80_713

TECHNICAL MANUAL

DAVITMODEL 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: [email protected]: http://www.alliedsystems.com

80-713 31 MARCH 2003

CHANGE LOGLIST OF PAGES AFFECTED

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

Page No.

Cover 1

7-41 1

Change No.

i

TABLE OF CONTENTS

CHAPTER/PARAGRAPH PAGECHAPTER/PARAGRAPH PAGE

1 GENERAL INFORMATION ANDSAFETY PRECAUTIONS

1.1 SAFETY PRECAUTIONS ................................ 1-11.2 INTRODUCTION .............................................. 1-11.2.1 Scope ....................................................... 1-11.2.2 Applicability .............................................. 1-11.3 DAVIT DESCRIPTION ...................................... 1-11.3.1 Davit Installation ....................................... 1-11.3.2 Hydraulic Power Unit ............................... 1-11.3.3 Control Console ....................................... 1-11.3.4 Control Tension Winch ............................ 1-21.3.5 Swing Drive .............................................. 1-21.3.6 Hydraulic System ..................................... 1-21.3.6.1 Control Valve ............................................ 1-21.3.6.2 Boom System ........................................... 1-31.3.6.3 Swing System .......................................... 1-31.3.6.4 Winch System .......................................... 1-31.3.6.5 Emergency System .................................. 1-31.3.7 Electrical System...................................... 1-31.3.7.1 Electric Motor ........................................... 1-31.3.7.2 Downstop Control .................................... 1-31.3.7.3 Anti-2-Block Control ................................. 1-3

2 OPERATION

2.1 INTRODUCTION .............................................. 2-12.2 OPERATING CREW ........................................ 2-12.3 INSTRUMENTS AND CONTROLS .................. 2-12.4 OPERATING THE DAVIT ................................. 2-12.4.1 Pre-Operational Test ................................ 2-12.4.2 Launching Operation ............................... 2-12.4.3 Recovery Operation ................................. 2-22.4.4 Emergency Operation .............................. 2-2

3 FUNCTIONAL DESCRIPTION

3.1 INTRODUCTION .............................................. 3-13.2 MECHANICAL SYSTEM .................................. 3-13.2.1 Davit .......................................................... 3-13.2.2 Winch ........................................................ 3-23.2.3 Swing Drive .............................................. 3-23.3 HYDRAULIC SYSTEM ..................................... 3-33.3.1 Boom System ........................................... 3-33.3.2 Swing System .......................................... 3-33.3.3 Winch System .......................................... 3-33.3.4 Emergency System ................................. 3-53.3.5 Downstop Control .................................... 3-53.3.6 Anti-2-Block Control ................................. 3-5

4 SCHEDULED MAINTENANCE

4.1 INTRODUCTION .............................................. 4-14.2 PREVENTIVE MAINTENANCE ....................... 4-14.3 SCHEDULED MAINTENANCE ....................... 4-14.3.1 Walk Around Inspection ........................... 4-14.3.2 Lubricant Specifications ........................... 4-14.3.3 Service Instructions .................................. 4-14.4 HYDRAULIC OIL MAINTENANCE................... 4-44.4.1 Storage and Handling ............................. 4-44.4.2 In-Operation Care .................................... 4-54.4.3 Analysis .................................................... 4-54.5 EXTENDED STORAGE PROCEDURES ......... 4-5

5 TROUBLESHOOTING

5.1 INTRODUCTION .............................................. 5-15.1.1 Safety ........................................................ 5-15.1.2 Problem Area Isolation ............................ 5-15.2 PRELIMINARY TROUBLESHOOTING ............ 5-15.2.1 Pump Test ................................................. 5-15.2.2 Control Valve Test .................................... 5-15.2.3 Winch System Test ................................... 5-15.3 FAULT ISOLATION .......................................... 5-15.3.1 Probable Mechanical Causes ................. 5-15.3.2 Probable Hydraulic Causes .................... 5-25.3.3 Probable Electrical Causes ..................... 5-2

TROUBLESHOOTING .............................. 5-3

6 CORRECTIVE MAINTENANCE

6.1 INTRODUCTION .............................................. 6-16.1.1 Maintenance Practices ............................ 6-26.2 HYDRAULIC AND ELECTRICAL

SYSTEM ADJUSTMENTS ............................... 6-36.2.1 Main System Relief Pressure .................. 6-36.2.2 Swing Dual Counterbalance ................... 6-36.2.3 Constant Tension Winch Pressure .......... 6-46.2.4 Downstop Control Adjustment ................. 6-46.2.5 Anti-2-Block Control Adjustment ............. 6-56.2.6 Cable Tension Sensor Adjustment ......... 6-66.3 REPAIRS .......................................................... 6-66.3.1 Swing Drive .............................................. 6-66.3.1.1 Removal ................................................... 6-66.3.1.2 Disassembly ............................................. 6-76.3.1.3 Assembly .................................................. 6-76.3.1.4 Swing Motor Disassembly ....................... 6-76.3.1.5 Swing Motor Assembly ............................ 6-76.3.1.6 Swing Brake Disassembly ....................... 6-96.3.1.7 Swing Brake Assembly ............................ 6-9

ii

TABLE OF CONTENTS

CHAPTER/PARAGRAPH PAGECHAPTER/PARAGRAPH PAGE

6.3.1.8 Swing Gear Reducer Disassembly ....... 6-106.3.1.8.1 Primary Carrier Disassembly ................. 6-116.3.1.8.2 Secondary Carrier Disassembly ........... 6-116.3.1.8.3 Primary Carrier Assembly ..................... 6-116.3.1.8.4 Secondary Carrier Assembly ................ 6-126.3.1.9 Swing Gear Reducer Assembly ............ 6-126.3.1.10 Swing Bearing ........................................ 6-126.3.1.10.1 Wear Check............................................ 6-126.3.1.10.2 Disassembly and Inspection .................. 6-136.3.1.10.3 Assembly ................................................ 6-146.3.1.11 Swing Drive Installation ......................... 6-146.3.2 Boom System ......................................... 6-146.3.2.1 Boom Lift Cylinder Removal .................. 6-146.3.2.2 Boom Lift Cylinder Disassembly ............ 6-146.3.2.2.1 Piston Seal Replacement ...................... 6-156.3.2.3 Boom Lift Cylinder Assembly ................. 6-156.3.2.4 Boom Lift Cylinder Installation ............... 6-166.3.3 Constant Tension Winch ........................ 6-166.3.3 Constant Tension Winch ........................ 6-166.3.3.1 Removal ................................................. 6-166.3.3.2 Disassembly ........................................... 6-166.3.3.2.1 Constant Tension End Disassembly ..... 6-166.3.3.2.2 Load Motor End Disassembly ................ 6-166.3.3.2.3 Spacer Removal .................................... 6-186.3.3.2.4 Piston and Housing Removal ................ 6-186.3.3.2.5 Drum and Brake Disassembly ............... 6-216.3.3.3 Assembly ................................................ 6-216.3.3.3.1 Drum and Brake Assembly .................... 6-226.3.3.3.2 Piston and Housing Installation ............ 6-226.3.3.3.3 Spacer Installation ................................. 6-226.3.3.3.4 Load Motor End Assembly ..................... 6-236.3.3.3.5 Constant Tension Motor End Assy ........ 6-236.3.3.4 Load Motor ............................................. 6-246.3.3.4.1 Disassembly ........................................... 6-246.3.3.4.2 Inspection ............................................... 6-256.3.3.4.3 Assembly ................................................ 6-256.3.3.5 Constant Tension Motor ......................... 6-266.3.3.5.1 Disassembly ........................................... 6-26

6.3.3.5.2 Inspection ............................................... 6-266.3.3.5.3 Assembly ................................................ 6-276.3.3.6 Winch Brake ........................................... 6-286.3.3.6.1 Disassembly ........................................... 6-286.3.3.6.2 Assembly ................................................ 6-286.3.3.7 Winch Gear Reducer ............................. 6-306.3.3.7.1 Gear Reducer Disassembly ................... 6-306.3.3.7.2 Primary Carrier Disassembly ................. 6-306.3.3.7.3 Secondary Carrier Disassembly ........... 6-306.3.3.7.4 Primary Carrier Assembly ..................... 6-306.3.3.7.5 Secondary Carrier Assembly ................ 6-306.3.3.7.6 Gear Reducer Assembly ........................ 6-316.3.3.8 Winch Installation ................................... 6-316.3.3.9 Winch Cable Installation ........................ 6-32

7 PARTS LIST

7.1 INTRODUCTION .............................................. 7-17.1.1 Major Subassemblies .............................. 7-17.1.2 Special Notes ........................................... 7-17.2 FORMAT .......................................................... 7-17.2.1 Item ........................................................... 7-17.2.2 Notes ........................................................ 7-17.2.3 ASC P/N ................................................... 7-17.2.4 Qty ............................................................. 7-17.2.5 Description ............................................... 7-17.2.6 Illustrations ............................................... 7-1

8 INSTALLATION

8.1 GENERAL ........................................................ 8-18.2 DAVIT INSTALLATION ..................................... 8-18.3 PREPARATION FOR OPERATION .................. 8-28.4 PREPARATION FOR RESHIPMENT ............... 8-2

iii

ABBREVIATIONS AND ACRONYMS

ABS ....................American Bureau of ShippingAdj .................................................. Adjustmentamp ...................................................... Ampere

API .......................American Petroleum InstituteAPL ....................................Allowance Parts ListA/R ................................................ As RequiredASC .......................... Allied Systems CompanyAux ...................................................... AuxiliaryAWG ...............................American Wire Gaugebar ...................... 14.5 pounds per square inchBrg ....................................................... BearingCAGE................. Commercial And Government

Entitycid ............................. cubic inch displacementCNTRL ................................................... ControlCT .......................................... Constant TensionCTRL ..................................................... ControlDIN ...................... Deutsche International NormEIPS .....................Extra Improved Plough SteelElec .................................................... ElectricalExt ........................................................ ExternalF .......................................................FahrenheitC........................................ Celsius (centigrade)fpm ........................................... feet per minuteFSCM ........................ Federal Supply Code for

Manufacturersgal .......................................................... GallonGalv ................................................. GalvanizedGnd ...................................................... Groundgpm .................................... Gallons Per Minutehp .................................................. HorsepowerHPU ................................. Hydraulic Power UnitHyd .................................................... HydraulicHz ............................ Hertz (cycles per second)ID .............................................. Inside DiameterIEEE ........................... Institute of Electrical and

Electronic EngineersISO ......... International Standards OrganizationIWRC ................. Independent Wire Rope CorekPa ................................................... kilopascalkw ......................................................... Kilowattlb ............................................................ poundlbs ........................................................ poundsLH ...................................................... Left Handlpm ......................................... Liters Per Minute

LT ................................................................. LeftMax .................................................... Maximummicron ..................................... 0.001 millimeterMin ..................................................... MinimumN.C. ........................................ Normally ClosedN.O. .......................................... Normally OpenNATO .......... North Atlantic Treaty OrganizationNC ........................................... National CoarseNEMA .......... National Electrical Manufacturer’s

AssociationNF ............................................... National FineNLGI ....... National Lubrication Grease InstituteN-m............................................. Newton-meterNom .................................................... NominalNPTF ................ National Pipe Tapered for FuelNSS ............................ Not Serviced SeparatelyNSTM................... Naval Ship Technical ManualOD .........................................Outside DiameterPC ................................ Pressure CompensatorPl ...............................................................PlateP/N ............................................... Part NumberPOS ......................................................PositionPot .............................................. Potentiometerpsi ...............................pounds per square inchPVB ....................................Pump Side ModulePVE...................... Proportional Valve ElectricalQty ...................................................... QuantityRef .................................................... ReferenceRH .................................................. Right Handrpm ...............................Revolutions Per MinuteRT ............................................................. RightSAE............... Society of Automotive EngineersSOL .................................................... SolenoidSOLAS .............................. Safety Of Life At SeaSpec ............................................. SpecificationSS .............................................. Stainless SteelSW .......................................................... SwitchTEFC ................. Totally Enclosed, Fan-CooledThk ........................................................... ThickTMCR ..................... Technical Manual Contract

RequirementTYP ........................................................ Typicalv ................................................................. Voltvac .............................. Volts Alternating Currentvdc .....................................Volts Direct CurrentVOM ........................................ Volt-Ohm Meter

iv

SAFETY SUMMARY

GENERAL SAFETY NOTICESSummarized on the following pages are general safety noticeswhich supplement specific warnings and cautions appearingelsewhere in this manual. Since all electrical and hydraulicequipment is dangerous when operated or maintainedincorrectly, you must thoroughly review and understand theSafety Summary before attempting to operate, troubleshootor service this crane.

