output shaft. 7. Remove output shaft (1) along with bearing cones (3) and (7). Remove shaft seal (2) from bore in hub (5). 8. Inspect bearing cups (4 and 6) while they are still in the hub (5). Do not remove them unless replacement is required. 6.3.1.8.1 Primary Carrier Disassembly See Figure 6-9. 1. Remove retaining ring (27) from pinion shaft (29). Mark the serrated pin on the shaft because spline variations require them to be installed in the same position. 2. Catch planet gear (22), needle bearings (23) and thrust washers (21) as the pinion shaft (29) is removed. 3. Repeat steps 1 and 2 for remaining planet gears.

6.3.1.8.2 Secondary Carrier Disassembly See Figure 6-9. 1. Remove retaining ring (16) from pinion shaft (19). Mark the serrated pin on each shaft because spline variations require them to be installed in the same position. 2. Catch planet gear (15), needle bearings (13), separators (14) and thrust washers (12) as the pinion shaft (19) is removed. 3. Repeat steps 1 and 2 for remaining planet gears.

6.3.1.8.3 Primary Carrier Assembly See Figure 6-9. 1. Install the larger diameter retaining ring (25) against sun gear (26) shoulder. Slide sun gear splines into primary planet carrier (24), then insert the smaller diameter retaining ring (28) in sun gear groove inside of the primary planet carrier. 2. Use a low melting point grease to hold the sixteen needle bearings (23) as they are inserted into planet gear bore. Centering pinion shaft (29) in planet gear bore will help align needle bearings. 3. Install a thrust washer (21) between planet gear (22) and carrier faces as gears are assembled into carrier (24).

4. Remove the retaining ring (28) from sun gear (26) groove inside primary planet carrier (24). Pull sun gear from carrier splines.

1 5 4 10

17

19 8

14 15 9 2 12 3 13 6 18 7 11

16

LEGEND 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

CASE COVER PISTON BRAKE SHAFT BEARING INPUT BEARING CAPSCREW PLUG SPRINGS FRICTION DISCS SEPARATOR PLATES BACKUP-RING BACKUP-RING O-RING O-RING O-RING SEAL GASKET GASKET
AMC114

Figure 6-8 Swing Brake 6 - 11

4.

Align thrust washer tang with recess cast into carrier.

5. Insert pinion shafts (29) into carrier and through each planet gear (22). Install retaining ring (27) to secure shaft. Install assembled pinion shafts in the exact position from which they were removed. 6. Ensure gears rotate freely without catching or binding. Allowable end play is 0.004 to 0.029 inches. 6.3.1.8.4 Secondary Carrier Assembly See Figure 6-9. 1. Use a low melting point grease to hold the sixteen needle bearings (13) as they are inserted into one end of each planet gear bore. 2. Install separator (14) and a second set of sixteen needle bearings (13) into the other end of the planet gear bore. 3. Insert pinion shafts (19) into carrier and through each planet gear (15). Install retaining ring (16) to secure shaft. Install assembled pinion shafts in the exact position from which they were removed. 4. Ensure gears rotate freely without catching or binding. Allowable end play is 0.004 to 0.029 inches. 6.3.1.9 Swing Gear Reducer Assembly See Figure 6-9. 1. If they were removed, press new bearing cups (4) and (6) into their bores in the hub (5). 2. Place bearing cone (3) into cup at seal end of hub (5). Press a new seal (2) into its bore in the hub. 3. Lubricate lips of seal (2) and place output shaft (1) into bore in hub (5). Avoid damaging the seal (2).

4. Install other bearing cone (7) and thrust washer (8), and secure with retaining ring (9). NOTE: Retaining rings (9) of different thicknesses are available to set bearing end play. Select the thickest retaining ring that will fit in the groove with the shaft/bearing group assembled. Allowable end play is 0.000" and 0.006". 5. Install secondary carrier assembly (11) over splines of output shaft (1). 6. Apply a continuous 1/16" bead of RTV sealant to gasket face of hub (5). 7. Install ring gear (10) on hub (5) carefully aligning bolt holes. Insert primary carrier assembly (20) and sun gear (26) in ring gear and secondary carrier assembly (11). 8. Apply a continuous 1/16" bead of RTV sealant to gasket face of ring gear (10). 9. Insert sun gear (30) in primary carrier assembly (20).

10. Install cover (32) on ring gear (10). Ensure the thrust washer (31) is installed. Install the twelve capscrews (36) and lock washers (35). Tighten to 40 lb-ft. 6.3.1.10 Swing Bearing 6.3.1.10.1 Wear Check See Figure 6-10. 1. Remove the Bearing from the davit and place it on a flat surface. Place the bearing so that the surface of the outer race is in contact with the work surface. 2. Secure a C-clamp on the bearing as shown, and tighten the clamp to remove any play.

6 - 12

3. Install a dial indicator 180 degrees from the C-clamp as shown and set the dial to zero (0). 4. Move the C-clamp to a position 180 degrees from its original position and tighten it to remove any play. 5. Observe the indicator reading. If the reading exceeds 0.030" (0.77 mm), disassemble and inspect the bearing for damage or signs of unusual wear.

6.3.1.10.2

Disassembly and Inspection

1. Remove the plug from the inner diameter of the bearing. 2. Rotate the inner race until a ball can be seen in the hole. Use a magnet to draw the ball from the hole, and then extract the plastic spacer using needle nose pliers. Repeat this process until all the balls and spacers are removed so the outer and inner races can be separated.

1 2 3 4 5 12 8 9 6 7 13 14

16

17 18

13

15

12 19

DETAIL A

27

26

25 24

10 11 SEE DETAIL A 20 SEE DETAIL B 31 32 33 34

LEGEND 1. OUTPUT SHAFT 2. SEAL 3. BEARING CONE 4. BEARING CUP 5. HUB 6. BEARING CUP 7. BEARING CONE 8. THRUST WASHER 9. RETAINING RING 10. RING GEAR 11. SECONDARY CARRIER ASSY 12. THRUST WASHER

21

22

23

21 29

28

30
AMC 115

DETAIL B

35

36
25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. RETAINING RING SUN GEAR RETAINING RING RETAINING RING PINION SHAFT SUN GEAR THRUST WASHER COVER PIPE PLUG PIPE PLUG LOCKWASHER CAPSCREW

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

NEEDLE BEARINGS SEPARATOR PLANET GEAR RETAINING RING PLANET CARRIER THRUST WASHER PINION SHAFT PRIMARY CARRIER ASSY THRUST WASHER PLANET GEAR NEEDLE BEARING PLANET CARRIER

Figure 6-9 Swing Gear Reducer 6 - 13

3. Inspect the balls and races for scoring, spalling or other damage. If damage is found, the bearing must be replaced. 6.3.1.10.3 Assembly

CAUTION
ENSURE ALL PARTS ARE CLEAN AND FREE OF DAMAGE PRIOR TO ASSEMBLY. 1. Lubricate the balls and races with grease (MIL-G-24139) EP1 or EP2 as appropriate.

THE CYLINDER MUST BE UNLOADED BEFORE DISCONNECTING HOSES/PIPES. REMOVE ANY LOAD FROM THE CYLINDER INCLUDING THE WEIGHT OF THE BOOM AND SECURE THE HYDRAULIC POWER UNIT. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN EQUIPMENT DAMAGE, SEVERE PERSONAL INJURY OR DEATH. 2. Disconnect hoses/pipes from the load lock valve manifold. Plug or cap all lines and ports to prevent contamination. 3. Suspend a cable operated hoist from the boom, and using a suitable choker or sling, attach the hook end to the boom lift cylinder at its midpoint. 4. Remove the lock collar capscrews and nuts. Using a slide hammer puller or drift pin, remove the stem end pin. 5. Lower the boom lift cylinder until it is level and remove the base end pin. 6. The boom lift cylinder can now be safely lowered to the deck. 6.3.2.2 Boom Lift Cylinder Disassembly 1. Remove capscrews from packing gland, and remove packing gland from barrel. 2. Pull the stem and eye assembly from the barrel. Be careful to avoid marring the inner surface of the barrel. 3. 4. Clean all metal components thoroughly. Remove nut from rod assembly. NOTE: Nut is torqued to 2000 lb-ft (2712 N-m). 5. Remove piston, spacer and packing gland.

CAUTION
ENSURE THE NUMBER OF BALLS EQUALS THE NUMBER OF SPACERS BEFORE ATTEMPTING TO ASSEMBLE THE BEARING. 2. Carefully assemble the bearing, alternating balls and spacers to prevent the balls from touching each other. 3. Lubricate the assembled bearing before use.

6.3.1.11 Swing Drive Installation See Figure 6-11. 1. Lift swing drive with a hoist and carefully lower into position in davit base opening. Place swing drive so pinion engages gear teeth on swing bearing, and align hydraulic lines. 2. Install eight capscrews (7) through flange in gear reducer (3) into tapped holes in mounting ring on turret. Leave the capscrews loose for now. 3. Adjust pinion gear backlash by moving the swing drive until the backlash is 0.000" on the bearing high spot. 4. 5. 6.3.2 Tighten eight capscrews (7) to 85 lb-ft. Install hydraulic lines to motor and brake. Boom System

6.3.2.1 Boom Lift Cylinder Removal 1. Lower the boom onto a support, capable of supporting at least 4800 lbs. Secure the HPU.

6. Inspect all metal components for damage. Examine sealing surfaces of the rod end and barrel for cuts and scratches. Small scratches may be polished out with fine emery cloth. Deeply scratched or gouged components must be replaced.

6 - 14

VIEW A

VIEW B

Figure 6-10 Swing Bearing Inspection 7. Replace all seals and O-rings on both packing gland and piston. Never reuse old seals. Coat O-rings with petroleum jelly before installing. 6.3.2.2.1 Piston Seal Replacement

6.3.2.3 Boom Lift Cylinder Assembly Reassemble the boom lift cylinder in the reverse order of disassembly.
LEGEND 1. HYDRAULIC MOTOR 2. BRAKE 3. GEAR REDUCER 4. PINION 10 5. PINION CAP 6. SHEAR BLOCK 7. CAPSCREW 9A 8. CAPSCREW 9. CAPSCREW 9A. CAPSCREW 6 10. GASKET 11. GASKET 7

1. Remove old seal from piston by cutting it with a knife. Careful heating with a flame will soften the seal, making removal easier. 2. Obtain seal replacement kit. NOTE: Piston and stem seal lips must face the base (blind) end of the barrel as shown. 3. Assemble the piston, seal and installation tools as shown in Figure 6-12. Lubricate seal and installation cone with petroleum jelly. 4. Turn the nut until the seal slides up the cone and drops into the seal groove in the piston.

1 9 2 11 3

AMC202

Figure 6-11 Swing Drive

AMC 112

6 - 15

1.

Tighten the piston nut to 2000 lb-ft (2712 N-m). packing gland capscrews to

2. Tighten the 210 lb-ft (285 N-m).

area. A rotating holding fixture is recommended for disassembly and assembly procedures.

6.3.2.4 Boom Lift Cylinder Installation 1. Suspend the boom lift cylinder from the boom. Hoist it up to a level position and insert the base end pin. 2. Hoist the stem end of the boom lift cylinder into position and using a hoist, install the stem end pin. 3. Install lock collar capscrews and nuts. Tighten capscrews and nuts to 124 lb-ft (168 N-m). 4. Carefully connect hoses/pipes and verify proper connection before applying hydraulic power. 5. Perform boom system test in accordance with paragraph 5.2.5. 6.3.3 Constant Tension Winch

DISASSEMBLY AND REPAIR OF THIS WINCH SHOULD NOT BE ATTEMPTED BY OTHER THAN FACTORY TRAINED PERSONNEL. BECAUSE IT REQUIRES EXACT PROCEDURES AND THE USE OF SPECIAL TOOLS, IT IS RECOMMENDED THAT THE WINCH BE RETURNED TO THE FACTORY OR TO AN AUTHORIZED REPAIR FACILITY FOR MAJOR REPAIRS. POTENTIAL FOR PERSONAL INJURY AND/OR DAMAGE TO WINCH COMPONENTS EXISTS. NOTE: See Table 6-1 for special tools required for winch repairs. 6.3.3.2 Disassembly 6.3.3.2.1 Constant Tension Motor End Disassembly See Figs. 6-22 and 6-23. 1. Mount winch to a suitable rotating workstand. Orient winch so that constant tension end is up. 2. Remove four capscrews (47). Remove motor (4) and spacer (19). 3. Remove 10 capscrews housing (20) from frame (7). (45) and remove

6.3.3.1 Removal See Figure 6-13. 1. Remove the cable and cable wedge. Refer to paragraph 6.3.3.9. 2. Relieve all pressure in the hydraulic system before any lines, fittings, or related items are disconnected or removed. 3. Drain all the oil from the winch.

4. Remove all hydraulic lines and electrical wires. Cap or plug any open lines or ports to prevent contamination.

4. Remove bearing (26) from housing (20) or from hub (17) using bearing puller. 5. Remove oil seal (36) from housing (20). Remove any gasket sealant from housing. NOTE: A new seal must be fitted at assembly. 6. Remove 10 capscrews (48) and remove hub (17) from drum (6). Jacking screw holes are provided. 6.3.3.2.2 Load Motor End Disassembly See Figs. 6-17. 1. Orient winch so that the main hoisting motor end is up. 2. Install spring compressor. See Figure 6-14.

CAUTION
BEFORE HOSES AND LINES ARE REMOVED, MANIFOLDS, HOSES, LINES AND PORTS SHOULD BE TAGGED FOR IDENTIFICATION TO ENSURE PROPER REINSTALLATION. IF HYDRAULIC PRESSURE AND RETURN LINES ARE REVERSED, THE WINCH WILL BE DAMAGED. 5. Secure a lifting chain or strap to the winch, and using a suitable overhead hoist with a lifting capacity of at least 1600 lbs, support the winch. Remove the four mounting bolts (11) and nuts (12), and lower the winch. Move it to a clean work

6 - 16

BUSHING PISTON SEAL

BASE

BARREL

NUT WEAR STRIP PISTON O-RING SPACER O-RING PACKING GLAND SEAL STEM WIPER RING

CAPSCREW (10) WEAR STRIP

BUSHING

EYE

STEM & EYE ASSEMBLY

THREADED ROD 3/4 NC X 15" (P/N 34197) INSTALLATION SLEEVE (P/N 33541) SPLIT RING (P/N 33544) SEAL NOTE: ENSURE SEAL LIP FACES DOWN PISTON NUT, 3/4 NC (P/N 00220081) SEAL REPLACEMENT TOOL KIT INSTALLATION CONE (P/N 33545) FLATWASHER, 3/4 (P/N 00103346)
AMC184

Figure 6-12 Boom Lift Cylinder 6 - 17

2. Compress the springs using a port-a-power between the spring compressor and hub (17). See Figure 6-14. USE EXTREME CAUTION WHEN WORKING WITH COMPRESSED SPRINGS. USE ONLY AUTHORIZED SPECIAL TOOLS/FIXTURES. 3. Remove the two nuts (13) and capscrews (43) and lift the main hoist motor (1) off the studs (54). 4. 5. Remove the studs (54). Remove the brake (2). 3. Remove the hub retaining ring (33).

4. Install CT winch hub retainer. See Figure 6-12. Orient winch so that main hoist motor end is up. 5. Remove retaining ring (34) and spacer (9) from hub.

6. Remove bearing assembly (30) using standard puller. Remove spacer (10). 6.3.3.2.4 Piston and Housing Removal See Figure 6-12. 1. 2. Adjust screw on CT winch hub retainer, to retain hub. Remove four capscrews (59) and cover (11). NOTE: Record the position of oil ports for assembly. 3. Remove O-ring (40), backup rings (41), O-ring (38) and fittings (35) from cover (11). 4. Remove piston (12) from hub (8).

6. Remove twelve capscrews (44) and remove cover from reducer assembly (3). Remove two spacers (52 and 53). 7. Lift out gear reducer assembly (3). Remove any sealant from sealing surfaces. 8. Remove shim (56) from gear reducer (3).

9. Remove spacer (5) from winch. Remove any sealant from sealing surfaces. 10. Remove spacer (50) from inner step of spacer (5). 6.3.3.2.3 Spacer Removal See Figure 6-12. 1. Orient winch 180 degrees so that Constant Tension end is up.

5. Remove two O-rings (38) and two backup rings (39) from grooves in piston (12). 6. Remove three springs (29).

7. Remove 12 capscrews (46). Lift housing (14) from frame and drum assembly. 8. Remove bearing cone (31) and bushing (16) from housing (14).

USE EXTREME CAUTION WHEN WORKING WITH COMPRESSED SPRINGS. USE ONLY AUTHORIZED SPECIAL TOOLS/FIXTURES.

6 - 18

1 4

6 3

11 12

WINCH MOUNTING PLATE 9

7 6 8

10

5 3
LEGEND 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

ELECTRICALLY OPERATED RELIEF VALVE CHECK VALVE PRESSURE REDUCING VALVE SEQUENCE VALVE MANIFOLD MANIFOLD SUB PLATE SHUTTLE VALVE COUNTERBALANCE VALVE SOLENOID VALVE BOLTS (4) NUTS (4)

Figure 6-13 Manifold Installation 6 - 19

AMC482

THIS PAGE INTENTIONALLY LEFT BLANK

6 - 20

RETAINING RING

6.3.3.2.5 Drum and Brake Disassembly See Figure 6-17. 1. With the main hoist motor end up, install Main winch hub retainer. See Figure 6-15. 2. Orient winch so that constant tension motor end is up. 3. Remove ring (15).

4. Beginning with a friction disc (27), alternately remove nine friction discs and eight separator plates (28).
SPRINGS HUB

5.

Remove hub (8), large end up, from drum (6).

6. With the constant tension end is up, remove drum assembly from frame (7). 7. Remove main winch hub retainer from main hoist motor end of frame. 8. Clean exposed oil seal surface.

SPRING COMPRESSOR P/N 41729 HYDRAULIC PORT-A-POWER P/N P39/RCH202 (ENERPAC)

AMC156

9. Remove oil seal (37) and clean off any excess gasket sealant. 10. Remove bearing cup (32) and spacer (18) from drum (6). NOTE: Treat all unpainted mating surfaces with cosmoline if the winch is not to be reassembled immediately.

Figure 6-14 Spring Compresser Installation

CT WINCH HUB RETAINER P/N 41727 CONSTANT TENSION MOTOR END UP

DISASSEMBLY AND REPAIR OF THIS WINCH SHOULD NOT BE ATTEMPTED BY OTHER THAN FACTORY TRAINED PERSONNEL. BECAUSE IT REQUIRES EXACT PROCEDURES AND THE USE OF SPECIAL TOOLS, IT IS RECOMMENDED THAT THE WINCH BE RETURNED TO THE FACTORY OR TO AN AUTHORIZED REPAIR FACILITY FOR MAJOR REPAIRS. POTENTIAL FOR PERSONAL INJURY AND/OR DAMAGE TO WINCH COMPONENTS EXISTS. NOTE: See Table 6-1 for special tools required for winch repairs.

AMC157

6.3.3.3 Assembly NOTE: Treat all threaded fasteners with anti-seize compound (MIL-A-907A).

Figure 6-15 Constant Tension Winch Retainer Installation

(6-20 blank)/ 6 - 21

6.3.3.3.1 Drum and Brake Assembly See Figs. 6-17. 1. 2. Mount frame (7) to rotating workstand. Install fitting (55) in drum (6) and apply PST sealant.

12. Orient winch frame so that main hoist motor end is up. Remove Main winch hub retainer. 6.3.3.3.2 Piston and Housing Installation See Figs. 6-23 and 6-24. 1. Drive bearing cone (31) onto housing (14). Press bushing (16) into housing (14). 2. Treat exposed and mating surfaces with cosmoline.

3. Fit spacer (18) into drum (6). The lip on the spacer must face the main hoist motor end of the winch. 4. Seat bearing cup (32) using driver.

5. Install oil seal (37) into bore in drum (6) using seal driver. Seal with sealing compound (MIL -S-45180). Seal lip must face the inside of the drum (6). Treat exposed oil seal surface with cosmoline. 6. Fit drum assembly into frame (7). Add three spacers under drum to center. Install Main winch hub retainer, to main hoist motor end of frame. 7. Orient frame so that constant tension motor end is up.

3. Lubricate seal lip and fit housing assembly over hub (8) and into frame and drum assembly. 4. Orient housing (14) to align cover (11) mounting holes at 1:30, 4:30, 7:30 and 10:30 positions. 5. Secure housing to frame with 12 capscrews (46) treated with anti-seize compound (MIL -A-907A). Torque to 45 lb-ft. 6. Install three springs (29) into housing (14), over hub (8). Place the first spring with the center high side facing down, the second spring with the center high side facing up, and the third with center high side facing down. 7. Fit two O-rings (38) and two backup rings (39) onto piston (12). 8. Fit piston assembly into the housing (14) so that it rests squarely on the springs (29). 9. Fit O-ring (40), backup rings (41), O-ring (38) and fittings (35) into cover (11). 10. Fit cover assembly (11) to housing (14); position housing oil ports at 3:30 and 9:30 positions. Secure with four capscrews (59). Torque to 36 lb-ft. 11. Tighten adjusting screw on CT winch hub retainer until hub is at its highest point.

8. Insert hub (8), large end up, into drum (6). Rest small end onto adjusting screw of hub retainer. 9. Beginning with a friction disc (27), alternately install nine friction discs and eight separator plates (28). NOTE: Missing teeth in friction discs (27) must align with fill/drain holes. 10. Install ring (15). 11. Fit brake ring retainer. See Figure 6-20. Fit CT winch hub retainer to frame to support and adjust hub (8).
MAIN WINCH HUB RETAINER P/N 41721

MAIN WINCH MOTOR END UP

CAUTION
DO NOT OVER TIGHTEN. 6.3.3.3.3 Spacer Installation See Figure 6-24. 1. Install spacer (10) and drive bearing assembly (30) using driver.
AMC158

NOTE: The larger ID of the bearing faces down. 2. Fit spacer (9) to hub (8) and secure with retaining ring (34).

Figure 6-15 Main Winch Hub Retainer Installation 6 - 22

BRAKE RING RETAINER P/N 41726 CONSTANT TENSION MOTOR END UP

6.

Install spacer (53) and spacer (52).

7. Install gear reducer cover (3). Seal with Loctite Ultra Blue and secure with 12 capscrews (44). Torque to 35-40 lb-ft. 8. Install two studs (54) in gear reducer cover (3).

9. Install brake (2) over studs (54). Make sure that there is a new gasket and O-ring at each end of the brake. 10. Install main hoist motor (1) over studs (54) and secure with two nuts (13) and two capscrews (43). Torque to 45 lb-ft.
AMC159

6.3.3.3.5 Constant Tension Motor End Assembly See Figure 6-24. 1. Orient winch so the constant tension motor is up.

Figure 6-17 Brake Ring Retainer Installation 3. See Figure 6-15. Install spring compressor. Orient winch so that constant tension motor end is up.