The following symbols/terms are used to emphasize safetyprecautions and notices in this manual:

THE “WARNING” SYMBOL APPEARS WHEREVERINCORRECT OPERATING PROCEDURES ORPRACTICES COULD CAUSE SERIOUS INJURY ORDEATH. CAREFULLY READ THE MESSAGE THATFOLLOWS TO PREVENT SERIOUS INJURY ORDEATH.

CAUTION

THE “CAUTION” SYMBOL APPEARS WHEREVERINCORRECT OPERATING PROCEDURES ORPRACTICES COULD CAUSE DAMAGE TOEQUIPMENT. CAREFULLY READ THE MESSAGETHAT FOLLOWS TO PREVENT EQUIPMENTDAMAGE.

NOTE: …

The term “NOTE” highlights operating proceduresor practices that may improve equipment reliabilityand/or personnel performance.

NOTE: All possible safety hazards cannot beforeseen so as to be included in this manual.Therefore, you must always be alert to potentialhazards that could endanger personnel and/ordamage the equipment.

OPERATING SAFETY

QualificationsThis crane must be operated and maintained by experienced,trained personnel. You must receive training prior tooperating this crane.

If you do not routinely operate this crane, refresher trainingis recommended. You must reacquaint yourself with thismanual and the equipment before starting, then proceedslowly.

Do Not Operate AloneIt is essential that someone be on deck to watch clearancesand give hand signals. Ensure that the director is clear ofthe crane and the load before you move it. Do not move thecrane or load if you cannot see this person.

Equipment HazardsDo not operate this crane if you know of malfunctions,missing parts, and/or misadjustments. Any one of thesesituations can cause or contribute to an accident or damagethe crane. Lower the load and stop the crane immediately ifproblems arise after starting.

Do not start the hydraulic power unit if the “start” switchhas been tagged-out with a “DO NOT START” or other redtag.

Never allow anyone under the load. Ensure the area is clearbefore moving the crane or the load.

Never attempt any lifting operation with fewer than fivewraps of cable on the winch drum. Cable clamps are notdesigned to hold loads.

Never attempt to dismantle any of the safety devices builtinto the crane.

When swinging the boom, always ensure that there isadequate clearance for both the boom and the load.

Do not overload the crane. Always operate within the ratedcapacity of the crane and rigging. Refer to the load chart forthis crane’s lifting capacity.

Inspect slings, chokers and other rigging devices frequentlyfor cuts, abrasion, rust, kinks or other damage. Do not usesuspected defective equipment to lift or move a load.

Always wear appropriate safety clothing and use prescribedsafety equipment—head, foot, hand and eye protection, etc.

Accurately place the load, keeping in mind how you expectthe load to respond when released.

Lower and remove the load before leaving the crane orsecuring hydraulic power.

Maintain proper clearance from energized equipment. If thecrane contacts energized equipment—stay clear of the craneand prevent anyone else from coming in contact with thecrane. If you are on the crane, stand fast—Do not jump off.

MAINTENANCE SAFETYUnless properly serviced, this crane can be extremelydangerous.

QualificationsIn order to ensure safety, each person working on this cranemust have the necessary skills, information, tools andequipment. Do not attempt to make adjustments, or performrepairs unless you are authorized and qualified to do so.

Do Not Work AloneNever attempt to service energized equipment alone.Someone capable of rendering aid in the event of accidentalshock must be present.

Do not rely on the hydraulic system to support any part ofthe crane during maintenance or lubrication. Never standunder a crane component that is supported only by thehydraulic system. Ensure components are resting on theirmechanical stops or supported with appropriate safety standsduring maintenance or lubrication.

Unless otherwise directed in this manual, never attemptservicing while power is applied. Tag the “START” switchand/or the disconnect switch with a “DO NOT START” signwhen required.

Never attempt servicing while the crane is moving or thehydraulic power unit is running. Lower the load and securepower.

Equipment SafetyTest Equipment. Ensure test equipment is in good condition.If an instrument must be held while taking measurements,ground the case of the instrument before energizingequipment. Do not touch live equipment or personnelworking on live equipment while holding a multimeter. Sometypes of measuring devices should not be grounded—do nothold such devices while taking measurements.

Heavy Equipment. Prevent personal injury or equipmentdamage by using a lifting device with a lifting capacity greaterthan twice the weight of any equipment to be lifted.

Pressurized Equipment. Wear safety goggles when workingon or near pressurized equipment.

Lower all loads and relieve all hydraulic pressure beforedisconnecting hydraulic lines. Otherwise, the load could fallon you or pressurized hydraulic oil could cause severepersonal injury. Never try to stop a hydraulic leak with anypart of your body.

SAFETY SUMMARY

v

Electrical Hazards

An electric shock could be fatal—typically, the hydraulicpower unit (HPU) is driven by a 440 vac, 3-phase, 60 Hzmotor. Ensure power to the crane is “OFF” before openingelectrical panels. Never attempt electrical testing or repairswhile standing in water.

Remove watches, rings, or any jewelry that may contactenergized circuits.

Hot Oil HazardsBurns from hot oil can be severe—Always allow lubricatingand hydraulic oil to cool before draining.

Fire HazardsHydraulic oil is flammable. Do not smoke when checking orfilling the tank. Keep open flames and sparks away from thecrane.

Regular steam cleaning is recommended for fire preventionand improves general safety by removing oil, and dirtaccumulations.

Never overfill the hydraulic tank because the overflow couldcontribute to a fire. Immediately repair any hydraulic leaksand clean up spills.

Compressed Air HazardsWhen using compressed air to dry parts, pressure shouldnot exceed 30 psi (200 kPa).

Air pressure penetrating your skin can be fatal. Never directcompressed air at anyone.

Falling HazardDue to the height of some lubrication points, it is essentialto personnel safety that approved ladders, personnel liftsand/or scaffolding be used while servicing this crane. Alwayslower the crane as far as possible before attempting toperform repairs or service.

Always use safety treads and handholds where provided. Thecrane can be dangerously slick whenever oily surfaces areexposed to rain or frost.

SAFETY SUMMARY

vi

1 - 1

CHAPTER 1GENERAL INFORMATION AND SAFETY PRECAUTIONS

1.1 SAFETY PRECAUTIONSWarnings and cautions appearing throughout this technicalmanual are of paramount importance to personnel andequipment safety. Before attempting to operate,troubleshoot, or service this equipment, you must thoroughlyreview and understand the Safety Summary that precedesthis chapter.

The following symbols/terms are used to emphasize safetyprecautions in this manual:

THE “WARNING” SYMBOL APPEARS WHEREVERINCORRECT OPERATING PROCEDURES ORPRACTICES COULD CAUSE SERIOUS INJURY ORDEATH. CAREFULLY READ THE MESSAGE THATFOLLOWS TO PREVENT SERIOUS INJURY ORDEATH.

CAUTION

THE “CAUTION” SYMBOL APPEARS WHEREVERINCORRECT OPERATING PROCEDURES ORPRACTICES COULD CAUSE DAMAGE TOEQUIPMENT. CAREFULLY READ THE MESSAGETHAT FOLLOWS TO PREVENT EQUIPMENTDAMAGE.

NOTE:

The term “NOTE” highlights operating proceduresor practices that may improve equipment reliabilityand/or personnel performance.

NOTE: All possible safety hazards cannot beforeseen so as to be included in this manual.Therefore, you must always be alert to potentialhazards that could endanger personnel and/ordamage the equipment.

1.2 INTRODUCTIONThis manual has been prepared to assist personnel operatingand servicing the D5700CT Low Profile DAVIT. Chapters1 through 6 comprise the operating and servicing instructions,Chapter 7 contains parts lists for all components of the craneand Chapter 8 provides installation procedures.

1.2.1 ScopeThis manual provides sufficient instructions to enablepersonnel to accomplish the following:

1. Install the crane.2. Prepare, operate, and secure the crane.3. Detect, isolate, and correct malfunctions.4. Remove, repair or replace, and reinstall parts.5. Perform scheduled maintenance.

Intermediate and depot level maintenance, specificallyinspection, operability tests, fault isolation, and overhaul ofitems such as motors, brakes, and winches, will normally beaccomplished at more extensive shop facilities.

1.2.2 ApplicabilityThis manual is applicable to the Model D5700CT Boat Davit.

1.3 DAVIT DESCRIPTIONSee Figure 1-1. The boat davit was developed for the launchingand retrieving rigid inflatable boats (RIB's) in heavy seas.

This davit is rated for a safe working load of 5,700 pounds atmaximum extension of 14 ft - 6 in, and has the capability toraise and lower the hook approximately 58 feet on a5/8 inch diameter (6 x 37) EIPS Type 1, Class 3 wire rope,rated for nominal breaking strength of 41,200 pounds. Winchhoisting speed is 85-100 feet per minute (fpm). Boom hoistspeed is approximately 6 degrees per second. Swing rate isapproximately 2 rpm.

1.3.1 Davit InstallationThe davit weldment and jib boom, the structural memberswhich support the load, are constructed of ASTM A514B,100,000 lb minimum yield steel with continuous welds. Thewinch is mounted to the jib boom assembly and a quickrelease hook is rigged for one-part reeving from the winchline, through a sheave. A shear ball type swing bearing isbolted to the underside of the davit to complete the davitand bearing assembly which is in turn bolted to a flangedpedestal welded to the deck.

1.3.2 Hydraulic Power UnitSee specific Technical Manual for information pertaining tothe hydraulic power unit and/or its components. Allied Systemsdid not supply the hydraulic power unit.

1.3.3 Control ConsoleSee Technical Manual TP2753A for information regardingthe control console and/or its components.

1 - 2

1.3.4 Constant Tension WinchSee Figure 1-2. A constant tension type winch is mounted tothe 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 spragueclutch in the main winch brake allows the load to be liftedwithout brake drag.

1.3.5 Swing Drive See Figure 1-3. Two swing drives bolted to the davit baseprovide swinging at approximately 2 rpm. Each drive consistsof a “roller stator” type hydraulic motor, spring applied/hydraulically released brake, gear reducer and pinion. Thepinion engages external gear teeth in the outer race of theswing bearing to drive the davit left or right. Adjustable swingstops are designed to limit the swing arc to 135 degrees ineither direction from center.

1.3.6 Hydraulic System

1.3.6.1 Control ValveSee Technical Manual TP2753A for information regardingthe control console and/or its components.

Figure 1-2 Constant Tension Winch

Figure 1-3 Swing Drive

LEGEND

1. HYDRAULIC MOTOR

2. BRAKE

3. GEAR REDUCER

4. PINION

2

3

4

1

AM

C 0

83

MAIN WINCH

HYDRAULIC

MOTOR

DOUBLE PLANETARY

GEAR REDUCER

CABLE DRUM

CABLE ANCHOR

MAIN WINCH

BRAKE

WINCH

FRAMESPRING

BRAKE

CONSTANT

TENSION

VANE TYPE

HYDRAULIC

MOTOR

CONSTANT

TENSION

CLUTCHES

AM

C1

28

1 - 3

1.3.6.2 Boom SystemThe boom system controls hydraulic power to extend andretract the jib boom. Hydraulic pressure from the controlvalve applied to the double acting boom lift cylinder extendsthe boom.