2. Remove main winch hub retainer and brake ring retainer. See Figure 6-19. 3. Coat mating surface on drum with Loctite Ultra Blue sealant. Fit hub (17) onto drum and secure with ten capscrews (48). Torque to 20 lb-ft. 4. Fit oil seal (36) into housing (20). Coat OD of seal with sealant (MIL-S-45180) before installation. Lubricate seal lip before installation. 5. Fit housing assembly (20) into frame (7) and secure with ten capscrews (45). Torque to 20 lb-ft. NOTE: Orient housing so that the motor mounting hole pattern is aligned with the frame mounting surface. 6. Drive bearing (26) into housing (20) and onto hub (8) using driver. 7. Install spacer with larger diameter up (19).

USE EXTREME CAUTION WHEN WORKING WITH COMPRESSED SPRINGS. USE ONLY AUTHORIZED SPECIAL TOOLS/FIXTURES. 4. Remove the CT winch hub retainer and compress the springs, using a port-a-power between the spring compressor and hub (8). 5. Secure the hub (8) with retaining ring (33).

6.3.3.3.4 Load Motor End Assembly See Figure 6-24. 1. 2. 3. Orient winch so that the hoist motor end is up. Remove spring compressor. Fit spacer (50) into spacer (5).

4. Fit spacer assembly to winch and seal with Loctite Ultra Blue sealant. 5. Install gear reducer assembly (3) and seal with Loctite Ultra Blue sealant. NOTE: If replacing the gear reducer (3), first remove the thrust washer cemented inside the new gear reducer cover.

8. Coat mating surface of constant tension motor (4) with Loctite Ultra Blue sealant. Install motor (4) and secure with four capscrews (47). Torque to 45 lb-ft. NOTE: Treat any unpainted surfaces with cosmoline.

6 - 23

6.3.3.4 Load Motor 6.3.3.4.1 Disassembly See Figure 6-18.

2. Remove the four capscrews (16) and washers (17) with a socket wrench. 3. Lift off the port end cover (4). If necessary to pry loose, refer to caution note. If the thrust plate (11) remains in the gear housing (3), it can be tapped out later with a wooden hammer handle. Be careful not to distort the thrust plate. 4. Pry the gear housing (3) from the gears (2) and off the dowels (14) from opposite sides taking care not to damage machined surfaces 5. Pry the thrust plates (11) from the shaft end cover (1) and port end cover (4) with a screwdriver or similar tool. Avoid distorting the thrust plates. Visually inspect thrust plates for wear or damage and replace if necessary. Remove and discard all rubber pocket seals (12) and gasket seals (13). 6. Examine all roller bearings (10) for scoring, spalling, or pitting. If replacement is necessary, remove the bearings with a bearing puller.
2

CAUTION
IF PRYING SECTIONS APART IS NECESSARY, AVOID MARRING OR DAMAGING MACHINED SURFACES. EXCESSIVE FORCE WHILE PRYING CAN RESULT IN MISALIGNMENT AND SERIOUSLY DAMAGE PARTS. GEARS ARE CLOSELY MATCHED AND THEREFORE MUST BE KEPT TOGETHER AS SETS WHEN REMOVED FROM A UNIT. HANDLE WITH CARE TO AVOID DAMAGE TO THE JOURNALS OR TEETH. 1. Mount the motor in a vise with the shaft end pointing down. Index mark all sections with a punch. Be sure to align these marks when reassembling.

LEGEND 1. SHAFT END COVER 2. GEAR SET 3. GEAR HOUSING 4. PORT END COVER 5. SNAP RING 6. OUTBOARD BEARING 7. DOUBLE LIP SEAL 8. CHECK ASSEMBLY 9. RING SEAL 10. ROLLER BEARING 5 11. THRUST PLATE 12. POCKET SEALS 13. GASKET SEAL 14. DOWEL PIN 15. SEAL RETAINER 16. CAPSCREW 17. WASHER

11 10 9 8 1 7 12 17 4 14 9 10 11 13 3 14 13 12
AMC 149

15 6

16

14

14

Figure 6-18 Load Motor 6 - 24

7. It is generally advisable to replace ring seals (9) when rebuilding unit. To replace, remove the drive gear bearing (10) with a bearing puller and remove ring seal from the bottom of bearing bore. 8. Place the shaft end cover (1) in a vise with the mounting face up. Remove the bearing snap ring (5) with a small screwdriver or awl. 9. Use a bearing puller to remove outboard bearing (6).

seals behind thrust plates, shaft seal and gasket seals. 7. Check valve (8) - Examine small check valve in shaft end cover (1) to ensure it is intact and functioning. 6.3.3.4.3 Assembly See Figure 6-18.

CAUTION
IF PARTS ARE STUBBORN DURING ASSEMBLY, DO NOT FORCE THEM AND NEVER USE AN IRON HAMMER. NEVER HAMMER ROLLER BEARINGS INTO BORES. USE ONLY AN ARBOR PRESS OR OTHER SUITABLE TOOL. 1. Stone off all machined surfaces with a medium grit carborundum stone. 2. If bearings (6,10) have been removed, deburr bearing bores. Rinse parts in a solvent. Air blast all parts and wipe with a clean lint free cloth before starting assembly. Reinstall bearings by pressing them into bearing bores with an arbor press. 3. Grip shaft end cover (1) in vise with mounting face down. Examine check valves (8) to be sure they're tightly in place. Replacement is necessary only if parts are damaged. Remove with screwdriver. If check valves are being replaced, screw check valves in tightly. Peen edge of hole 1/32" to 1/ 16" with 1- 1/2" diameter steel ball. 4. If ring seals (9) are being replaced, insert into bottom of drive gear (2) bearing bore. The notch in the ring seal must be visible. This is a check to be certain the notched side is next to the bearing. 5. Before inserting a new lip seal (7) in the shaft end cover (1), coat the outer edge of the lip seal and its recess with Permatex Aviation Form-A-Gasket No. 3 non-hardening sealant or equivalent. With the metal side of the lip seal up, press it into the mounting flange side of the shaft end cover with an arbor press and bar. Do not attempt to bottom-out seal; press in only until it is flush with the face of the recess. Wipe off surplus sealant. 6. Check all thrust plates for wear and replace if necessary.

10. Grip the shaft end cover (1) in a vise with the mounting face down. Remove the double lip seal (7). Tap the seal out and discard. 6.3.3.4.2 Inspection See Figure 6-18. 1. Gear Housing (3) - Wear in excess of 0.005" cutout necessitates replacement of the gear housing. Place a straightedge across bore. If you can slip a 0.005" feeler gage under the straightedge in the cutout area, the gear housing requires replacement. Where wear is moderate, 0.005" or less, gear housing is in good condition, and both ports are of the same size, housing may be flopped over and reused. 2. Gear Sets (2)- Any wear on gear hubs detectable by touch, or in excess of 0.002" necessitates replacement. Scoring, grooving, or burring of outside diameter of teeth requires replacement. Nicking, grooving, or fretting of teeth surfaces also necessitates replacement. Wear in the shaft seal areas indicate oil contamination. Wear or damage to splines necessitates replacement. 3. Thrust plates (11) - The thrust plates seal the gear section at the sides of the gears. Wear here will allow internal slippage, that is, oil will bypass within the pump. Maximum allowable wear is 0.002". Replace thrust plates if they are scored, eroded or pitted. Check center of thrust plates where the gears mesh. Erosion here indicates oil contamination. Pitted thrust plates indicate cavitation or oil aeration. Discolored thrust plates indicate overheating, probably insufficient oil. 4. Dowel pins (14) - If either the dowel pin or dowel hole is damaged, the pin or machined casting, or both, must be replaced. If more than reasonable force is required to seat dowels, the cause may be poorly deburred or dirty parts; cocking of dowel in the hole; or improper pin-to-hole fit. 5. Roller bearings (10) - If gears are replaced, bearings must be replaced. Bearings should fit into bore with a light press fit. A neat hand fit is allowable. If bearings can fall out, bore may be oversize. 6. Seals and gaskets - Replace all rubber and polymer seals whenever disassembling pump. Include all O-rings, pocket

7. Grip the shaft end cover (1) in a vise with the mounting face down. Cut two pocket seals (12) 7/32" long from the pocket seal strip. Grease these pocket seals well and insert them into the middle slots on the reverse side of the thrust plate (11). 6 - 25

8. With the pocket seals (12) facing down, place the thrust plate (11) over the bearings in the shaft end cover (1). Tap thrust plate with a soft hammer to about 1/32" from the machined surface. 9. Cut four pocket seals (12) approximately 1/4" long from the pocket seal strip. Insert one pocket seal into each of the slots in the thrust plate. Push each pocket seal all the way in so that it touches the roller bearings. Tap the thrust plate down firmly against the machined surface with a soft hammer. Use a sharp razor blade to trim exposed end of the pocket seal square and flush with the thrust plate.

15. Guide the outboard bearing (6) into its recess in the shaft end cover (1). This is not a press fit. Insert the snap ring (5) into its groove to retain the outboard bearing. 16. Once you are sure there is no internal binding, torque diagonally opposed fasteners to 200 lb-ft. 6.3.3.5 Constant Tension Motor 6.3.3.5.1 Disassembly See Figure 6-19. 1. Remove snap ring (1).

CAUTION
TEMPORARILY COVER THE SPLINED PORTION OF THE INTEGRAL GEAR AND DRIVE SHAFT (2) WITH A PROTECTIVE SLEEVE BEFORE INSERTING SHAFT THROUGH DOUBLE LIP SEAL (7). FAILURE TO DO SO WILL DAMAGE THE LIP SEAL. 10. Insert the integral gear and drive shaft (2) with sleeve into the shaft end cover (1) with a twisting motion. Be careful not to damage the double lip seal. Push down carefully until the gear rests against the thrust plate (11). Remove the sleeve. Insert the driven gear. 11. Grease the new gasket seals (13) and insert them into the grooves in both sides of the gear housing (3). Examine all dowel pins (14). Before inserting a pin, make certain the hole is clean and free from burrs. Start pin into hole gently and straight, tapping lightly with a soft hammer. 12. Slide gear housing (3) over the gears (2) and tap it with a soft hammer until it rests tightly against the shaft end cover (1). Be careful not to pinch the gasket seal (13). Squirt oil over the gears to provide initial lubrication when pump is started. Line up the dowels (14) with the matching holes. When parts are parallel, squeeze them together or gently tap alternately over dowels with a plastic hammer until the parts become parallel and move smoothly together. Do not force. 13. Place the port end cover (4) over the gear journals and tap tightly against the gear housing (3). Be careful not to pinch the gasket seal (13). Align the dowels with the holes in the mating casting. Being careful not to pinch the gasket seal, tap the port end cover lightly in the center between bearing bores to engage the dowels and to move parts together in final seating. 14. Thread the four cap screws (16) and washers (17) into the shaft end cover and tighten alternately or cross-corner. Rotate the drive shaft with a 6" wrench to make certain there is no binding in the pump. 6 - 26

2. Pry out seal plate (2) with two screwdrivers. Remove seal plate O-ring (4) from groove in bearing bore. 3. Mark one side of the motor for proper reassembly, ensuring that the rotor/stator assembly (15 - 21) will not be installed upside down. Secure the motor and loosen and remove the 5/8" bolts (9). 4. Remove front housing (10). NOTE: Two 5/32" ball checks (22) and one main body O-ring (12) may fall out. 5. Press shaft (8) and ball bearing (7) out of front housing (10). 6. Remove snap ring (6) from shaft (8). Press shaft out of bearing. 7. Lift up rotor/stator assembly (15 - 21) and remove from the rear housing (24). 8. Place assembly on any object which will hold it off the table. Remove two each plate screws (13). Remove timing plate (14). 9. Remove O-ring (12) and springs (16, 20, 21) with a small screw driver. Remove dowel pins (11). 10. Replace timing plate (14) on rotor/stator assembly. Turn assembly over, and repeat steps 8 and 9. 11. Remove the 10 rotor vanes (19) and stator vanes (17). Remove the rotor (18). 6.3.3.5.2 Inspection See Figure 6-19. 1. If any wear on either seals or springs is detected, replace with new parts. 2. Inspect all parts and replace any which obviously show excessive wear or damage.