1.3.6.3 Swing SystemThe swing system controls hydraulic power to swing the davit.Hydraulic pressure from the control valve releases the swingbrakes and turns the swing motors. A lever operated swingstop valve, mounted to the underside of the davit,automatically limits swing arc. Dual counterbalance valvesat the swing motor ports hydraulically lock the swing motorsuntil activated.

1.3.6.4 Winch SystemThe winch system controls hydraulic power to the winch foreither normal hoisting and lowering, or constant tensionfunctions. Hydraulic power is applied to either a load orconstant tension hydraulic motor. A counterbalance valvehydraulically locks the winch and keeps the load fromdropping. A spring applied hydraulic release brake acts as aparking brake.

1.3.6.5 Emergency SystemThe emergency operating system is designed to allow limiteduse 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 regardingthe control console and/or its components.

1.3.7 Electrical SystemBoth power distribution and control functions are served bythe electrical system. For this reason, the electrical system isdivided into Primary Crane Control and HPU subsystems.

1.3.7.1 Electric MotorThe hydraulic pump is driven by a 50 hp 460 vac 3-phase, 60Hz electric motor. This motor is energized by a solid statesoft start system.

1.3.7.2 Downstop ControlThe Downstop Control is designed to prevent the operatorfrom paying out the winch cable beyond the last three wrapson the drum. The Downstop Control consists of a spring-loaded drum roller, a proximity switch and a cam.

1.3.7.3 Anti-2-Block ControlThe Anti-2-Block Control is designed to prevent the operatorfrom “2-blocking” the davit (hoisting the hook into thesheave). The Anti-2-Block Control consists of a proximityswitch, a spring and a weight and cable.

1 - 4

Table 1-1 Reference Data

Characteristics Description

Ratings:Safety Factor, Structural 6:1Safety Factor, Wire Rope 5:1Load 5,700 lbsHoist Speed 85 fpm nominal (Bare Drum Speed)Swing Speed 2 rpm nominalSwing Arc 135° in each direction from centerWire Rope 5/8" 6 x 37 EIPS RR-W-410 Type 1 Class 3 Nominal Strength

41,200 lbs

Hook 5,700 lb Capacity, Quick Release

Test Weights:Dynamic (150% of Rated Load) 8,550 lbsStatic (200% of Rated Load) 11,400 lbs

Electrical Power Requirements: 460 vac, 3-phase, 60 Hz

Hydraulic System:Operating Pressure 2,500 psiRelief Pressure 2,750 psiRequired Pump Output 34 gpmTemperature Range 0° F to 180° F (-17° C to 82° C)Hydraulic Fluid Mobil DTE 13M (MIL-H-17672, 2110-T-H)

Hydraulic Power Unit: See TP2754

Control Valve See TP2753A

Boom: Double ActingExternally Applied Forces Column Loading OnlyMaximum Shock Pressure 3000 psi

Winch: Constant Tension TypeMaximum Rated Load 5,700 lbsNormal Hoisting Speed 85-100 fpmConstant Tension Speed 550 fpmResistance (Constant Tension Mode) 25-300 lbsGear Ratio (Normal Hoisting) 40 : 1Drum Torque 38,590 lb-inDrum Speed 32 rpmDrum Capacity 75 feet, 5/8" cableMaximum CT Pressure 1200 psiLoad Hydraulic Motor 4.5 cid Gear TypeConstant Tension Hydraulic Motor 7.0 cid Vane TypeWinch Brake Spring applied/hydraulically released multiple disc type with one-

way sprag clutch

1 - 5

Table 1-1 Reference Data - Continued

Characteristics Description

Hydraulic System: (continued)

Swing:Swing Bearing Shear Ball Roller TypeNumber of Teeth 84Maximum Torque 102,500 lb-ft Maximum MomentHydraulic Motor 6.8 cid each - Roller Stator Type x 2Gear Ratio 40.96 :1Maximum Intermittent Output Torque 100,000 lb-inMaximum Input Speed 3,000 rpmSwing Brake Spring applied/hydraulically released multiple disc type

Environmental:

Atmospheric Davit and equipment will withstand frequent soaking by saltspray and ambient atmospheric conditions

Temperature Davit and equipment will operate within ambient temperaturerange of -40° to 120° F

Humidity Davit and equipment will withstand effects of relative humidityranging from 0 to 100% under operating and stowage conditions

Stability Davit is capable of lifting and swinging its rated load at maximumboom extension of 14 feet - 6 inches at 10 degrees adverse list

1 - 6

Figure 1-4 Dimensional Data

Model ........................................................... D5700CTNomenclature .............................................Boat DavitRated Capacity ............................................ 5,700 lbsOverturn Moment .......................................93,150 lb-ftSwing Moment ....................................... 542,041 lb-inDavit Gross Weight ....................................... 4,750 lbsWinch Gross Weight ........................................ 950 lbs

NOTE: Capacities shown in this manual make noallowances for freely suspended loads, operatingspeeds, or weights of any accessories.

113.25"

(2877 mm)

STORAGE HEIGHT

TO DECK

153.50" MAX

(3899 mm)

6" BORE

(152 mm)

SINGLE PART REEVING WITH

TOTAL SIDE TO SIDE

SWING MOTION OF 60°

34"

(864 mm)

BEARING INSTALLATION:

SEE TABLE 7-2, PAGE 7-5

AND TABLE 7-4, PAGE 7-7

25"

(635 mm)

SWING RADIUS

DAVIT INSTALLATION AM

C4

43

168"

(4267 mm)

DECK

137.50" MAX

(3493 mm)

37.50"

(952 mm)

TO DECK

Note: For information regarding HPU or control console

, consult Technical Manuals Tp2754 and TP2753A respectively

2 - 1

CHAPTER 2OPERATION

2.1 INTRODUCTIONThis chapter provides detailed information and step-by-stepinstructions for safely and effectively operating the BoatDavit, model D5700CT.

Use extreme care when operating this equipment for the firsttime. Inexperienced operators should perform the variousfunctions with no load to become familiar with the davit andits controls.

2.2 OPERATING CREWThe full operating crew will be specified by the ship’s manningdocument. Normally the davit will be controlledby one (1) crew member, the operator. Additional crewmembers will be required to tend the hook, give signals tothe operator, and handle rigging.

2.3 INSTRUMENTS AND CONTROLS

The davit was designed to interface an array of existing consolesthat are current onboard equipment. Though the functions ofdifferent consoles are very similiar, there may be differencesin physical layouts of the components such as indicator lights,push bottons and control valve handles. Reference theinstruments and controls section of the manual supplied withyour original crane for specific control locations.

The operator should become thoroughly familiar with thelocation and function of all instruments and controls beforeoperating the davit. Check all instruments immediately uponstarting, and at frequent intervals during operation to ensureproper care through prompt detection of irregularities. If anyinstrument or control does not register or operate properly,secure power, and locate and correct the cause before resumingoperation.

2.4 OPERATING THE DAVIT

2.4.1 Pre-Operational Test

1. Check the reservoir fluid level on the hydraulic powerunit (HPU) sight gauge, if one exists.

2. Cycle Swing and Boom Control Levers respectively, andensure that they return to neutral position when released.

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 AccumulatorPressure Gauge reads approximately 2500 psi.

2.4.2 Launching OperationThe following procedure is used for lowering a boat into thesea during rough weather.

1. Perform the Pre-Operational Test specified in paragraph2.4.1.

2. Use the boom, swing and winch controls to position theboat for launching.

Boom Control Lever - Pulling the lever rearward raises theboom. Pushing the lever forward lowers the boom.

Swing Control Lever - Pulling the lever rearward swings thedavit to the right. Pushing the lever forward swings the davitto the left.

Winch Joystick - Pulling the lever rearward raises the load.Pushing the lever forward lowers the load.

NOTE: If the Constant Tension Select pushbuttonis pressed while the boat is suspended by thewinch, the winch cannot go into constant tensionmode. As soon as the boat is supported by the waterand the cable becomes slack, the boom cylinderpressure switch activates the selector valve solenoidand puts the system into constant tension mode.

3. As the boat approaches the water, the operator depressesthe Constant Tension Select pushbutton which turns on theamber light in the switch. When the boat enters the water, thesystem shifts into constant tension mode and the yellowConstant Tension Engaged indicator light comes on. Movewinch joystick back for maximum tension.

4. In order to release the hook from the boat, the winchjoystick must be returned to the “MIN TENSION” position.This will allow the crew and the seas to pay out cable from thedrum.

2 - 2

IF A DELAY OCCURS IN THE BOAT OR IFWEATHER CONDITIONS ARE EXTREME, THEWINCH JOYSTICK MAY BE EASED BACK INTOMAXIMUM TENSION POSITION (PULLEDREARWARD) TO STABILIZE THE BOAT ANDPREVENT SLACK FROM ENDANGERING THECREW MEMBERS. THE WINCH JOYSTICK MUSTBE RETURNED TO MINIMUM TENSION POSITION(NEUTRAL) BEFORE ANY ATTEMPT ATRELEASING THE HOOK FROM THE BOAT.

5. When the hook has been released from the boat and theoperator, is ready to retrieve the cable, quickly move the winchjoystick to the right and return it to the neutral position tocancel the constant tension mode. The yellow Constant TensionEngaged indicator light will go out, and the winch will be innormal hoisting mode.

IF THE WINCH JOYSTICK IS MOVED SLOWLYFROM “MAX TENSION” POSITION TO CANCELCONSTANT TENSION, OR IS ALLOWED TO RESTIN “MAX TENSION” POSITION, THE HOOK WILLBE RETRIEVED AT A SPEED IN EXCESS OF 500FPM.

6. Move the winch joystick back to “WINCH UP” toretrieve the hook.

2.4.3 Recovery OperationThe following procedure is used for recovering a boat from thesea during rough weather.

1. Perform the Pre-Operational Test specified in paragraph2.4.1.

2. Use the boom, swing and winch controls to position theboat for recovery.

Boom Control Lever - Pulling the lever rearward raises theboom. Pushing the lever forward lowers the boom.

Swing Control Lever - Pulling the lever rearward swings thedavit to the right. Pushing the lever forward swings the davitto 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 Selectpushbutton (9) until the indicator light in the switch comes on

and then move the winch joystick to “MIN TENSION” so thatcable tension will be zero.

IF A DELAY OCCURS IN THE BOAT OR IFWEATHER CONDITIONS ARE EXTREME, THEWINCH JOYSTICK MAY BE EASED BACK INTOMAXIMUM TENSION POSITION (PULLEDREARWARD) TO STABILIZE THE BOAT ANDPREVENT SLACK FROM ENDANGERING THECREW MEMBERS. THE WINCH JOYSTICK MUSTBE RETURNED TO THE MINIMUM TENSIONPOSITION (NEUTRAL) BEFORE ANY ATTEMPT ATCONNECTING THE HOOK TO THE BOAT.

4. When the crew has connected the hook to the boat,slowly move the winch joystick rearward. This graduallyincreases tension so the boat can rise and fall on a taut cable.

5. As the boat reaches the crest of a wave, cancel constanttension by moving the winch joystick quickly to the right andimmediately returning it to hoist position. At this time thewinch will be in normal hoisting mode, and will begin hoistingthe boat at a speed which corresponds to the winch joystickposition. (Sometimes it is easier to watch the drum payingout and taking in cable to determine the best point to hoistthe boat.)

IF CONSTANT TENSION MODE IS CANCELLEDWHILE THE BOAT IS TENDING DOWN A SWELL,THE DAVIT WILL SHOCK THE LOAD, CREATINGTHE POTENTIAL FOR DAVIT FAILURE.

6. When the boat is clear of the water, slow hoisting andwhen the boat clears the deck edge, position the boat overits cradle so it can be lowered and secured.

2.4.4 Emergency OperationShould an electrical power failure occur which prevents startingthe hydraulic power unit, the davit is equipped with a backuphydraulic/mechanical system to launch.

Operators should practice using the emergency systems toreduce confusion in the event of an actual emergency. Allemergency lowering components with exception to the winchlowering tee handle are located on the console. See TechnicalManual TP2753A for information pertaining to the use of theemergency operation components.

3 - 1

CHAPTER 3FUNCTIONAL DESCRIPTION

Note: The control console and power unit werenot supplied with the davit. Consult TP2754 forinformation regarding the hydraulic power unit and2753A for information regarding the control console.

3.2 MECHANICAL SYSTEM

3.2.1 DavitThe davit weldment and jib boom are the structural memberswhich support the load, and the winch is mounted to the jib

3.1 INTRODUCTIONThe model D5700CT Boat Davit provides the capability tolaunch and retrieve rigid inflatable boats (RIB's) in unevenseas by use of a constant tension winch. When placed inConstant Tension mode, this winch reels the cable in andout automatically, maintaining cable tension, in response torising and falling seas.

The functions and capabilities of the davit are the result ofseveral systems working together: Davit; Winch; SwingDrive(s); Operator Controls; Hydraulic System; ElectricalSystem; and the Hydraulic Power Unit.

Figure 3-1 Component Identification

SHEAVE CASE

JIB BOOM

DAVIT

LIFT CYLINDER

DOWNSTOP

CONTROL

ANTI-2-BLOCK

CONTROL

SWING

BEARING

SWING

DRIVES

HYDRAULIC LID

DAVIT INSTALLATION

QUICK RELEASE

HOOK

3 - 2

boom. An automatic release hook is rigged for one-part reevingfrom the winch line, through a sheave at the tip of the jib boom.A shear-ball type swing bearing is bolted to the underside ofthe davit weldment. The davit and bearing assembly is in turnbolted to the pedestal, which is welded to the deck.

3.2.2 WinchSee Figure 3-2. The Constant Tension Clutches freewheel in“WINCH UP,” but prevent the Cable Drum from turning inthe opposite direction unless the Spring Brake is releasedby “WINCH DN” selection. In Constant Tension Mode, theConstant Tension Clutches disconnect the Load HydraulicMotor from the drivetrain and valves installed in manifoldsbolted to the Constant Tension Hydraulic Motor controlwinch operation.

3.2.3 Swing DriveSee Figure 3-3. Two Swing Drives are required to operatethe davit. A dual counterbalance valve is used to release theSwing Brakes as fluid is directed to the Swing HydraulicMotors. Pinions engage external gear teeth on the outer race ofthe swing bearing.



MAIN WINCH

HYDRAULIC

MOTOR

DOUBLE PLANETARY

GEAR REDUCER

CABLE DRUM

CABLE ANCHOR

MAIN WINCH

BRAKE

WINCH

FRAMESPRING

BRAKE

CONSTANT

TENSION

VANE TYPE

HYDRAULIC

MOTOR

CONSTANT

TENSION

CLUTCHES

AM

C1

28

LEGEND

1. HYDRAULIC MOTOR

2. BRAKE

3. GEAR REDUCER

4. PINION

2

3

4

1

AM

C 0

83

3 - 3

3.3 HYDRAULIC SYSTEM

3.3.1 Boom SystemSee Figure 3-7. In order to prevent free fall, the boom system isdesigned to be powered down as well as up. When the boomcontrol lever is actuated, fluid passes through the boom controlvalve section to the boom lift cylinder junction block. Theboom lift cylinder junction block is mounted directly to thebase end of the boom lift cylinder and it houses the load lockvalve.

The load lock valve allows free flow to the base (lifting) end ofthe boom lift cylinder and a check valve built into the cartridgeprevents reverse flow to the control valve. Then the load lockvalve prevents the boom from lowering until sufficient backpressure, 850 psi, accumulates in the stem (lowering) end ofthe boom lift cylinder. Finally, the load lock valve dischargesto tank at 3400 psi to protect the davit from hydraulic shockloading and pressure spikes.

3.3.2 Swing SystemSee Figure 3-7. When the swing control lever is actuated, fluidpasses through the swing dual counterbalance valve to releasethe spring applied/hydraulically released swing brakes anddrive the swing hydraulic motors. The swing hydraulic motorsare mounted in line with the swing brakes and the swing gearreducers.

The swing dual counterbalance valves lock the swing driveshydraulically until rotation is directed by the control valve.When the swing lever is not actuated, the swing dual

counterbalance valve traps fluid inside the swing motors,preventing them from rotating, and the swing brakes are alsoengaged. Hydraulic pressure applied to the swing dualcounterbalance valve is directed first through an internal shuttlevalve to release the swing brakes. Then the swing dualcounterbalance valve begins to open at 500 psi (3,447 kPa),and relieves at 2000 psi (13,789 kPa) allowing fluid to returnto tank.

A lever actuated swing stop valve vents pressure to tankwhenever the davit swings into the mechanical swing stop,to prevent abrupt stops.

3.3.3 Winch SystemSee Figure 3-4. The winch system distributes hydraulic fluidto the winch for either normal hoisting, or constant tensionfunctions. Hydraulic power is applied to either the load orconstant tension hydraulic motor in the winch. Acounterbalance valve controls return oil flow in the loweringdirection during normal hoisting.

Normal hoisting is controlled by directing oil to the loadhydraulic motor, which drives the cable drum through doubleplanetary reduction gears, then through a spring applied/hydraulically released brake equipped with an integral one-wayroller clutch. The one-way roller clutch freewheels in the updirection, but prevents the shaft from rotating in the downdirection unless the brake is released by hydraulic pressurefrom “WINCH DN” selection. Ultimately, the drum is driven


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

AM

C4

76

1

2

8

7

6

5

43

EMERGENCY

LOWER

CT

RETURN

CT

PRESSURE

WINCH

UP

WINCH

DOWN

3 - 4

through a spring clutch which locks the shaft (hub) to the drum.In constant tension mode, the load hydraulic motor isdisconnected from the drivetrain when the spring clutch ishydraulically released allowing the constant tension hydraulicmotor to drive the cable drum directly.

Manifolds bolted to the constant tension motor contain valvesthat control the constant tension winch:

The electrically operated proportional relief valve (1) controlsthe pilot pressure to the constant tension relief valve. It isfactory set and should not require adjustment.

The sequence valve is set to 1200 psi to ensure that there isenough pressure to release the clutch which sets line tension.

The pressure reducing valve is set at 800 psi to limit the pressureapplied to the clutch piston.

An electrical solenoid valve connects the constant tension clutchdirectly to tank when the winch is in normal hoisting mode.This allows faster transition from constant tension mode tonormal hoisting mode. When the solenoid valve is shifted toconstant tension position, hydraulic pressure releases the springapplied /hydraulically released clutch, disconnecting the shaft(hub) from the normal hoisting drivetrain.

3.3.4 Emergency SystemSee Figure 3-7. The emergency system consists of theemergency valve, hand pump, accumulator, emergency winchcontrol lever and the accumulator pressure gauge.

During normal operation hydraulic pressure passing througha parallel check valve is stored in the accumulator. The handpump is used to recharge the accumulator during emergencyoperation.

The boom and swing control levers function as in normaloperation, but are “powered” by the accumulator through theemergency valve.

IF THE SWING JUNCTION BLOCK NEEDLE VALVEIS ROTATED EXCESSIVELY, THE BOAT CAN FREEFALL RESULTING IN PERSONAL INJURY ORDEATH.

Figure 3-5 Downstop Control

1

6

3

7

24,5LEGEND

1. PROXIMITY

SWITCH

2. DOWNSTOP

WELDMENT

3. ARM

4. ROLLER

5. BEARING

6. SPRING

7. PLATE

AM

C 2

22

1/16"

3 - 5

Figure 3-6 Anti-2-Block Control

CAUTION

CAUTION: IF THE ELECTRICAL DISCONNECTSWITCH IS NOT IN THE “OFF” POSITION PRIORTO EMERGENCY WINCH OPERATION, THE WINCHSOLENOID WILL BE DAMAGED.

Emergency lowering is best accomplished by rotating theswing junction block needle valve slowly counterclockwisewhich vents the accumulated fluid in the boom lift cylinderthrough a restrictor to the swing section of the main controlvalve and then to tank. Simultaneously, pressure vented to theswing junction block releases the winch brake. Lowering speedis controlled by the swing junction block needle valve.

The emergency winch control lever is behind the front consolecover, under the left end of the control valve. Pull the levertoward you for “WINCH UP” and push away for “WINCHDN.”

3.3.5 Downstop Control

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

Normally, the drum roller rides against the spooled cable onthe drum. When only three wraps of cable remain on the drum,the roller drops down and by riding directly on the surface ofthe drum, moves the sensor arm adjacent to the proximityswitch. The proximity switch triggers the downstop inhibitcircuit which stops the “WINCH DN” operation.

3.3.6 Anti-2-Block Control

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

1

3

LEGEND

1. PROXIMITY SWITCH

2. SENSOR ARM

3. SPRING

4. CABLE

5. WEIGHT

6. CABLE CLIP

AM

C 2

63

4

6

6

1/16"

2

5

3 - 6

THIS PAGE INTENTIONALLY LEFT BLANK

Figure 3-7 Hydraulic Schematic Diagram

3-7 / (3-8 blank)

LEGEND1. Winch, CT2. Cylinder3. Manifold4. Valve, Deceleration5. Swing Drive Assy6. Valve, Counterbalance7. Manifold

Figure 3-8 Electrical Control Diagram

3-9 / (3-10 blank)

Figure 3-9 Electrical Schematic Diagram

3-11 / (3-12 blank)

4 - 1

CHAPTER 4SCHEDULED MAINTENANCE

4.1 INTRODUCTIONPeriodic maintenance and lubrication is necessary to ensurelong life and proper function of the davit’s components. Toobtain the best performance and prevent unnecessary wear,it is essential that the maintenance and lubrication schedulesin this chapter be followed. If the davit is operatedextensively, or in severe conditions, service intervals shouldbe shortened.

4.2 PREVENTIVE MAINTENANCEA sensible, conscientiously applied preventive maintenanceprogram can greatly reduce the chance of equipment failureand increase the service life of the davit. A preventivemaintenance program should be based on the maintenanceand lubrication charts, and the amount of anticipated use ofthe davit.

4.3 SCHEDULED MAINTENANCE

4.3.1 Walk Around InspectionOperators shall perform a walk around inspection beforeeach operating session, looking for loose fasteners, leakingconnections, worn or damaged hoses, or any other defectsor dangerous conditions. Promptly report any defects toproper authority.

4.3.2 Lubricant SpecificationsAll lubricants and oils used on the equipment shall conformto the following specifications. The numbers in the Frequencyof Maintenance fields of the Maintenance and LubricationChart (Table 4-1) correspond to the lubricant specificationitem numbers below.

➀ . 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.

➁ . GEAR LUBRICANT (MIL-G-18548) Formulated forlubricating exposed gears.

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

➃ . SWING GEAR REDUCER OIL (MIL-L-2105E) Use onlyHD 80W-90 multipurpose gear oil.