3. Inspect the vanes (17 and 19) for excessive wear. Normal wear results in slight flattening of vane tips, which does not impair motor performance. Replace vane if outside radius is reduced by 50%. NOTE: There is normally 0.010" clearance between a vane and a vane slot. 4. Inspect the timing plates (14) for excessive wear. Normal wear results in marking of timing plates which does not impair motor performance. 5. Inspect the rotor (18) for excessive wear or damage. Normal wear results in polishing of rotor faces which does not impair motor performance. 6. Inspect the stator (15) for excessive wear or damage. Normal wear results in polishing of cam form which does not impair motor performance. 7. Measure the rotor and stator length to the fourth decimal point, and supply measurement when ordering rotor, stator, or vanes.

6.3.3.5.3 Assembly See Figure 6-19. 1. Place the stator (15) on a raised surface, and place the rotor (18) inside the stator. Install stator vanes (17) and rotor vanes (19) in their slots. NOTE: Make sure that the radiused edge of each stator vane points to the rotor, and the radiused edge of each rotor vane points to the stator. 2. Install two front dowel pins (11) in the stator. Using a small screw driver, install the vane springs. NOTE: Make sure springs are seated in the bottom of the spring pocket in both the rotor and stator. 3. Install O-ring (12) and timing plate (14). Install two timing plate screws (13). 4. Turn assembly over and repeat steps 1 through 3, except install rear dowel pins (5). 5. Install ball checks (22) into rear housing. Install main body O-ring (12).

Figure 6-19 Constant Tension Motor 6 - 27

6.

Place rotor/stator assembly onto rear housing (24). NOTE: Ensure assembly marks from disassembly procedure are aligned.

7. Remove retaining ring (8) from outer spline (11) then slide bearing (9) and sprag bearing (10) out of outer spline (11). Noting direction of individual sprags in sprag bearing (10) will aid in reassembly. NOTE: Use care when handling sprag bearing (10) so as not to rotate or dislodge sprags from retainer. Removal of needle bearing (12) from outer spline (11) is not recommended. If needle bearing requires servicing, contact factory for further information. 8. Remove retaining ring (1) from cover (6) and press out oil seal (5) and bearing (3) if required. 9. Remove four capscrews (14). A suitable holding fixture is useful to hold brake in position.

7.

Press bearing (7) onto shaft (8). Install snap ring (6).

8. Press shaft and bearing assembly into front housing (10) by pressing on the outer race of bearing (7). 9. Place seal plate O-ring (4) into groove in the front housing (10). Press seal plate (2) into front housing. Install snap ring (1). 10. Install main body O-ring (12) into front housing (10). Install ball checks (22) into front housing. Place a small amount of grease over ball checks and O-ring. Wipe off any excess grease. 11. Pour a small amount of clean hydraulic oil into the rotor/stator assembly. Install front housing (10) onto the rotor/stator assembly. Make sure the alignment marks from disassembly are lined up. 12. Install 5/8" bolts (9) and tighten to 50 lb-ft. Rotate the shaft in both directions to assure that the shaft turns smoothly. Now tighten the bolts (9) to 175 lb-ft. Rotate the shaft again in both directions to verify that the shaft still turns smoothly. 6.3.3.6 Winch Brake 6.3.3.6.1 Disassembly See Figure 6-20. 1. Remove two capscrews (4). A suitable holding fixture is useful to keep brake in position. 2. Tap female end of spline shaft assembly (7 - 13) and spring plate (20) with soft mallet to separate cover. If sections will not separate, use a screwdriver to carefully pry sections apart. 3. Remove retaining ring (2) from spline shaft assembly (7 - 13). 4. Remove spline shaft assembly (7 - 13) from cover (6) by tapping male end of spline shaft assembly with soft mallet. 5. If disassembly of spline shaft assembly (7 - 13) is required, remove retaining ring (7) from spline shaft (13). 6. The retaining ring (8), bearing (9), sprag bearing (10), outer spline (11) and needle bearing (12) can be removed from spline shaft (13) as a subassembly.

CAUTION
DO NOT REMOVE CAPSCREWS (14) WITHOUT PRESSURIZING BRAKE TO APPROXIMATELY 300 PSI. 10. Before removing primary disc (15), rotor discs (16) and stator discs (17), note pattern for assembly purposes. 11. Release the pressure to brake before removing the four capscrews (18). 12. Remove spring plate (20). 13. Remove gasket (19) from spring plate (20). 14. Before removing springs (21), note pattern and color for reassembly purposes. 15. Remove piston (22) by carefully exerting hydraulic pressure through brake release port on pressure plate (27). 16. Remove O-rings (24 and 26) and backup rings (23 and 25) from piston (22). NOTE: Avoid scratching or marring piston. 17. Remove gasket (19) from pressure plate (27). 6.3.3.6.2 Assembly See Figure 6-20. NOTE: Lubricate all rubber components from repair kit with clean hydraulic fluid of the same type used in the hydraulic system.

6 - 28

28

30

78

29 2

10

11

12

13 14 15 16 17

18 19 20 21 22 23 24 25

26

19 27

29 30

LEGEND 1. RETAINING RING 2. RETAINING RING 3. BEARING 4. CAPSCREW 5. SEAL 6. COVER 7. RETAINING RING 8. RETAINING RING 9. BEARING 10. BEARING SPRAG 11. OUTER SPLINE 12. NEEDLE BEARING 13. SPLINE SHAFT 14. CAPSCREW 15. PRIMARY DISK 16. ROTOR DISK 17. STATOR DISK 18. CAPSCREW 19. GASKET 20. SPRING PLATE 21. SPRING 22. PISTON 23. BACKUP-RING 24. O-RING 25. BACK-UP RING 26. O-RING 27. PRESSURE PLATE 28. PLUG 29. GASKET 30. O-RING
AMC153

Figure 6-20 Winch Brake 1. Clean all parts thoroughly before assembling. 9. Install retaining ring (7) onto spline shaft (13) and retaining ring (8) into outer spline (11) to complete spline shaft assembly (7 - 13). 10. Press spline shaft assembly (7 - 13) into bearing (3) until shaft bottoms on shaft shoulder. Bearing inner race must be supported during this operation. 11. Install retaining ring (2) on spline shaft assembly (7 - 13). 12. Install backup rings (23 and 25) on piston (22) towards spring pockets. 13. Install O-rings (24 and 26) on piston (22). Ensure O-rings are flat and all twists removed. NOTE: Avoid scratching or marring piston. 14. Lubricate piston (22) with clean hydraulic fluid of the same type as is used in the hydraulic system. Carefully press piston into pressure plate (27). Be sure piston is oriented such that threaded holes in piston are in alignment with through holes in spring plate (20) when installed. NOTE: Alternate different colored springs.

2. Press seal (5) into bore until it is flush with bearing shoulder. Seal (5) must be installed with closed side facing pilot end of cover (6). 3. Press bearing (3) into position until it bottoms out on oil seal bore step. 4. Install retaining ring (1) into cover (6).

5. With needle bearing (12) installed in outer spline (11), carefully slip sprag bearing (10) into outer spline (11) to form outer spline subassembly. 6. With spline shaft (13) sitting upright on a flat surface, take outer spline subassembly and carefully place over spline shaft (13) making sure that sprag bearing (10) slides freely over spline shaft (13). 7. While holding outer spline (11) stationary, spline shaft (13) must rotate freely in the counterclockwise direction when facing the male end of spline shaft (13). 8. After proper rotation is determined, install bearing (9) between outer spline (11) and spline shaft (13).

6 - 29

15. Affix gaskets (19) to pressure plate (27) and spring plate (20). 16. Place unit on a press. Using a suitable fixture, depress and install four shouldered capscrews (18) with two drops of thread locking compound (MIL-S-22473E) applied to each capscrew. Torque bolts to 35 - 40 lb-ft. A suitable holding fixture is useful to hold brake in position. 17. Install stator discs (17) and rotor discs (16) in same sequence as noted during disassembly. 18. Install primary disc (15). NOTE: The assembled stack height of discs (15), (16) and (17) must be 1-1/4" minimum. 19. Align discs and partially screw in four shouldered capscrews (14) with two drops of thread locking compound (MIL-S-22473E) applied to each capscrew. Inspect for free movement of stack. Pressurize brake release port to approximately 300 psi to release discs. Torque shoulder bolts to 15 - 18 lb-ft and release pressure. A suitable holding fixture is useful to hold brake in position. 20. Install cover (6) using capscrews (4) with two drops of thread locking compound (MIL-S-22473E) applied to each capscrew. Torque bolts to 9 - 11 lb-ft.

2. Catch planet gear (13), needle bearings (18) and thrust washers (14) as each pinion shaft (15) is removed. 3. Repeat steps 1 and 2 for remaining planet gears.

4. Remove the retaining ring (16) from sun gear (12) groove inside primary planet carrier (20). Pull sun gear from carrier splines. 6.3.3.7.3 Secondary Carrier Disassembly See Figure 6-21. 1. Remove retaining ring (10) retaining a pinion shaft (8). Mark the serrated pin on each shaft so they may be replaced as described at reassembly. 2. Catch planet gear (7), needle bearings (5), separator (6), and thrust washers (4) as each pinion shaft (8) is removed. 3. Repeat steps 1 and 2 for remaining planet gears.

6.3.3.7.4 Primary Carrier Assembly See Figure 6-21. 1. Install the larger diameter retaining ring (17) against sun gear (12) shoulder. Slide sun gear splines into primary planet carrier (20), then insert the smaller diameter retaining ring (16) in sun gear groove inside of the primary planet carrier. 2. Use a low melting point grease to hold the sixteen needle bearings (18) as they are inserted into planet gear bore. Centering pinion shaft (15) in planet gear bore will help align needle bearings. 3. Install a thrust washer (14) between gear (13) and carrier faces as gears are assembled into carrier (20). 4. Align thrust washer tang with recess cast into carrier.

CAUTION
IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE BRAKE ASSEMBLY, RELEASE PRESSURE SHOULD NOT EXCEED 1000 PSI UNLESS FOUR ADDITIONAL BOLTS ARE USED FOR SUPPLEMENTAL CLAMPING. 6.3.3.7 Winch Gear Reducer 6.3.3.7.1 Gear Reducer Disassembly See Figure 6-21. 1. 2. 3. 4. Remove cover (22) and spacer (25). Remove sun gear (21) and spacer (26). Remove primary carrier assembly (11). Remove secondary carrier assembly (2).

5. Insert pinion shafts (15) into carrier and through each gear (13). Install retaining ring (19) to secure shaft. Install pinion shafts in the exact position from which they were removed. 6. Ensure gears rotate freely without catching or binding. Allowable end play is 0.004 to 0.029 inches. 6.3.3.7.5 Secondary Carrier Assembly See Figure 6-21. 1. Install thrust washer (9) in recess inside of carrier (3).

6.3.3.7.2 Primary Carrier Disassembly See Figure 6-21. 1. Remove retaining ring (19) holding a pinion shaft (15). Mark the serrated pin on each shaft so they may be replaced as described at reassembly. 6 - 30

2. Use a low melting point grease to hold the sixteen needle bearings (5) as they are inserted into one end of each planet gear bore.