➄ . WINCH GEAR REDUCER OIL (MIL SPEC not available)Use only Exxon Torque Fluid 56.

➅ . HYDRAULIC SYSTEM OIL (MIL-H-17672, 2110-T-H) Useonly premium grade, anti-wear hydraulic oil. Themanufacturer recommends Mobil DTE 13M.

NOTE: Failure to use the recommended oil duringthe warranty period may void warranty (expressedor implied) on related hydraulic components, ifinspection indicates lubrication related cause. Oilsamples will be required with submission of allhydraulic components for warranty consideration.

4.3.3 Service InstructionsThe Maintenance and Lubrication Chart (Table 4-1) showsmaintenance 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 BEARINGLubricate the swing bearing through the lube fittinglocated on the davit. Rotate the davit in 30 degreeincrements between applications. Rotate the davitthrough its entire swing arc after lubrication to distributethe lubricant.

Figure 4-1 Swing Bearing Lubrication

30°

TYPA

MC

47

7

4 - 2

SHUT OFF THE ELECTRICAL SUPPLY TOTHE HYDRAULIC POWER UNIT BEFOREPERFORMING MAINTENANCE OR SERVICE ONTHE PINIONS AND RING GEAR. FAILURE TO DOSO COULD CAUSE SERIOUS INJURY OR DEATH.

2. PINIONS AND RING GEARDistribute lubricant around the outside face of the gear.Visually inspect the gear and pinions for excessive wear ordamage. Also, check that the pinion retaining caps andcapscrews are secure.

3. SWING DRIVEAdd approved gear oil as required. To check the oil level,clean the area around the plug on the top of the swing gearreducer. Then remove the plug and ensure the oil level isvisible through the hole. Check the swing drive for leaks.

NOTE: Drain and refill with fresh oil every 2000hours or every 12 months , whichever occurs first.

Figure 4-2 Maintenance and Lubrication Diagram

76

9

10

AM

C5

32

4 5

11

1,2

3

13

DAVIT INSTALLATION

8

CONSTANT TENSION

WINCH

5

5

4 - 3

4. LIFT CYLINDERSee Fig. 4-3. Check the hydraulic cylinder every 30 days forleakage around the stem and packing gland. If leakage ispresent, refer to Chapter 6, Corrective Maintenance.

5. CONSTANT TENSION WINCHTo check the oil level, clean the area around the plug in thecenter of the end housing on the constant tension end of thewinch, and then remove the plug. The oil level should be atthe bottom of this port. Add approved oil as required. Drainand refill annually, capacity is approximately 1 U.S. gallon(3.8 liters). Check the winch assembly for leaks.

NOTE: Disassemble the winch, inspect all wearitems, and change oil every 2,000 operating hoursor 12 months, whichever occurs first.See Chapter 6 for winch disassembly andinspection procedures. Figure 4-3 Boom Lift Cylinder

Table 4-1 Maintenance and Lubrication Chart

MAINTENANCE POINT DESCRIPTION FREQUENCY OF MAINTENANCE

NOTE: Numbers in FREQUENCY OF MAINTENANCEcolumn correspond to LUBRICANT SPECIFICATIONS

REF in Section 4.3.2. An “X” in this position indicates that DAILY WEEKLY MONTHLY ASinspection only is required. Numbers in REF column 10 HRS 50 HRS 200 HRS REQUIREDcorrespond to Fig. 4-2 and/or paragraph 4.3.3.

1 SWING BEARING ➀➀➀➀➀

2 PINIONS AND RING GEAR ➁➁➁➁➁

3 SWING DRIVE ⌧ ➃➃➃➃➃

4 LIFT CYLINDER ⌧

5 WINCH ➄➄➄➄➄

6 WINCH CABLE ➂➂➂➂➂

7 SHEAVE PIN & BUSHING ⌧

8 HOOK ⌧

9 DAVIT INSTALLATION ⌧ ⌧

10 PIVOT BEARINGS ⌧

11 DAVIT MOUNTING BOLTS ⌧

12 FASTENERS ⌧

13 HYDRAULIC LINES AND FITTINGS ⌧

Stem

Packing Gland

AM

C1

82

4 - 4

6. WINCH CABLELubricate to prevent rust and internal friction. One excellentmethod of application is to apply lubricant to the cable whileit passes through a sheave, working it into the valleys betweenthe strands and coating the outer wires and lubricating thewire rope at the base of the end fittings. Remove excessgrease from the wire rope. See NSTM Chapter 613 forappropriate cleaning instructions to remove new wire ropeshipping preservative. Periodically inspect the entire lengthof the winch cable. Look for fraying, severe kinks, brokenstrands or rust. If any damage is found or if the wire ropehas stretched to a diameter smaller than that listed in Table4-2, the entire cable must be replaced.

NOTE: The inspection, care, and maintenance ofthe winch cable should comply with current safetyrules.

Nominal Diameter of Undersized OversizedRope in Inches Inches Inches

0-3/4 0 1/3213/16 - 1-1/8 0 3/641-3/16 - 1-1/2 0 1/161-9/16 - 2-1/4 0 3/32

2-5/16 and larger 0 1/8

Table 4-2 Wire Rope Tolerances

7. SHEAVE PIN & BUSHINGNo lubrication is necessary. Check sheave groove, pin andbushing for excessive wear or damage. Replace any parts asrequired.

8. HOOKInspect 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

Give the davit a fresh water washdown weekly. On a monthlybasis, thoroughly clean davit assembly and associatedcomponents with detergent and fresh water. Rinse with freshwater.

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 thincoat of silicone compound to bare metal surfaces.

Return the davit to readiness condition.

10. PIVOT BEARINGSCheck cylinder, boom and cable sheave bearings for wearevery 90 days. Wear must not extend beyond the fabric liningof the bearings, approximately 0.012" (0.030 mm), nor exceeda total wear of 0.024" (0.060 mm).

11. DAVIT MOUNTING BOLTSCheck the davit mounting bolts for security after the firstthree to four hours of operation. Thereafter, check securityevery 500 hours of operation. Ensure all hardware is in placeand of the correct grade. Tighten the davit mounting boltsas indicated in Figure 8-1 Davit Installation.

12. FASTENERSSee Figure 4-4. Unless otherwise specified, check all fastenersfor security every six months.

Note: See Figure 8-1 for Davit, Pedistal and RingGear installation fasteners.

13. HYDRAULIC LINES AND FITTINGSInspect all hydraulic lines and fittings for damage or leakageand tighten or replace as required. Replace any hose, fittingor O-ring that is damaged or leaking during operation andcannot be corrected by proper tightening. Never attempt tostop a leak by overtightening.

4.4 HYDRAULIC OIL MAINTENANCEThe presence of dirt, water and other contaminants inhydraulic oil will adversely affect its condition and lead topremature breakdown due to high operating temperaturesand/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.

CAUTION

DISCONNECTED HYDRAULIC LINES MUST BECOVERED TO PREVENT HYDRAULIC SYSTEMCONTAMINATION. ENSURE OPEN PORTS ONHYDRAULIC COMPONENTS INCLUDING HOSES,TUBING, AND FITTINGS ARE EITHER CAPPED, ORPLUGGED DURING INSTALLATION, SERVICE ANDREPAIR PROCEDURES.

4.4.1 Storage and Handling

1. Store drums on their sides. If possible, keep themindoors or under a roof. Keep the drums sealed tightly.

4 - 5

2. Before opening a drum, clean the top of the drumthoroughly to prevent dirt from entering.

3. Use only clean containers, hoses, etc. to transfer oil fromthe drum to the hydraulic tank. An oil transfer pump equippedwith a 10 micron filter is recommended. Keeping the oil cleanand moisture-free will help it last much longer and preventcontamination damage to close-fitting parts.

4.4.2 In-Operation Care

NOTE: Replace the return filter element after thefirst 50 hours of operation on new or rebuiltwinches.

1. Prevent contamination by keeping the system tight andusing proper filtration.

2. Prevent hydraulic system overheating. If anycomponent is hotter than 180° F (82° C), shutdown the davitand allow the system to cool. If the overheating problempersists, isolate and correct the problem.

3. Establish oil change intervals in accordance withmanufacturer's recommendations and actual operatingconditions so oil is replaced before it breaks down.

NOTE: Change oil annually or every 2,000operating hours, whichever occurs first.

4. Keep the tank properly filled to prevent moisture fromcondensing on inside walls.

5. Repair all leaks immediately.

6. Watch filter indicators and replace filter elements whenrequired.

4.4.3 Analysis

1. Obtain a sample from the hydraulic system while theoil is hot to ensure an accurate analysis.

2. If water appears at the bottom of the sample after it hasstood for several minutes, there is either an opening for waterto enter the system or the system has been subjected to severetemperature fluctuations which caused condensation.

3. Maintain ISO 4406 cleanliness standard of17/14 or better.

4.5 EXTENDED STORAGE PROCEDURESIf 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 unusualleakage or damage. Repair or correct any leakage or damagefound.

2. Perform all maintenance and lubrication proceduresas outlined previously in this chapter.

3. Preserve the winch and cable, bearings, bushings, swinggear and other unpainted surfaces with a non-running grease.

4. Cover electrical power equipment and unpaintedsurfaces with a moisture barrier material that will not causecondensation.

5. Store in a dry, enclosed building if possible.

6. Inspect all items every 6 months.

7. Restore paint that has been damaged in transit orhandling. Procedures are available upon request from themanufacturer.

SAE & SBC

IDENTIFICATION

316

S.A.E. GRADE 8

(General purpose

bolts)

STAINLESS STEEL

(Used for corrosion

resistant applications)

S

B

C

FX

AM

C2

76S.A.E. GRADE 9

(Used for load

carrying bolts)

S.A.E. GRADE 5

(General purpose

bolts)

S

C

B

Figure 4-4 Bolt Identification

4 - 6


5 - 1

CHAPTER 5TROUBLESHOOTING

5.1 INTRODUCTIONThe purpose of this chapter is to aid shipboard personnel inthe isolation and correction of problems that can occur duringoperation of the davit and related equipment. This chapterprovides general instructions for the inspection and isolationof mechanical, hydraulic and electrical problems as well ascorrective maintenance procedures for restoring the davitto normal operation as soon as possible.

5.1.1 SafetyThe safety summary in the front of this manual lists generalprecautions. In addition, any warnings and cautions providedin this chapter and throughout this manual shall be observed.

5.1.2 Problem Area IsolationThis chapter contains provisions for isolating malfunctionsin the davit’s mechanical, hydraulic, and electrical systems.You may isolate a malfunction by operating the davit andobserving performance in sequential order. Additionally,listening for unusual noises and vibrations aids in isolating amalfunction to a specific component.

5.2 PRELIMINARY TROUBLESHOOTINGTo recognize malfunctions of either electrical, hydraulic ormechanical systems and to isolate and identify the mostcommon or probable causes of system malfunctions, thefollowing preliminary checks should be made:

1. Verify that electrical power is available. Check all fusesand visually inspect all external electrical circuits for bare orbroken wire.

2. Verify that hydraulic power is available and that hosesare correctly connected. Should the davit fail to operateproperly, perform the following tests using a 0-3000 psipressure gauge and a 0-50 gpm (0-200 lpm) flow meter.

5.2.1 Pump TestSee specific manual for information regarding the pump and/or HPU. Allied Systems did not supply the HPU.

5.2.2 Control Valve TestSee TP2753A for information regarding the control valve and/or console.

5.2.3 Winch System TestVerify hydraulic oil delivery to the winch by connecting a 0-3000 psi pressure gauge to the inlet line of the load hydraulicmotor.

1. If the load hydraulic motor is receiving adequate pressureand flow, but is not operating properly, repair or replace themotor.

2. If the winch lifts properly, but chatters when starting orstopping, check the overcenter valve on the load motor junctionblock because this valve controls winch brake release and maycause intermittent brake application.

5.2.4 Swing System TestVerify hydraulic oil delivery to the swing drives by connectinga 0-3000 psi pressure gauge to the inlet line of the swinghydraulic motors. If the swing drives are receiving adequatepressure and flow, but are not operating properly, repair orreplace the motor(s).

5.2.5 Boom System TestVerify adequate hydraulic oil delivery to the boom liftcylinder. If the boom lift cylinder is not lifting the load and/or creeps down when it should be locked, it may be causedby hydraulic oil seeping around the cylinder seal, or adefective or cross-connected load lock valve.

1. Place a load on the davit and then carefully disconnectthe hydraulic line between the stem end of the boom liftcylinder and the load lock valve. If fluid continues to run outof the fitting on the stem of the cylinder, replace the cylinderseal because it is leaking. Otherwise, the load lock valve isdefective.

REMOVE ANY LOAD FROM THE BOOM LIFTCYLINDER, INCLUDING THE WEIGHT OF THEBOOM, BEFORE REMOVING THE LOAD LOCKCARTRIDGE OR MANIFOLD. FAILURE TO DO THISWILL CAUSE THE LOAD TO FALL RESULTING INPERSONAL INJURY OR DEATH.

2. Repair or replace the defective load lock valve.

5 - 2

5.3 FAULT ISOLATION

5.3.1 Probable Mechanical CausesMechanical malfunction or failure can be attributed to anyor all of the following:

1. Poor lubrication techniques and failure to performpreventive maintenance on a scheduled basis as outlined inChapter 4.

2. Loosely mounted control components due tomechanical vibration.

3. Dirt and accumulations of other foreign matter onmoveable parts.

4. Worn and/or broken parts. Such parts shall be repairedor replaced in accordance with the applicable procedure inChapter 6.

a. Unusual noise or vibration may indicate bearing or gearproblems.

b. Brake slippage may indicate worn friction discs.

5. Overloaded or physically damaged componentsincluding the davit structure, wire rope, hooks, sheaves andmounting hardware.

5.3.2 Probable Hydraulic CausesHydraulic malfunction or failure can be attributed to any orall of the following:

1. Incorrect adjustment of relief valves, pressure switches,load holding valves, etc.

2. Inadequate hydraulic system pressure or flow, orcontaminated hydraulic oil.

3. Internal leaks in components or componentoverheating.

CAUTION

IF ANY OF THE HYDRAULIC COMPONENTSGENERATES EXCESSIVE HEAT, DISCONTINUEOPERATION IMMEDIATELY AND DETERMINE THECAUSE OF OVERHEATING. OPERATINGTEMPERATURE MUST NOT EXCEED 180° F(82° C).

4. Sticking valve spools, damaged motors/pumps,restrictions in lines, or faulty relief/load holding valves.

5. Incorrect pipe/hose connections.

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

ONLY QUALIFIED PERSONNEL SHOULDTROUBLESHOOT AND PERFORM REPAIRS ANDADJUSTMENTS TO ELECTRICAL SYSTEMS.

1. Open Circuit. An open circuit is caused by a brokenwire or connection.

2. Partial Ground. A partial ground is caused by damagedinsulation permitting excessive current leakage.

3. Short Circuit. A short circuit is caused by two barewires or connectors contacting each other.

5 - 3

Table 5-1 General Troubleshooting Table

Symptom / Malfunction Probable Cause Corrective Action

No davit functions. No power to hydraulic power unit. Restore power.

Tripped circuit breaker. Locate cause, reset breaker.

Defective control circuit wiring. Locate fault and correct.

Broken or incorrectly connected Repair or replace.hydraulic lines or fittings.

Restricted hydraulic filter. Replace filter element. Examine hydraulicsystem for contamination.

Low hydraulic oil level. Replenish hydraulic oil.

Defective pump or motor. Repair or replace.

Excessive heat (above 180° F). Low hydraulic oil level. Replenish hydraulic oil.

Malfunctioning relief valve. Repair or replace.

Wrong grade of hydraulic oil. Replace oil with correct grade.


Restriction in circuit. Locate and correct (checkhydraulic filter element).

Main control valve leaking internally. Repair or replace.

Hydraulic motor(s) leaking internally. Repair or replace.

Sluggish functions. Low hydraulic oil level. Replenish hydraulic oil.

Restricted filters. Replace filter element.

Leaking suction lines. Repair all leaks.

Restriction in circuit. Locate and correct (check filter element).


Defective hydraulic motor. Repair or replace.

Erratic functions. Defective pump or motor. Repair or replace.

Defective control valve actuators (PVE). Repair or replace.

Davit function continues after control Valve spool or handle binding. Repair or replace valve.handle is released.

5 - 4

Table 5-2 Swing Troubleshooting Table


No Swing function. Defective swing dual counterbalance valve. Adjust, repair or replace.

Defective control valve. See valve troubleshooting.

No pressure to brake. Repair or replace.

Swing brake(s) not releasing or binding. Repair or replace. Check for pluggedlines to brake.

Defective swing drive motor(s). Repair or replace.


Swing function "jerky". Defective swing brake(s). Repair or replace.

Misadjusted or defective swing Adjust, repair or replace.dual counterbalance valve.

Swing brake slips. Excessive back pressure in the Check return filter, hose size, restrictions inactuation line of the brake, reducing other hydraulic components.holding torque.

Disc plates worn. Check disc stack thickness. Replaceworn discs.

Springs broken or have taken a Check release pressure. Replacepermanent set. springs if required.

Swing brake drags or runs hot. Low release pressure. Place pressure gauge in bleed portand check pressure with system on.Pressure should be a minimum of20 psi over the full release pressure.

Bearing failure, causing excessive drag. Replace bearing.

Brake will not release. Stuck or clogged valve. Place pressure gauge in bleed port,check for adequate pressure. Replacedefective line or component.

Defective O-rings. Replace.

Discs frozen, due to severeemergency stop or prolongedreduced release pressure operation. Replace disc stack.

Noise or looseness in swing mechanism. Dry or defective swing bearing. Lubricate or replace.

Excessive gear backlash. Check backlash. Replace swing drivepinions and/or bearing if required.

Defective gear reducer or brake. Repair or replace.

5 - 5

Table 5-3 Boom Troubleshooting Table


No "boom up" function. Cylinder leaking internally. Repair or replace.

Defective control valve. Repair or replace.

Defective pump. Repair or replace.

No "boom down" function. Defective load lock valve. Repair or replace.

Defective pump. Repair or replace.

Improper hose/pipe connections. Correct hose/pipe connections.

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

Defective load lock valve. Repair or replace.

Improper hose/pipe connections. Correct hose/pipe connections.

Table 5-4 Winch Troubleshooting Table

CT SELECT or ENGAGE light not working. Bulb failed. Replace bulb.

Relay defective. Replace relay.

Pushbutton defective. Replace.

CT mode will not engage. Downstop control or anti-2-block control Adjust, repair or replace.defective or improperly adjusted.

Tension switch proximity failure. Replace.

CT mode will engage, Improper hose/pipe connection. Correct hose/pipe connections.but will not function.

The drum locks up when Constant Clutch not releasing. Check pressure, repair or replace clutchTension mode is selected. solenoid valve.

Winch does not maintain constant tension Winch joystick not in MAX position. Ensure joystick is unobstructed.on cable while in CT mode.

Minimum Tension set too low or too high. Adjust Minimum Tension (Max. Out).

Insufficient clutch release pressure. Adjust pressure reducing valve (800 psi).

Insufficient CT pressure. Adjust sequence valve (1200 psi).

Malfunctioning main control valve. Adjust, repair or replace.

Malfunctioning electrically operated Repair or replace.relief valve.


Sluggish winch functions. Low hydraulic oil level. Fill tank to correct level.

Blocked hydraulic filter element. Replace filter element.

Leaking suction lines. Repair or replace.

Restriction in circuit. Locate and correct. Check filter element.


Defective hydraulic motor or control valve. Repair or replace.

Winch will not lift a load. Davit overloaded. Reduce load.


Defective winch motor. Repair or replace.

Davit 2-blocked, or anti-2-block Lower load.control defective or improperly adjusted. Adjust or repair anti-2-block control.

Winch will not hold load. Defective winch counterbalance valve. Repair or replace.

Defective winch brake. Repair or replace.

High back pressure affecting winch brake Locate and eliminate restriction in returnor winch counterbalance valve. line (check return filter).

Winch will not lower load. Defective or improperly adjusted down- Adjust, repair or replace.stop control.

Defective winch counterbalance valve. Repair or replace.

Winch jerks when lowering load. Defective winch counterbalance valve. Repair or replace.

Defective winch brake. Repair or replace.

IF THE CONSTANT TENSION SYSTEM EXHIBITSANY SIGN OF ERRATIC OPERATION, OR TENSIONCONTROL DIFFICULTIES, APPROPRIATETROUBLESHOOTING TESTS AND REPAIRS MUSTBE PERFORMED IMMEDIATELY. CONTINUEDOPERATION IN THIS MANNER COULD RESULT INEQUIPMENT DAMAGE, PERSONAL INJURY, ORDEATH.

NOTE: If constant tension winch performancedecreases significantly after a change in climate,verify that the winch is serviced with the correctoil. See Chapter 4, Scheduled Maintenance, forlubricant specifications.

5 - 6

Table 5-5 Control Valve Troubleshooting Table


Main spool moves but pump fails to come Worn or damaged ball and seat in PVB Replace PVB and contact manufacturer.on stroke (manual activation only). shuttle valve.

Main spool moves with no resultant oil from Damaged or faulty compensator. Inspect for oil contamination and contactworking ports (manual activation only). manufacturer.

Maximum load pressure matched with Adjust PVB load sense relief.PVB load setting.

PVB load sense relief valve damaged. If load sense relief not adjustable, contactmanufacturer.

Working pressure has exceeded main Reduce working load pressure.relief valve setting. Increase PVP relief setting and contact

manufacturer.

5 - 7 / (blank)

6 - 1

CHAPTER 6CORRECTIVE MAINTENANCE

Maintenance procedures are presented in two sections.Section 6.2 describes required adjustment procedures andSection 6.3 describes the procedures necessary to remove,disassemble, clean, inspect, repair, replace, assemble, andreinstall the equipment.

Table 6-1 lists tools and supplies recommended formaintenance. Most repairs can be performed with ordinaryhand tools although some specialized tools will be required.

6.1 INTRODUCTIONThis chapter provides maintenance personnel withprocedures necessary to perform corrective maintenance onthe equipment.

This chapter identifies the specific corrective maintenanceprocedures for shipboard, intermediate, and depot levelmaintenance of the equipment. Detailed instructions, withillustrations, explain how to perform required maintenance.

Tool / Supply Application / Description

Open end/box end combination wrench set and socket Sized from 1/4 inch to 1-5/8 inches for removal and reinstallationwrench set of components.

Screwdrivers Various standard sizes for removal reinstallation, and adjustmentof components.

Retaining ring pliers Various sizes for removal and reinstallation of components.

Adjustable pliers Various sizes for removal and reinstallation of components.

Allen wrench set Sized from 1/16 inch to 9/16 inch for removal and reinstallationof components.

Leather mallet For removal and reinstallation of components without marringmachined surfaces.

Torque wrench Scaled from 0 to 2000 lb-ft.

Torque wrench Scaled from 0 to 200 lb-in.

Gear and bearing pullers Various sizes for removal of components.

Dial indicator To make alignment and end play checks.

Micrometer To measure diameters and thickness with precision.

Hydraulic pressure gauge (with JIC and CPV fittings) Scaled from 0 to 3000 psi.

Hydraulic flow meter Scaled from 0 to 50 gpm.