10

2 (ITEMS 3-10) 3

1 4 26

9 12 5 17

11 (ITEMS 12-20) 20

16

23

8 14 13

19

18

21

14 15

27 22 24 25

LEGEND 1. RING GEAR 2. SECONDARY CARRIER ASSY 3. CARRIER 4. THRUST WASHER 5. NEEDLE BEARING 6. SEPARATOR 7. PLANET GEAR 8. PINION SHAFT 9. THRUST WASHER 10. RETAINING RING 11. PRIMARY CARRIER ASSY 12. LARGE SUN GEAR 13. PLANET GEAR 14. THRUST WASHER 15. PINION SHAFT 16. RETAINING RING 17. RETAINING RING 18. NEEDLE BEARING 19. RETAINING RING 20. CARRIER 21. SMALL SUN GEAR 22. COVER 23. FILLER PLUG 24. MAGNETIC DRAIN PLUG 25. SPACER 26. SPACER 27. SHIM
AMC 154

Figure 6-21 Winch Gear Reducer 3. Install a separator (6) and a second set of sixteen needle bearings (5) into the other end of the planet gear bore. 4. Insert pinion shafts (8) into carrier and through each gear (3). Install retaining ring (7) to secure shaft. Install pinion shafts in the exact position from which they were removed. 5. Ensure gears rotate freely without catching or binding. Allowable end play is 0.004 to 0.029 inches. 6.3.3.7.6 Gear Reducer Assembly See Figure 6-21. 1. Place ring gear (1) on clean work surface. 4. Install spacer (26) into bore of small sun gear (21) and install spacer (25) over other end of small sun gear. Install this assembly, with teeth of small sun gear meshing with planet gears (13) into primary carrier assembly (11). 5. Install the shim (27) and cover (22). Do not use sealant at this time. Temporarily bolt the assembly together using 5-1/2" long capscrews and nuts. 6.3.3.8 Winch Installation See Figure 6-13. 1. Secure a lifting chain or strap to the winch, and using a suitable overhead hoist with a lifting capacity of at least 1600 lbs, lift the winch and move it into position on the davit. Install the four mounting bolts (11) and nuts (12) and tighten to 282 - 310 lb-ft in approximate 40 lb-ft increments. Lubricate with marine grease (MIL-G-24139). 2. Install the cable wedge and cable. Refer to paragraph 6.3.3.9. 3. Fill winch with the proper oil. Refer to Chapter 4.

2. Place secondary carrier assembly (2) into bore of ring gear, engaging planet gears with ring gear. 3. Install primary carrier assembly (11). The sun gear (12) in the carrier (20) meshes with the planet gears (7) of the secondary carrier assembly (2).

6 - 31

4. Install all hydraulic lines. Start davit and allow system to warm up and air to pass through the lines to the tank. Check system for leaks. 5. Install the hook and related reeving components.

NOTE: The winch cable should not be installed onto the drum until initial adjustments have been made as instructed in paragraph 6.2.3. 1. Insert the cable from the inside of the drum into the small hole in the drum flange and pass the free end through the small opening in the wedge pocket. 2. Loop cable by pushing the free end back through the pocket and install a cable clamp on the dead end. 3. Insert the cable wedge in the loop with the small end toward the drum and pull slack out of the cable through the drum. 4. The cable wedge will slip into the pocket to secure the cable onto the drum.

6.3.3.9 Winch Cable Installation See Figure 6-22.

CABLE CLAMPS ALONE ARE NOT DESIGNED TO HOLD RATED LOADS. NEVER OPERATE THE DAVIT WITH FEWER THAN THREE COMPLETE WRAPS OF CABLE ON THE DRUM.

CABLE CLAMP CABLE WEDGE

CABLE DRUM CONSTANT TENSION HYDRAULIC MOTOR CABLE WEDGE

LOAD HYDRAULIC MOTOR

Figure 6-22 Winch Cable Installation 6 - 32

AMC293

50
LEGEND 1. LOAD MOTOR 2. BRAKE ASSEMBLY 3. GEAR REDUCER ASSEMBLY 4. CONSTANT TENSION MOTOR 5. SPACER 6. DRUM 7. FRAME 8. HUB 9. SPACER 10. SPACER 11. COVER 12. PISTON 13. NUT 14. HOUSING 15. RING 16. BUSHING 17. HUB 18. SPACER 19. SPACER 20. HOUSING 26. ROLLER BEARING 27. FRICTION DISC 28. SEPARATOR PLATE 29. DISC SPRING 30. BEARING 31. BEARING CONE 32. BEARING CUP 33. RETAINING RING 34. RETAINING RING 35. FITTING 36. SEAL 37. SEAL 38. O-RING 39. BACKUP-RING 40. O-RING 41. BACKUP-RING 42. CABLE WEDGE 43. CAPSCREW, 1/NC x 6 SS 44. CAPSCREW, 3/8NC x 10-1/2 G8 45. CAPSCREW, 3/8NC x 1-1/4 SKT HD SS 46. CAPSCREW, 1/2NC x 1-3/4 SS 47. CAPSCREW, 1/2NC x 1-1/4 SS 48. CAPSCREW, 3/8NC x 1 SKT HD SS 50. SPACER 52. SPACER 53. SPACER 54. STUD 55. FITTING 56. SHIM 58. CHECK VALVE 59. CAPSCREW, 3/8NC x 1-1/4 SKT HD G8 60. SHIM

58

3 56 3 44 6 43 52 2 53 37

42 55

1 54

13 59

35 9 30 10

11

38

41

40

41

38

39

38

39

12

8 18 16 7 48 45

47

34

32 31 14 46 29 15 60 33 36 17 26

19 20

27 28

Figure 6-22 Constant Tension Winch Figure 6-23 Constant 6 - 33 / (6 - 34 blank)

AMC440

4
LEGEND 1. LOAD MOTOR 2. BRAKE ASSEMBLY 3. GEAR REDUCER ASSEMBLY 4. CONSTANT TENSION MOTOR 5. SPACER 6. DRUM 7. FRAME 8. HUB 9. SPACER 10. SPACER 11. COVER 12. PISTON 13. NUT 14. HOUSING 15. RING 16. BUSHING 17. HUB 18. SPACER 19. SPACER 20. HOUSING 26. ROLLER BEARING 27. FRICTION DISC 28. SEPARATOR PLATE 29. DISC SPRING 30. BEARING 31. BEARING CONE 32. BEARING CUP 33. RETAINING RING 34. RETAINING RING 35. FITTING 36. SEAL 37. SEAL 38. O-RING 39. BACKUP-RING 40. O-RING 41. BACKUP-RING 42. CABLE WEDGE 43. CAPSCREW, 1/NC x 6 SS 44. CAPSCREW, 3/8NC x 10-1/2 G8 45. CAPSCREW, 3/8NC x 1-1/4 SKT HD SS 46. CAPSCREW, 1/2NC x 1-3/4 SS 47. CAPSCREW, 1/2NC x 1-1/4 SS 48. CAPSCREW, 3/8NC x 1 SKT HD SS 50. SPACER 52. SPACER 53. SPACER 54. STUD 55. FITTING 56. SHIM 58. CHECK VALVE 59. CAPSCREW, 3/8NC x 1-1/4 SKT HD G8

26

36

47 33 29 18 28 27 15

31,32 16

55

17

48

45

20

19

5 58 59 40,41 35 11

37

14

30 12 35 10

46

38

39

50

44

56

53

34

13,54

43

Figure 6-23 Constant Tension Winch Sectional View Figure 6-24 Constant Tension Winch Sectional 6 - 35 / (6-36 blank)

AMC441

VIEW A-A

52

42

CHAPTER 7 PARTS LIST

7.1 INTRODUCTION This illustrated parts list contains all components of the davit that can be separately identified as well as parts necessary for equipment support. 7.1.1 Major Subassemblies Figure/Table 7-1 identifies all major subassemblies of the davit. Quantities indicated are total per davit except indented items which indicate total per subassembly. Equipment specifications (such as power requirements, dimensions, etc.) for major subassemblies are contained in Chapter 1. 7.1.2 Special Notes Essential information regarding the interchangeability of parts, initial condition settings or special installation procedures are offset in italicized text in the parts breakdown illustrations when necessary. 7.2 FORMAT Component parts lists (Pages 7-5 through 7-75) are presented in 5-column format. 7.2.1 Item Index numbers found in this column correspond to the numbers found on the respective parts location illustration. Some items are shown for reference purposes only to illustrate their relationship to other systems. 7.2.2 Notes This column identifies footnotes applicable to specified items. 7.2.3 ASC P/N This column lists the Allied Systems Company Part Number. 7.2.4 Qty This column lists the total number of a specific item required per assembly or subassembly. This number may not necessarily be the number of items used in the end item or system. Only one set of components is listed whenever the components of two assemblies are the same. A/R (as required) identifies bulk items whose length or other dimension must be specified when requisitioning. Ref identifies items shown for reference purposes only to illustrate their relationship to other systems. NSS (not sold separately) identifies items such as valve housings and spools, ring gears and pinions, etc., which must be ordered as a set because they are closely mated at manufacture. 7.2.5 Description This column lists the item nomenclature along with those modifiers necessary to identify the item. Additionally, cross references for repairable subassemblies are listed in this column. One dot preceding the description indicates that the item is a component part of the previously listed item or assembly with no dot. Two dots indicate that the item is part of the previously listed item with one dot. Example: Electric Swivel . Collector Ring Assembly . . Screw . . Brush Holder Assembly . . . Brush Spring The Collector Ring Assembly is a first level subassembly of the Electric Swivel as indicated with one dot. The Screw and the Brush Holder Assembly are second level components of the Collector Ring Assembly as indicated by the two dots. The Brush Spring is a third level component of the Brush Holder Assembly which is indicated with three dots. 7.2.6 Illustrations Parts location illustrations may differ from engineering drawings because they have been altered to fit on the page or to improve clarity by omitting items that are not replaceable components such as weld-ons.

7-1

1 9

10 8 6

11 3 2 7

Figure 7-1 D5700CT Boat Davit 7-2

ITEM 1 2 3 4 5 6

ASC P/N D5700CT 48850 49233 27164 47045 52197 42269 236945 23939 240247 48857 49100 25829 38693 48855 48856 48860

QTY 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1

DESCRIPTION Boat Davit . Davit Assembly . . Remote Lube Assy . . Pedestal Assembly (Ref) Customer Supplied . Swing Stop Installation . Boom Lift Cylinder . Jib Boom Assembly . Swing Drive . . Swing Motor . . Swing Gear Reducer . . Swing Brake . Control Console (Ref) Customer Supplied . Swing System . . Swing Junction Block . . Swing Stop Valve . . Swing Dual Counterbalance Valve . Boom System . Winch System . Bulkhead Plate

PAGE 7-2 7-5 7-6 7-7 7-8 7-9 7-10 7-11 7-12 7-14 7-16 7-18 7-19 7-20 7-21 7-22 7-23

ITEM 9

ASC P/N 46450 45675 45670 39163 235621 235622 235623 234728 237425 236421 235378 235377 235411 52201 52202 47220 47221 47222 45362

QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

DESCRIPTION . Reeving Components . . Constant Tension Winch . . . Manifold Installation . . . . Winch Electrically Operated Relief Valve . . . . Winch Check Valve . . . . Winch Pressure Reducing Valve . . . . CT Sequence Valve . . . . Counterbalance Valve . . . . Winch Solenoid Valve . . . Load Hydraulic Motor . . . Winch Brake . . . Winch Gear Reducer . . . CT Hydraulic Motor . Electrical System . . Junction Box . . Anti-2-Block Control . . Downstop Control . . Cable Tension Sensor . Hydraulic Power Unit (Ref) (Customer Supplied)

PAGE 7-24 7-26 7-28 7-30 7-31 7-33 7-34 7-35 7-36 7-37 7-38 7-39 7-40 7-42 7-44 7-45 7-46 7-47

7 8

10

11

Table 7-1 List of Major Components 7-3

Figure 7-2 Davit Assembly 7-4

ITEM Fig. 7-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

NOTES

ASC P/N 48850 48853 49233 27164 46157 36681 234130 44050 38340 233866 245098 226684 245097 25097 229324 233852 R13802633 25450

QTY DESCRIPTION 1 1 1 2 2 8 1 2 4 26 1 31 1 1 1 46 1 Davit Assembly . Davit Weldment . Remote Lube System - See Table 7-3 . Swing Stops Installation - See Table 7-4 . Plate, Cover . Gasket . Capscrew . Nameplate . Plate, Cover . Capscrew . Capscrew . Bearing . Capscrew . Pin . Capscrew . Nut, Esna . Washer, Flat . Gasket

Table 7-2 Davit Assembly Parts List 7-5

Figure 7-3 Remote Lube System

ITEM Fig. 7-3 1 2 3 4 5 NOTES ASC P/N 49233 46541 237800 239617 10643 233858 QTY DESCRIPTION 1 1 1 1 1 Remote Lube System . Tube Assembly . Fitting . Fitting . Fitting, Lube . Fitting

Table 7-3 Remote Lube System Parts List 7-6

3 2 1

120 TYP

Figure 7-4 Swing Stop Installation

ITEM Fig. 7-4 1 2 3 NOTES ASC P/N 27164 25810 26061 245100 QTY DESCRIPTION 1 1 6 Swing Stop Installation . Swing Stop, LH . Swing Stop, RH . Capscrew

Table 7-4 Swing Stop Installation Parts List 7-7

Figure 7-5 Boom Lift Cylinder

ITEM Fig. 7-5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 NOTES ASC P/N 47045 47073 25314 25317 25318 09419545 25319 21865 25320 21866 25333 25334 223390 26586 25360 25075 34196 25417 QTY DESCRIPTION 1 1 1 1 1 1 1 1 1 1 1 10 1 1 2 Boom Lift Cylinder . Barrel Weldment . Stem & Eye Weldment . Piston . Packing Gland . Nylock Nut . Spacer . Wear Strip (Bearing Pad) . Wear Strip (Bearing Pad) . Seal . Seal . Wiper Ring . Capscrew . O-Ring . O-Ring . Bushing Seal Installation Tool Kit Service Kit

* * * * * * *

Table 7-5 Boom Lift Cylinder Parts List 7-8

Figure 7-6 Jib Boom Assembly

ITEM Fig. 7-6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 NOTES ASC P/N 52197 52198 228458 25098 233864 25076 25093 25099 25322 25303 25077 226846 231851 25096 25020 225788 228460 25097 229324 233852 12977 241239 QTY DESCRIPTION 1 1 1 1 2 1 1 1 2 1 1 1 1 2 1 1 1 1 1 1 1 Jib Assembly . Jib Weldment . Nut, Esna . Pin . Capscrew . Bushing . Sheave Case Assembly . Pin Assembly, Sheave . Sheave Assembly . Washer . Bushing . Capscrew . Nut, Esna . Pin . Bushing . Capscrew . Nut, Esna . Pin . Capscrew . Nut, Esna . Lock Collar . Washer, Flat

Figure 7-6 Jib Boom Assembly 7-9

11

2 10

3 7

Figure 7-7 Swing Drive

ITEM Fig. 7-7 1 2 3 4 5 7 8 9 10 11 NOTES * * * * ASC P/N 42269 236945 240247 23939 31475 24014 233853 233854 233855 516672 -----QTY DESCRIPTION 1 1 1 1 1 8 2 4 1 Ref Swing Drive . Swing Motor - Table 7-8 . Swing Brake - Table 7-9 . Swing Gear Reducer - Table 7-10 . Pinion . Pinion Cap . Capscrew . Capscrew . Capscrew . Gasket Gasket - Table 7-9 Recommended Spare Part - Qty 1

Table 7-7 Swing Drive Parts List 7 - 10

5 12 11 10 13 4 6 1 9 3 7 8 14 15 17 16

18

19

Figure 7-8 Swing Motor

ITEM Fig. 7-8 1 2 3 4 5 6 NOTES * * * * * * * * * ASC P/N 236945 236722 236723 236724 236725 236726 236727 236728 236729 236730 236731 236732 236733 -----236735 236736 236737 236738 236739 236740 236741 236742 -----236743 25408 QTY DESCRIPTION 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 Swing Motor . Dust Seal . Snap Ring . Backup Shim . Housing Seal (High Pressure) . Body Seal . Seal Spacer Assembly . . Seal Carrier . . Shaft Seal . . Teflon Backup . . Backup Shim . Thrust Washer . Thrust Bearing . Housing . Spline Shaft . Cooling Plug . Drive Link . Wear Plate . Rotor Set Assembly . Pin, Drive Link . Ball . End Cover . Identification Tag . Bolt Service Kit

7 8 9 10 11 12 13 14 15 16 17 18 19

Table 7-8 Swing Motor Parts List 7 - 11

1 2 3 4 5 12 8 9 6 7 13 14

16

17 18

13

15

12 19

DETAIL A

27

26

25 24

10 11 SEE DETAIL A 20 SEE DETAIL B 31 32 33 34 35 36 21 22

23

21 29

28

30

DETAIL B

Figure 7-9 Swing Gear Reducer 7 - 12

ITEM Fig. 7-9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

NOTES

ASC P/N 23939 25414 225334 225335 225336 225337 225338 225339 228886 225341 225342 225343 228887 228888 228889 NSS NSS NSS 228890 228891 225344 228887 NSS 228893 NSS NSS NSS NSS NSS 228894 225345 225346 225348 --------------------33276

QTY DESCRIPTION 1 1 1 1 1 1 1 1 1 1 1 6 96 3 3 3 1 1 3 1 6 3 48 1 1 1 3 1 3 1 1 1 1 1 12 12 Swing Gear Reducer . Output Shaft . Seal . Bearing Cone . Bearing Cup . Hub . Bearing Cup . Bearing Cone . Thrust Washer . Retaining Ring . Ring Gear . Secondary Carrier Assembly . . Thrust Washer . . Needle Bearing . . Separator . . Planet Gear . . Retaining Ring . . Planet Carrier . . Thrust Washer . . Pinion Shaft . Primary Carrier Assembly . . Thrust Washer . . Planet Gear . . Needle Bearing . . Planet Carrier . . Retaining Ring . . Sun Gear . . Retaining Ring . . Retaining Ring . . Pinion Shaft . Sun Gear . Thrust Washer . Cover . Pipe Plug . Pipe Plug . Lockwasher . Capscrew Service Kit

* * * * * *

* * *

* * * *

* *

Table 7-9 Swing Gear Reducer Parts List 7 - 13

1 5 4 10

17

19 8

14 15 9 2 12 3 13 6 18 7 11

16

Figure 7-10 Swing Brake

ITEM Fig. 7-10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 NOTES ASC P/N 240247 237407 -----229607 225332 225331 225333 232508 228076 225174 237698 226559 27356 27359 27357 27358 240208 27192 239736 -----27171 31077 QTY DESCRIPTION 1 1 1 1 1 1 4 1 5 1 7 1 1 1 1 1 1 1 Ref Swing Brake . Case . Cover . Piston . Shaft . Bearing, Output . Bearing, Input . Capscrew . Plug . Spring . Friction Disc Kit (includes 8 discs) . Plate, Separator . Backup-Ring . Backup-Ring . O-Ring . O-Ring . O-Ring . Seal . Gasket Gasket - Table 7-6 Seal Kit Disc & Bearing Kit

*b *b

*b *b *a *a *a *a *a *a *a *a *b

Table 7-10 Swing Brake Parts List 7 - 14

THIS PAGE INTENTIONALLY LEFT BLANK

7 - 15

Figure 7-11 Swing System (7 - 16 blank) / 7 - 16 7 - 15

ITEM Fig. 7-11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

NOTES

ASC P/N 48857 49100 25829 233867 228413 49030 49031 49032 49033 49034 49035 49036 38693 237764 237765 237766 228490

QTY DESCRIPTION 1 1 2 2 2 3 1 1 1 1 1 2 9 3 7 1 Swing System . Swing Manifold Assembly - Table 7-12 . Valve, Stop - Table 7-13 . Capscrew . Nut, Hex . Tube Assembly . Tube Assembly . Tube Assembly . Tube Assembly . Tube Assembly . Tube Assembly . Tube Weldment . Counterbalance Assembly,Dual - Table 7-14 . Fitting . Fitting . Fitting . Fitting

Table 7-11 Swing System Parts List 7 - 17

2 11

S2

S1

S3

S4

6
V2

SB V1

3 14

13

12

10

11

Figure 7-12 Swing Junction Block

ITEM Fig 7-12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 NOTES ASC P/N 49100 49101 25903 25905 25906 25907 25908 26982 203430 25911 203425 26266 27044 27018 209744 QTY DESCRIPTION 1 1 2 1 1 2 2 1 1 1 1 1 1 1 Swing Manifold Assembly . Manifold . Retainer,Ball . Check, Shuttle . Ball, Steel . Fitting . Fitting . Spring, Comp . O-Ring . Backup Ring . O-Ring . Valve Weldment, Needle . Valve, Check . Fitting . O-Ring

Table 7-12 Swing Junction Block Parts List 7 - 18 7 - 18

25

27

26

24

22 23 21 20 19 18

29

3 4 30 28

15 11 10 9 2 1

Figure 7-13 Swing Stop Valve

ITEM Fig. 7-13 1 2 3 4 9 10 11 15 18 19 20 21 22 23 24 25 26 27 28 29 30 NOTES ASC P/N 25829 231327 ---------------232150 -------------------------233632 --------------------------------------------------27203 QTY DESCRIPTION 1 2 4 4 1 1 1 1 1 1 1 1 1 1 1 3 3 3 1 1 1 Swing Stop Valve . Handle . Setscrew . Capscrew . Lockwasher . Centering Spring . Pin . Housing . Stop Pin . Thrust Washer . Thrust Bearing . Detent Disc . Rotor . Shaft . O-Ring . O-Ring . Seat, Shear Seal . O-Ring . Backup Ring . Washer, Spring Seat . Body . Dowel Pin Service Kit

* *

* * * * * *

Table 7-13 Swing Stop Valve Parts List 7 - 19

3 4

10 9

SERVICE NOTE See Hydraulic Schematic for correct pressure setting

Figure 7-14 Swing Dual Counterbalance Valve

ITEM Fig. 7-14 1 2 3 4 5 6 7 8 9 10 NOTES ASC P/N 38693 38694 230404 -------------------------233843 230794 201566 234650 QTY DESCRIPTION 1 2 1 1 1 2 2 2 4 4 Swing Dual Counterbalance Valve . Manifold . Cartridge . . O-Ring . . O-Ring . . O-Ring . . Backup-Ring . . Backup-Ring . Square Ring . Capscrew . Lockwasher Seal Kit NOTE: One Seal Kit Required Per Cartridge Recommended Spare Part - Qty 2

*b *a *a *a *a *a

*a,b *b

Table 7-14 Swing Dual Counterbalance Valve Parts List 7 - 20

Figure 7-15 Boom System

ITEM Fig 7-15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 NOTES ASC P/N 48855 41426 234728 R13811044 203443 49021 49022 49023 49024 25908 246885 237799 245956 241986 237764 237797 247217 247218 247219 QTY DESCRIPTION 1 1 4 1 1 1 1 1 1 2 1 2 1 2 1 1 1 1 Boom System . Manifold . Cartridge, Valve - Table 7-25 . Capscrew . O-Ring . Tube Assembly . Tube Assembly . Tube Assembly . Tube Assembly . Fitting . Fitting . Fitting . Fitting . Fitting . Fitting . Fitting . Hose Assembly . Hose Assembly . Hose Assembly