Multimeter (VOM) To make voltage, current and resistance checks.

Drift pin set Various sizes for removal of components.

Chain fall or hand operated cable hoist For handling smaller heavy components such as the winch,the swing drives or the control valve.

Slide hammer and/or 20 lb machinist's hammer To remove anchor pins.

Table 6-1 Tools and Supplies

6 - 2

6.1.1 Maintenance Practices

1. Cleanliness is of the utmost importance when servicingany hydraulic equipment. Cap any open hydraulic lines toprevent dirt from entering the system. Use clean tools andlint-free rags.

2. Inspect all parts prior to reassembly to detect any wearor damage which may have occurred in operation or shipping.

CAUTION

ENSURE OPEN PORTS ON HYDRAULICCOMPONENTS, INCLUDING HOSES, TUBING,AND FITTINGS, ARE EITHER CAPPED ORPLUGGED DURING SERVICE OR REPAIR TOPREVENT HYDRAULIC SYSTEMCONTAMINATION.

Tool/Supply Application/Description

Crane Sufficient capacity for lifting heavy components.

Mineral-base cleaning solvent (FED SPEC P-D-680, Type II) For cleaning parts.

Gasket cement (NSN 8040 00 664 4134) For replacing gaskets.

Grease gun For component lubrication.

Crocus cloth, 400 grit For polishing and corrosion removal.

Machinist's vise, equipped with jaw protectors For holding components in place. Jaw protectors preventmarring of machined surfaces.

Bladder Pull Rod (P/N: 11-503) For assembling the accumulator.

Winch Repair Tool Kit (P/N: 42383) For winch assembly and disassembly.

• Main Winch Hub Retainer (P/N: 41721) For removing main winch hub from drum.

• Brake Ring Retainer (P/N: 41726) For aligning winch brake and hub during assembly.

• CT Winch Hub Retainer (P/N: 41727) For spacer removal.

• Spring Compressor (P/N: 41729) For winch brake removal.

• Drivers (P/N: 41732, 41734, 41735) For winch service.

• Spacers, set of 3 (P/N: 41733) For centering drum in winch frame.

• Seal Driver (P/N: 41737) For installing winch drum oil seal.

Port-A-Power (P/N: P39/RCH202) For use with Spring Compressor (P/N: 41729).

Press For removing gears and bearings from shafts.

Anti-seize compound (MIL-A-907A) For installation of specific fasteners.

Thread Locking Compound (MIL-S-22473E) For installation of specific fasteners.

Sealing compound (Permatex No. 2, MIL-S-45180) For installation of components.

Sealing Compound, Loctite "Ultra Blue" Sealant For sealing of mating surfaces.

Petroleum Jelly For installation of O-rings and seals.

Cosmoline To prevent corrosion of bare metal surfaces.

Table 6-1 Tools and Supplies - Continued

6 - 3

3. Use only authorized replacement parts. Never reuseexpendable parts such as oil seals, backup rings, gaskets, etc.Although they may appear to be in good condition, they canbe defective.

4. Clean all metal parts with approved cleaning solvent.

CAUTION

DO NOT USE ORGANIC SOLVENTS TO CLEANO-RINGS, SEALS OR PACKINGS.

5. Lubricate all O-rings with petroleum jelly or cleanhydraulic oil prior to installation.

6. Secure the hydraulic power unit (HPU) beforeperforming electrical tests on the control valves.

7. Prevent metal tools from coming into contact withsensitive electronic components.

8. Turn power off before connecting or disconnecting valvecoils or other electrical loads.

6.2 HYDRAULIC AND ELECTRICALSYSTEM ADJUSTMENTSSee Table 6-2. This section describes procedures for adjustinghydraulic and electrical components. Hydraulic systemsettings should not require adjustment unless componentsare changed.

NEVER ADJUST HYDRAULIC COMPONENTS TOSETTINGS HIGHER THAN THE VALUES GIVEN INTHIS MANUAL. ANY ATTEMPT TO GAIN “EXTRA”LIFTING CAPACITY WILL CAUSE OVERLOADINGWHICH MAY RESULT IN EQUIPMENTDAMAGE,PERSONAL INJURY OR DEATH.

NOTE: The hydraulic system must be at operatingtemperature before accurate adjustments can bemade.

6.2.1 Main System Relief PressureSee TP2753A for information regarding the control valve andsetting the main relief.

6.2.2 Swing Dual CounterbalanceValve AdjustmentSee Figure 6-1.

1. The swing dual counterbalance valve cartridges arefactory set to open at 450 psi pilot pressure and relieve totank at 2000 psi.

NOTE: If the swing dual counterbalance valvesrequire adjustment for any reason, remember thatthe “Swing LH” and “Swing RH” functions must beadjusted separately.

2. Connect a 0 - 3000 psi pressure gauge at the unused swingbrake port on one of the swing drive motors.

3. The swing dual counterbalance valve controls onlyreturn flow from the motor back to the tank and should beginto open at 450 psi.

4. With the HPU running and at operating temperature,slew the davit right or left while observing the gauge. Onecartridge of the counterbalance valve controls return flowwhile swinging in one direction, and the other controls returnflow in the opposite direction. Slew the davit in the oppositedirection while observing the gauge.

5. To adjust the cracking pressure, loosen the jamnut onthe cartridge and turn the stem in or out with a hex wrenchuntil the gauge reads 450 psi. If the pressure cannot beadjusted, replace the cartridge.

Relief Pressure Setting Reference

Main System Relief Valve 2750 psi Para. 6-2.1

Winch Sequence Valve 1000 psi Figure 3-13

Winch Counterbalance Valve 3000 psi Figure 3-13

Swing Dual CounterbalanceValve 2000 psi Para. 6-2.2

Constant Tension MotorPressure 1200 psi Para. 6-2.3

Constant Tension ClutchPressure 800 psi Para. 6-2.3

Table 6-2 Pressure Settings

6 - 4

6. After adjustment/replacement has been accomplished andthe gauge has been removed, cycle the davit several times topurge air from the system and check for leaks.

6.2.3 Constant Tension WinchPressure AdjustmentsSee Figure 6-2.

1. Secure the HPU and connect one 0-3000 psi gauge witha tee fitting in the line at port “P” and another at the clutchpressure port as shown.

2. Start the HPU and allow the system to reach operatingtemperature.

3. Loosen the locknut on the sequence valve and slowlyadjust the valve until the gauge at port “P” reads 1200 psi.Tighten locknut.

4. Loosen the locknut on the pressure reducing valve andslowly adjust the valve until the gauge at the clutch pressureport 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 AdjustmentSee Figure 6-3.

This is a limiting device designed to prevent the operator frompaying out cable beyond the last three wrapson the drum.

IT IS CRITICAL THAT THIS CONTROL BEPROPERLY ADJUSTED. FAILURE TO DO SOCOULD CAUSE A SERIOUS ACCIDENTRESULTING IN EQUIPMENT DAMAGE, PERSONALINJURY OR DEATH. NEVER OPERATE THE DAVITWITH FEWER THAN THREE COMPLETE WRAPS OFCABLE ON THE DRUM BECAUSE CABLE CLAMPSARE NOT DESIGNED TO HOLD RATED LOADS.

1. Winch down until three complete wraps of cable remainon the drum. Maintain at least 100 lbs tension on the cablewhile lowering. Secure the HPU. The roller (4) must dropdown from the first layer of cable and ride directly on thedrum’s surface.

2. Adjust the arm (3) until it is centered over the face of theproximity switch (1).

Figure 6-1 Swing Dual Counterbalance Valve Adjustment

LOCK NUT

ADJUSTMENT

SCREW

AM

C 1

06

6 - 5

3. Loosen the locknut on the proximity switch (1) and adjustthe switch by screwing it in or out until there is 1/16" clearancebetween the switch face and the arm (3). Tighten the locknut.

4. Start the HPU and carefully operate the davit to ensurethat the winch stops immediately after the roller contactsthe bare drum with three complete wraps of cable remaining.Readjust if necessary.

6.2.5 Anti-2-Block Control AdjustmentSee Figure 6-4. This is a limiting device designed to preventthe operator from hoisting the hook into the sheave.

CAUTION

IT IS IMPORTANT THAT THIS CONTROL BEPROPERLY ADJUSTED. FAILURE TO DO SOCOULD CAUSE EQUIPMENT DAMAGE.

CONSTANT

TENSION

PRESSURE

(1000 PSI)

P

CLUTCH

PRESSURE

(800 PSI)

CLUTCH PRESSURE

ADJUSTMENT

(PRESSURE REDUCING VALVE)

SET TO 800 PSI

R

T

CONSTANT TENSION

ADJUSTMENT

(SEQUENCE VALVE)

SET TO 1000 PSI

CT

MOTOR

END

TEMPORARY

TEE - FITTING

GAUGE PORT

(ON OPPOSITE SIDE)

HOIST

MOTOR

END

AM

C1

61

Figure 6-2 Constant Tension Winch Pressure Adjustment

6 - 6

1

6

3

7

24,5LEGEND

1. PROXIMITY

SWITCH

2. DOWNSTOP

WELDMENT

3. ARM

4. ROLLER

5. BEARING

6. SPRING

7. PLATE

AM

C 2

22

1/16"

Figure 6-3 Downstop Control Adjustment

1. Winch up until the hook ball begins to lift theweight (5). Secure the HPU.

2. With the weight just lifted by the hook ball, ensure thatthe spring (3) is able to move the sensor arm (2) near theproximity switch (1). Also inspect the cable for fraying ordragging as this would prevent the arm from moving when theweight is lifted.

3. Loosen the locknut on the proximity switch (1) and adjustthe switch by screwing it in or out until there is1/16" clearance between the switch face and the sensorarm (2). Tighten the locknut.

4. Start the HPU and winch down until the weight (5) ishanging freely. Ensure that the weight pulls the sensorarm (2) away from the proximity switch (1).

5. Carefully operate the davit to ensure that the winch stopsbefore the hook ball contacts the sheave case. Adjust the lengthof cable (4) if necessary.

6.2.6 Cable Tension Sensor AdjustmentSee Fig. 6-5. The cable tension sensor senses tension in thewinch cable inhibiting constant tension mode while there is aload on the cable.

1. Inspect the assembly for excessive wear on the roller whichmight prevent correct operation or adjustment. Replace anycomponents as required.

2. With slack in the cable, manually move the arm (2) untilit obstructs the proximity switch (1). Loosen the locknut on

the proximity switch (1) and adjust the switch by screwing it inor out until there is 1/16" clearance between the switch faceand the arm (2). Tighten the locknut.

6.3 REPAIRS

6.3.1 Swing Drive

6.3.1.1 RemovalSee Figure 6-6.

1. Secure the HPU and ensure that all pressure in hydrauliclines is relieved.

2. Disconnect all hydraulic hoses from the swing motor andbrake. 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 BEFOREREMOVING THE DRIVES.

3. Remove the eight capscrews (7) securing the swing driveto the davit.

4. Install lifting eyes in the gear reducer (3) housing andremove the swing drive using an overhead hoist. Place theunit in a clean work area for disassembly.

6 - 7

6.3.1.2 DisassemblySee 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 removeany traces of dirt.

2. Remove two capscrews (9A) and withdraw thebrake (2) from gear reducer (3). Discard gasket (11) frombetween brake and reducer.

3. Remove two capscrews (8) from pinion cap (5), andremove pinion (4).

6.3.1.3 AssemblySee Figure 6-6. Assembly is basically the reverse of disassembly.Install new gaskets (10) and (11) under the hydraulic motor(1) and brake (2). Tightencapscrews (7) to 85 lb-ft; tighten capscrews (8) to35 lb-ft; and tighten capscrews (9) and (9A) to 125 lb-ft.