Table 7-15 Boom System Parts List 7 - 21

Figure 7-16 Winch System

ITEM Fig. 7-16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 NOTES ASC P/N 48856 49025 49026 49027 49028 49029 237765 241477 244075 241986 237775 242320 508253 508254 201617 201568 237779 247215 244040 247232 247216 QTY DESCRIPTION 1 1 1 1 1 1 1 3 1 1 1 1 2 4 4 1 1 2 1 1 Winch System . Tube Assembly . Tube Assembly . Tube Assembly . Tube Assembly . Tube Assembly . Fitting . Fitting . Fitting . Fitting . Fitting . Fitting . Spacer . Flange, Split . Capscrew . Washer, Lock . Fitting . Hose Assembly . Hose Assembly . Hose Assembly . Hose Assembly

Table 7-16 Winch System Parts List 7 - 22

Figure 7-17 Bulkhead Plate

ITEM Fig. 7-17 1 2 3 4 5 6 7 8 9 10 11 12 13 14

NOTES

ASC P/N 48860 49073 49074 49075 49076 49077 49078 243862 243863 243861 246886 242510 242511 241246 241969

QTY DESCRIPTION 1 2 1 1 2 2 3 1 2 2 3 1 4 1 Bulkhead Plate Assembly . Plate, Bulkhead . Tube . Tube . Tube . Tube . Tube . Fitting . Fitting . Fitting . Fitting . Fitting . Fitting . Fitting . Flange, Weld

Table 7-17 Bulkhead Plate Part List 7 - 23

6,7

14,15

15

17 14 1,2,3 10,11,12 16

8,9

Figure 7-18 Reeving Components 7 - 24

ITEM Fig. 7-18 1 4 6 7 8 9 10 11 12 14 15 16 17 18 19

NOTES

ASC P/N 46450 45675 34220 223945 223188 39119 237034 43608 243298 243297 ----------241364 -----247398 237614

QTY 1 1 4 4 1 4 1 2 4 Ref Ref 1 Ref 1 1

DESCRIPTION Reeving Components . Constant Tension Winch - Table 7-20 . Wire Rope Assembly . Capscrew . Locknut . Reeving Chart . Drive Screw . Pin . Cotter Pin . Flat Washer Downstop Control - Table 7-34 Anti-2-Block Control - Table 7-33 Quick Release Hook Sheave Case Fitting Fitting

Table 7-18 Reeving Components Parts List 7 - 25

50 1 56 5 44 5

58

42 55

8 43 52 4 53 37

3 54

15 59

35 30 12

13

38

41

40

41

38

39

38

39

14

33 10 18 20 47

34

11

9 60

45

48 32 31 16 46 29 17 27 28 19 36 26 22 21

Figure 7-19 Constant Tension Winch 7 - 26

ITEM Fig. 7-19 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 50 52 53 54 55 56 58 59 60 61

NOTES

ASC P/N 45675 45670 41661 236421 235378 235377 237411 37303 48209 41662 37306 37307 37308 37309 37345 223587 37312 37319 37322 37315 37320 37317 37318 235384 235422 235423 235374 235382 235383 201138 235385 235386 235387 235388 236275 203560 235390 203475 235391 237613 R13811089 240751 235628 R13811076 R13801842 R13811804 37872 37870 37871 37869 234712 37311 240405 00138243 46086 47231 39797

QTY DESCRIPTION 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 9 8 3 1 1 1 1 1 4 1 1 3 2 1 2 1 2 12 10 12 4 10 1 1 1 2 1 1 1 4 1 A/R Constant Tension Winch Assembly . Manifold Installation - Table 7-20 . Constant Tension Winch . . Load Hydraulic Motor - Table 7-21 . . Winch Brake - Table 7-28 . . Winch Gear Reducer - Table 7-29 . . CT Hydraulic Motor - Table 7-30 . . Spacer . . Drum Weldment . . Frame Weldment . . Hub . . Spacer . . Spacer . . Cover . . Piston . . Nut . . Housing . . Ring . . Bushing . . Hub . . Spacer . . Spacer . . Housing . . Roller Bearing . . FrictionDisc . . Separator Plate . . Spring . . Thrust Bearing . . Tapered Roller Bearing . . Bearing Cup . . Retaining Ring . . Retaining Ring . . Fitting . . Seal . . Seal . . O-Ring . . Backup Ring . . O-Ring . . Backup Ring . . Wedge . . Capscrewl . . Capscrew . . Capscrew . . Capscrew . . Capscrew . . Capscrew . . Spacer . . Spacer . . Spacer . . Stud . . Fitting . . Shim . . Relief Valve . . Capscrew . . Decal, CT5 Serial No. . . Shim Service Kit

* * * * * *

Table 7-19 Constant Tension Winch Parts List 7 - 27

7 - 28
1 4 35,42 33 27 44 30 20 47 18 39 11 31 21 19 16 45 22 7 40 37 3 17 29 27,43 36 34 24 28 25 41 26 22 32 15 31 46 47

22

13,14

44

8,12

Figure 7-20 Manifold Installation

10

14

ITEM Fig. 7-20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 24 25 26 27 28 29 30 31 32 33 34 35 36 37 39 41 42 43 44 45 46 47

NOTES

ASC P/N 45670 39163 235621 235622 235623 37497 37498 37499 37503 230895 242953 228177 228198 230095 203446 39067 46390 38316 38319 39069 39070 224303 228403 237436 232916 209766 233840 39068 228214 232848 228492 19759 228315 521926 45656 237425 235734 231483 203443 234728 209768 228221 45669 236859 243469

QTY DESCRIPTION 1 1 1 1 1 1 1 1 4 4 1 4 4 6 1 1 1 1 1 1 1 6 1 1 1 4 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 Manifold Installation . Winch Electrically Operated Relief Valve - Table 7-21 . Winch Check Valve - Table 7-22 . Winch Pressure Reducing Valve - Table 7-23 . CT Sequence Valve - Table 7-24 . Winch Manifold . Manifold . Tube Assembly . Subplate . Capscrew . Capscrew . Fitting . Capscrew . Capscrew . O-Ring . Tube Assembly . Tube Assembly . Tube Assembly . Tube Assembly . Tube Assembly . Tube Assembly . Shuttle Valve . Fitting . Fitting . Fitting . Fitting . Fitting . Tube Assembly . Fitting . Fitting . Fitting . Fitting . Fitting . Flange, Gauge Port . Manifold . Winch Solenoid Valve - Table 7-26 . Fitting . Fitting . O-Ring . Counterbalance Valve - Table 7-25 . Fitting . Fitting . Tube Assembly . Fitting . Fitting

Table 7-20 Manifold Installation Parts List 7 - 29

1 5 3 7 4 6

9 10 11 12

13 8 14 15 17

16

15

Figure 7-21 Winch Electrically Operated Relief Valve

ITEM Fig. 7-21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 NOTES ASC P/N 39163 39164 228410 235379 238012 238013 -----39165 235650 238015 ---------------NSS NSS NSS -----NSS -----238016 QTY DESCRIPTION 1 4 1 1 2 4 1 4 1 1 1 1 1 1 1 2 1 Ref Winch Electrically Operated Relief Valve . Valve Shield . Capscrew . Relief Valve, Reworked . . Pressure Relief Valve, Proportional . . . Seal . . . Capscrew . . Cover Plate Rework . . . Capscrew . . Poppet Assembly . . . Seal . . . Backup Ring . . . Seal . . . Cap . . . Spring . . . Piston . . . Seal . . . Poppet Winch Manifold - Table 7-31 (5) Seal Kit

* * *

Table 7-21 Winch Electrically Operated Relief Valve Parts List 7 - 30

1 2

3 4

Figure 7-22 Winch Check Valve

ITEM Fig. 7-22 1 2 3 4 NOTES * * * * * ASC P/N 235621 --------------------237511 QTY DESCRIPTION 1 1 1 1 Winch Check Valve . O-Ring . Backup-Ring . Backup-Ring . O-Ring Seal Kit

Table 7-22 Winch Check Valve Parts List 7 - 31

THIS PAGE INTENTIONALLY LEFT BLANK

7 - 32

SERVICE NOTE See Hydraulic Schematic for correct pressure setting

Figure 7-23 Winch Pressure Reducing Valve

ITEM Fig. 7-23 1 2 3 4 5 6 NOTES * * * * * * * ASC P/N 235622 ------------------------------234655 QTY DESCRIPTION 1 1 1 1 2 1 Winch Pressure Reducing Valve . Backup Ring . O-Ring . O-Ring . Backup Ring . Backup Ring . O-Ring Service Kit

Table 7-23 Winch Pressure Reducing Valve Parts List (7 - 32 blank) / 7 - 33

SERVICE NOTE See Hydraulic Schematic for correct pressure setting

Figure 7-24 CT Sequence Valve

ITEM Fig. 7-35 1 2 3 4 5 6 NOTES * * * * * * * ASC P/N 235623 ------------------------------229054 QTY DESCRIPTION 1 1 1 1 2 1 CT Sequence Valve . Backup Ring . O-Ring . O-Ring . Backup Ring . Backup Ring . O-Ring Service Kit

Table 7-24 CT Sequence Valve Parts List 7 - 34

3 4
SERVICE NOTE See Hydraulic Schematic for correct pressure setting

5 6

Figure 7-25 Winch Counterbalance Valve

ITEM Fig. 7-25 1 2 3 4 5 6 NOTES ASC P/N 234728 ------------------------------234693 QTY DESCRIPTION 1 1 1 1 1 1 Counterbalance Valve . Cartridge . . O-Ring . . Backup Ring . . O-Ring . . Backup Ring . . O-Ring Service Kit

* * * * * *

Table 7-25 Winch Counterbalance Valve Parts List 7 - 35

Figure 7-26 Winch Solenoid Valve

ITEM Fig. 7-26 1 2 3 4 5 NOTES ASC P/N 237425 -----237858 -----237859 237860 237861 QTY DESCRIPTION 1 1 1 1 1 Winch Solenoid Valve . Nut . Coil . Washer . Cartridge . Body Complete Seal Kit

Table 7-26 Winch Solenoid Valve Parts List 7 - 36

Figure 7-27 Load Hydraulic Motor

ITEM Fig. 7-27 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 NOTES ASC P/N 236421 226233 ----------222939 226230 228108 27195 223855 -----224622 -----222743 224629 222938 ---------------27193 QTY DESCRIPTION 1 1 1 1 1 1 1 1 2 4 2 1 2 4 1 4 4 Load Hydraulic Motor . Shaft End Cover . Gear Set . Gear Housing . Port End Cover . Snap Ring . Bearing . Lip Seal . Check Assembly . Ring Seal . Roller Bearing . Thrust Plate . Pocket Seal Strip . Gasket Seal . Dowel Pin . Seal Retainer . Capscrew . Washer Service Kit

* * * *

Table 7-27 Load Hydraulic Motor Parts List 7 - 37

Figure 7-28 Winch Brake

ITEM NOTES ASC P/N 235378 235765 238353 238354 235768 238355 238356 238357 238358 238359 238360 238361 238362 238363 238364 229483 227487 227489 235761 238365 235762 226013 227491 238366 238367 238368 238369 238370 238371 238372 229484 238373 238374 238375 238376 QTY DESCRIPTION 1 1 1 2 1 1 1 1 1 1 1 1 1 4 1 5 4 4 2 1 6 1 1 1 1 1 1 4 2 2 Winch Brake . Retaining Ring . Retaining Ring . Bearing . Capscrew . Seal . Cover . . Retaining Ring . . Retaining Ring . . Bearing . . Bearing Sprag . . Outer Spline . . Bearing, Needle . . Spline Shaft . Capscrew . Primary Disc . Rotor Disc . Stator Disc . Capscrew . Gasket . Spring Plate . Spring . Piston . Backup-Ring . O-Ring . Backup-Ring . O-Ring . Pressure Plate . Plug (O-Ring) . Gasket . O-Ring Seal Kit Lining Kit Bearing Kit Spring Kit Fig. 7-28 1 2 3 *c 4 5 *a*c 6 7 8 9 *c 10 *c 11 12 *c 13 14 15 *b 16 *b 17 *b 18 19 *a,b,c,d 20 21 *d 22 23 *a 24 *a 25 *a 26 *a 27 28 29 *a,b,c,d 30 *a,b,c,d *a *b *c *d

Table 7-28 Winch Brake Parts List 7 - 38

Figure 7-29 Winch Gear Reducer

ITEM Fig. 7-29 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 NOTES ASC P/N 235377 225342 225343 -----238260 228888 228889 238261 228891 228890 229745 225344 238263 238265 238260 228894 -----238264 228893 229745 -----228313 238267 -----226108 ---------------QTY DESCRIPTION 1 1 1 6 96 3 3 3 1 3 1 1 3 6 3 1 1 48 3 1 1 1 1 1 Ref Ref Ref Winch Gear Reducer . Ring Gear . Secondary Carrier Assembly . . Carrier . . Thrust Washer . . Needle Bearing . . Separator . . Planet Gear . . Pinion Shaft . . Thrust Washer . . Retaining Ring . Primary Carrier Assembly . . Large Sun Gear . . Planet Gear . . Thrust Washer . . Pinion Shaft . . Retaining Ring . . Thrust Washer . . Needle Bearing . . Retaining Ring . . Carrier . Small Sun Gear . Cover . Filler Plug . Drain Plug, Magnetic Spacer - Table 7-30 (52) Spacer - Table 7-30 (53) Shim - Table 7-30 (56)

Table 7-29 Winch Gear Reducer Parts List 7 - 39

Figure 7-30 CT Hydraulic Motor

ITEM Fig. 7-30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 NOTES * * * * ASC P/N 237411 238060 240967 240872 -----238080 238062 238063 238064 238065 238066 238067 -----238068 238069 238070 238071 238072 238073 238074 238075 238076 238077 238078 238079 39574 QTY DESCRIPTION 1 1 1 1 2 1 1 1 4 1 2 4 4 2 1 8 4 1 10 20 20 4 1 1 CT Hydraulic Motor . Snap Ring . Seal Plate . Shaft Seal . O-Ring . Dowel Pin, Rear . Snap Ring . Ball Bearing . Shaft . Bolt . Front Housing . Dowel Pin, Front . O-Ring . Screw . Plate . Stator . Vane Spring . Stator Vane . Rotor . Rotor Vane . Vane Spring, Outer . Vane Spring, Inner . Ball Checks . Needle Bearing . Rear Housing Seal Kit

Table 7-30 CT Hydraulic Motor Parts List 7 - 40

THIS PAGE INTENTIONALLY LEFT BLANK

7 - 41

Figure 7-31 Electrical System (7 -- 42 blank) / 7 - 42 7 41

ITEM Fig. 7-31 1 2 3 4 5 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

NOTES

ASC P/N 52201 52202 238442 238440 238441 230840 239304 240880 230839 238438 238439 47220 47221 47222 233572 230337 231851 234214 241983 241981 241980 247275 240811

QTY DESCRIPTION 1 1 1 1 1 10' 50' 1 1 1 1 1 1 4 4 18 4 3 6 13 1 9 Electrical System . Junction Box Assembly - Table 7-32 . Housing . Terminal, Female . Plate . Connector, Cord . Cable, Shielded . Cable, Shielded . Connector, Cord . Hood, Side Entry . Terminal, Male . Anti-2-Block Assembly - Table 7-33 . Downstop Assembly - Table 7-34 . Switch Assembly,Tension - Table 7-35 . Washer, Lock . Capscrew . Nut, Esna . Capscrew . Clamp . Clamp . Clamp . Adapter, Thread . Stud, Weld

Table 7-31 Electrical System Parts List 7 - 43

Figure 7-32 Junction Box

ITEM Fig. 7-32 1 2 3 4 5 6 7 8 9 12 13 14 15 16 NOTES 52202 52203 23475 231827 27663 27054 236827 236828 222257 22628 241761 232239 232242 230839 27055 1 1 1 4 5 11 1 2 A/R 2 3 1 1 1 ASC P/N QTY DESCRIPTION Junction Box . Junction Box, Rework . Panel . Connector . Connector . Ring Nut . Terminal Block . End Plate . Capscrew . Rail . End Stop . Jumper . Card, Marker . Connector . Ring Nut

Table 7-32 Junction Box Parts List 7 - 44

Figure 7-33 Anti-2-Block Control

ITEM Fig 7-33 1 2 3 4 5 6 7 8 9 NOTES ASC P/N 47220 46311 234552 231853 231660 231658 40819 225669 231851 231593 QTY DESCRIPTION 1 2 3 2' 2 1 2 5 1 Anti-2-Block Assembly . Switch Assembly,A-2-B . Capscrew . Washer, Flat . Wire Rope . Clip, Cable . Weight Assembly . Capscrew . Nut, Esna . Clamp

Table 7-33 Anti-2-Block Control Parts List 7 - 45

Figure 7-34 Downstop Control

ITEM Fig. 7-34 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 NOTES ASC P/N 47221 244112 40836 234129 234051 40837 34330 25002 228461 233882 226849 226848 231893 233888 234170 40838 232518 234216 QTY DESCRIPTION 1 1 3 1 1 1 4 1 4 4 2 1 2 2 1 1 1 Downstop Control . Switch, Prox . Downstop Weldment . Capscrew . Capscrew . Arm Weldment . Roller . Bearing, Nyliner . Nut, Esna . Washer, Flat . Washer, Flat . Nut, Esna . Spring, Ext . Capscrew . Nut, Esna . Plate . Capscrew . Capscrew

Table 7-34 Downstop Control Parts List 7 - 46

Figure 7-35 Cable Tension Sensor

ITEM Fig. 7-35 1 2 3 4 5 6 7 8 9 NOTES ASC P/N 47222 45910 45900 45898 45897 243751 45899 226849 226848 244112 QTY DESCRIPTION 1 1 1 1 2 1 4 4 1 Cable Tension Sensor . Switch Base Weldment . Tension Weldment . Rod . Rod . Spring, Ext . Roller . Washer, Flat . Nut, Esna . Switch, Proximity

Table 7-35 Cable Tension Sensor Part List 7 - 47

CHAPTER 8 INSTALLATION
8.1 INTRODUCTION This chapter is provided to assure a smooth and satisfactory installation of the boat davit, model D5700CT. 1. Have a crane available that will safely lift the davit and jib boom (3,400 lbs). 2. Ensure adequate swing clearance between the davit and ships structures or other deck mounted equipment. 8.2 DAVIT INSTALLATION Figure 8-1 shows the swing stops in place on the underside of the davits mounting surface. Each swing stop is held in place by three capscrews, which also serve as davit mounting bolts. They are set at the factory for 180 degrees of rotation in each direction from center. Moving the stop one bolt hole will change the swing arc by 11 degrees and 15 minutes. 1. Install swing stops as shown in Figure 8-1. 4. Position the davit so that its center line is aligned with the pedestal, and that the swing stops are centered on the davits proposed swing arc. Install 26, capscrews (six capscrews through swing stops) with 3/4" hard washers under each capscrew and tighten as indicated in Figure 8-1, Davit Installation. 5. Mount the control console in its position on the deck. Make openings in the deck for hydraulic and electrical line routing between the hydraulic power supply, control console and davit as necessary. 6. Connect hydraulic lines between control console, hydraulic power supply and davit installation as shown in Hydraulic Schematic Diagram, and Figure 8-2, Plumbing Diagram. 7. Flush all lines and fittings to prevent damage to the davit's hydraulic system. a. Use couplings to connect lines from the hydraulic power unit (HPU) together. b. Start the HPU and flush lines for a period of at least 5 minutes to carry any debris left in the lines to the HPU tank return filter.

2. Remove the davit inspection plate, and install lines onto hydraulic lid. 3. Lift the davit assembly over the mounting flange on the pedestal so that the cable will be centered over the boat. Guide any hydraulic or electrical lines down through the pedestal flange to below deck.

TORQUE 330-335 LB-FT, LUBRICATED

135

CAPSCREWS (26) UNRC X 2-1/2 FRY HD 12PT BLK CERTS WITH HARDWASHERS TORQUE 330-335 LB-FT, LUBRICATED CAPSCREWS (6) 3/4NC x 4-1/2 FERRY HEAD WITH FLATWASHERS TORQUE 335 LB-FT, LUBRICATED SWING STOPS SHOWN SET FOR 120 EACH DIRECTION
AMC533

TORQUE 330-335 LB-FT, LUBRICATED

WELD TO DECK

Figure 8-1 Davit Installation 8-1

c. Secure the HPU, disconnect the lines from one another, and connect them to the control valve in the control console. d. Connect the SWING lines from the davit installation to the control valve. Disconnect the SWING lines at the hydraulic lid and connect them together with a hose nipple. e. Start the HPU and operate the SWING control lever in both directions for about 5 minutes to carry any debris to the HPU tank return filter. f. Repeat steps c through e for both the WINCH and BOOM systems. 8.3 1. PREPARATION FOR OPERATION Check all lines, fittings and bolts for security. NOTE: Refer to the Hydraulic and Electrical Schematics to verify hydraulic and electrical connections. 2. Trace all hydraulic and electrical circuits. Ensure all connections are correct before applying power to the system. 3. Check the hydraulic fluid level. Add fluid if required, but do not overfill. 4. Start the HPU and allow to warm up to operating temperature and purge air from the system. 5. Inspect for hydraulic leaks, unusual sounds, vibrations, or other problems. Correct as required. 6. Perform preliminary checks described in Chapter 5, Troubleshooting. 7. Carefully operate the swing control lever, and ensure that the davit stops at the correct points in its swing arc. NOTE: The winch should have at least 100 lbs of weight on the hook to perform its functions. 8. Carefully operate the winch control lever, and ensure that the winch stops at the correct points. When raising a load, it should stop just before the hook block reaches the sheave. When lowering a load, it should stop when there are at least three wraps of cable remaining on the drum. If the winch does not stop at the correct point, refer to Chapter 6, Corrective Maintenance.

IT IS CRITICAL THAT THE WINCH DOWNSTOP , ANTI-TWO-BLOCK CONTROLS AND BOOM CYLINDER PRESSURE SWITCH BE PROPERLY ADJUSTED. INCORRECT ADJUSTMENT COULD CAUSE EQUIPMENT DAMAGE, SEVERE PERSONAL INJURY OR DEATH. 8.4 PREPARATION FOR RESHIPMENT To prepare the davit for reshipment, perform the following: 1. Remove the hook. Wind the cable neatly onto the drum and secure the end of the cable to the drum. 2. Secure electrical and hydraulic power.

3. Remove the davit and console service covers. Close the console cover and secure with a nut and bolt.

ENSURE THAT THE POWER TO THE EQUIPMENT IS OFF BEFORE ATTEMPTING TO DISCONNECT THE CABLES. AN ELECTRICAL SHOCK COULD BE FATAL. 4. Tag and disconnect hydraulic lines and electrical wiring between the davit , control console and HPU.

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 OR PLUGGED DURING INSTALLATION, SERVICE AND REPAIR PROCEDURES. 5. Support the davit with an overhead crane that can safely lift at least 3,400 lbs, and remove the pedestal flange mounting bolts. Stand clear when the davit becomes free, in case it is not well balanced with the rigging being used. Move the davit to a safe location. 6. Similarly remove the control console. The console weighs approximately 500 lbs. 7. Long-term storage procedures are listed in Chapter 4, Scheduled Maintenance.

8-2

Figure 8-2 Plumbing Diagram 8-3 / (8-4 blank)