6.3.1.4 Swing Motor DisassemblySee Figure 6-7. After removing hydraulic lines, cap or plug alllines and ports to prevent contamination and ensure workbenchsurface 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 portsfacing the jaws.

2. Remove four bolts (19) and end cover (17).

3. Shift wear plate (13) to clear end of drive link (12) andlift group [rotor assembly (14) and wear plate (13)] fromhousing (9).

4. Remove shaft (10) and drive link (12) from housing bypushing up on shaft end with palm of one hand and liftingshaft 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 upsidedown (mounting flange up) on workbench. This allows thrustbearings (7) and (8) to fall free. Next insert fingers throughdust seal (1) and push seal carrier (6) out the opposite endof the housing. Avoid marring the housing bore with the sealcarrier.

6. Mount housing assembly (9) in a vise, and using the gripend of a large screwdriver, tap dust seal (1) until it falls free.

7. With small screwdriver, carefully remove retainingring (2), seal (4) and shim (3).

6.3.1.5 Swing Motor AssemblySee Figure 6-7.

1. Wash all parts in clean solvent and discard seals.

1

3

LEGEND

1. PROXIMITY SWITCH

2. SENSOR ARM

3. SPRING

4. CABLE

5. WEIGHT

6. CABLE CLIP

AM

C 2

63

4

6

6

1/16"

2

5

Figure 6-4 Anti-2-Block Control Adjustment

6 - 8

2. Position housing with mounting flange up, and install anew seal (4) in groove.

3. Install shim (3) into groove next to seal (4).

4. Push retaining ring (2) into position.

5. Place housing in vise as in Disassembly step 1, clampedat port area with groove side up.

6. Place thrust bearings (7) and (8) on shaft (10) followedby the seal carrier assembly (6) with large diameter facingthe thrust bearings.

Figure 6-5 Cable Tension Sensor Adjustment

AM

C4

85

4

2 5 5

6

3

1

LEGEND

1. PROXIMITY SWITCH

2. TENSION ARM

3. ROLLER

4. ROD

5. SPRING

6. BASE

6 - 9

7. Install the drive link (12) into shaft (10). Align mark atroot of drive link tooth with mark on cupped end of shaft.Fill end of drive link with grease.

NOTE: If markings are indistinguishable, the rootof the drive link tooth should be placed with thedeeper slot of the output shaft to the right and 1/4"through hole to the left. Mark alignment asdescribed on end of drive link with soft pencil if nomarks appear.

8. Slide assembled shaft into housing (9). Shaft must beflush or slightly below housing.

9. Insert a lightly oiled O-ring (5) in groove of housing.

10. Place wear plate (13) on top of drilled end of housing,ensuring alignment of seven feed holes. Ensure alignmentgroove of wear plate is in direction of ports.

11. Insert a lightly oiled O-ring (5) in groove ofrotor (14). With seal side down, place rotor (14) over drivelink and align mark on drive link root with rotor valley(minimum diameter). Align mark on stator with slot in wearplate and verify alignment of seven feed holes with wear plateand housing. Align four bolt holes with housing and ensurethat seal stays in place.

NOTE: Counterbore on rotor faces away fromhousing.

12. Insert a lightly oiled O-ring (5) in end cover (17).

13. Press grease into recess in center of end cover face. Ifrecess 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 dislodgingO-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 androtate shaft to ensure the suction port is in the same directionof rotation.

6.3.1.6 Swing Brake DisassemblySee Figure 6-8.

1. Loosen the four 12-point capscrews (7) from the inputend of the brake. Alternately unscrew the bolts 1/2 turn at atime until all the internal spring force is relieved. Removethe cover (2).

CAUTION

DO NOT CLAMP OR OTHERWISE RESTRAINCOVER (2) WHILE REMOVING CAPSCREWS (7)SINCE THE BRAKE IS UNDER A HIGHCOMPRESSIVE LOAD.

2. Apply low air pressure, 20-30 psi, to the brake releaseport while holding one hand on top of the piston (3) andsprings (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 AssemblySee Figure 6-8. Assemble in reverse order of disassembly withthe following additional instructions:

LEGEND

1. HYDRAULIC MOTOR

2. BRAKE

3. GEAR REDUCER

4. PINION

5. PINION CAP

6. SHEAR BLOCK

7. CAPSCREW

8. CAPSCREW

9. CAPSCREW

9A. CAPSCREW

10. GASKET

11. GASKET

11

37

6

10

9A

4

5 8

1

AM

C 1

12

9

2


6 - 10

1. Install the shaft (4) by pushing shaft downward throughthe bearing (5) and seal (17) until shoulder on shaft is seatedagainst bearing.

NOTE: Soak new friction discs (10) in hydraulicoil for ten minutes before installation.

2. Install friction discs (10) and separator plates (11) inexactly the same order as they were removed with a frictiondisc (10) on each end. Avoid contaminating the frictionsurfaces with dirt, grease, or fluid other than that specifiedfor the hydraulic system.

NOTE: If a separator plate (11) is placed next tothe piston (3) the brake will overheat and seizeup.

3. Pour hydraulic oil over the stack until the fluid level iseven 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 nearesteach other and the two backup rings (12) and (13) are outsideof them. Gently slide the piston (3) into the case until thelarge O-ring (15) touches the case. Now press down firmlyon the piston with the heel of both hands to squeeze theO-rings into the case and seat the piston against the frictiondiscs.

5. Insert the springs (9) into the piston (3).

6. 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 covertouches the springs.

8. Start the four capscrews (7) through the cover and intothe case by hand. Alternately tighten 1/2 turn at a time untilthe cover is seated against the case and then torque the fourcapscrews (7) to 80 lb-ft.

6.3.1.8 Swing Gear Reducer DisassemblySee Figure 6-9.

1. Remove capscrews (36) from cover (32). Remove coverand thrust washer (31).

NOTE: Bolts assembled with Loctite may requireheating before removal.

2. Remove sun gear (30).

3. Remove primary carrier assembly (20).

4. Remove secondary carrier assembly (11).

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 AM

C 1

13

18

6

4

1

2

3

7

8

10

11

9

13

12

19

14

1516

17

5

Figure 6-7 Swing Motor

6 - 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 bearingcones (3) and (7). Remove shaft seal (2) from borein hub (5).

8. Inspect bearing cups (4 and 6) while they are still in thehub (5). Do not remove them unless replacementis required.

6.3.1.8.1 Primary Carrier DisassemblySee Figure 6-9.

1. Remove retaining ring (27) from pinion shaft (29).Mark the serrated pin on the shaft because spline variationsrequire them to be installed in the same position.

2. Catch planet gear (22), needle bearings (23) and thrustwashers (21) as the pinion shaft (29) is removed.

3. Repeat steps 1 and 2 for remaining planet gears.

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

6.3.1.8.2 Secondary Carrier DisassemblySee Figure 6-9.

1. Remove retaining ring (16) from pinion shaft (19).Mark the serrated pin on each shaft because spline variationsrequire them to be installed in the same position.

2. Catch planet gear (15), needle bearings (13),separators (14) and thrust washers (12) as the pinionshaft (19) is removed.


6.3.1.8.3 Primary Carrier AssemblySee Figure 6-9.

1. Install the larger diameter retaining ring (25) againstsun gear (26) shoulder. Slide sun gear splines into primaryplanet carrier (24), then insert the smaller diameter retainingring (28) in sun gear groove inside of the primary planet carrier.

2. Use a low melting point grease to hold the sixteen needlebearings (23) as they are inserted into planet gear bore.Centering pinion shaft (29) in planet gear bore will help alignneedle bearings.

3. Install a thrust washer (21) between planet gear (22) andcarrier faces as gears are assembled into carrier (24).

3

18

6

12

11

19

15

13

2

1614

10

4

17

9

7

8

1

5

AM

C1

14

LEGEND

1. CASE

2. COVER

3. PISTON

4. BRAKE SHAFT

5. BEARING

6. INPUT BEARING

7. CAPSCREW

8. PLUG

9. SPRINGS

10. FRICTION DISCS

11. SEPARATOR PLATES

12. BACKUP-RING

13. BACKUP-RING

14. O-RING

15. O-RING

16. O-RING

17. SEAL

18. GASKET

19. GASKET

Figure 6-8 Swing Brake

6 - 12

4. Align thrust washer tang with recess cast into carrier.

5. Insert pinion shafts (29) into carrier and through eachplanet gear (22). Install retaining ring (27) to secure shaft.Install assembled pinion shafts in the exact position fromwhich 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 AssemblySee Figure 6-9.

1. Use a low melting point grease to hold the sixteenneedle bearings (13) as they are inserted into one end ofeach planet gear bore.

2. Install separator (14) and a second set of sixteen needlebearings (13) into the other end of the planet gear bore.

3. Insert pinion shafts (19) into carrier and through eachplanet gear (15). Install retaining ring (16) to secure shaft.Install assembled pinion shafts in the exact position fromwhich they were removed.


6.3.1.9 Swing Gear Reducer AssemblySee 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 ofhub (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), andsecure with retaining ring (9).

NOTE: Retaining rings (9) of different thicknessesare available to set bearing end play. Select thethickest retaining ring that will fit in the groovewith the shaft/bearing group assembled. Allowableend play is 0.000" and 0.006".

5. Install secondary carrier assembly (11) over splines ofoutput shaft (1).

6. Apply a continuous 1/16" bead of RTV sealant to gasketface of hub (5).

7. Install ring gear (10) on hub (5) carefully aligning boltholes. 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 gasketface of ring gear (10).

9. Insert sun gear (30) in primary carrier assembly (20).

10. Install cover (32) on ring gear (10). Ensure the thrustwasher (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 CheckSee Figure 6-10.

1. Remove the Bearing from the davit and place it on aflat surface. Place the bearing so that the surface of the outerrace is in contact with the work surface.

2. Secure a C-clamp on the bearing as shown, and tightenthe clamp to remove any play.

6 - 13

3. Install a dial indicator 180 degrees from the C-clamp asshown and set the dial to zero (0).

4. Move the C-clamp to a position 180 degrees from itsoriginal position and tighten it to remove any play.

5. Observe the indicator reading. If the reading exceeds0.030" (0.77 mm), disassemble and inspect the bearing fordamage or signs of unusual wear.

6.3.1.10.2 Disassembly and Inspection

1. Remove the plug from the inner diameterof the bearing.

2. Rotate the inner race until a ball can be seen in thehole. Use a magnet to draw the ball from the hole, and thenextract the plastic spacer using needle nose pliers. Repeatthis process until all the balls and spacers are removed sothe outer and inner races can be separated.

3

20

SEE DETAIL B

6

5

2

13

4

1

34

36

11

SEE DETAIL A

8

10

32

31

33

7

14

1315

23

12

12

16

17

18

19 DETAIL A

2221

2821

2726

25

30

24

29DETAIL B

9

35

LEGEND

1. OUTPUT SHAFT 13. NEEDLE BEARINGS 25. RETAINING RING

2. SEAL 14. SEPARATOR 26. SUN GEAR

3. BEARING CONE 15. PLANET GEAR 27. RETAINING RING

4. BEARING CUP 16. RETAINING RING 28. RETAINING RING

5. HUB 17. PLANET CARRIER 29. PINION SHAFT

6. BEARING CUP 18. THRUST WASHER 30. SUN GEAR

7. BEARING CONE 19. PINION SHAFT 31. THRUST WASHER

8. THRUST WASHER 20. PRIMARY CARRIER ASSY 32. COVER

9. RETAINING RING 21. THRUST WASHER 33. PIPE PLUG

10. RING GEAR 22. PLANET GEAR 34. PIPE PLUG

11. SECONDARY CARRIER ASSY 23. NEEDLE BEARING 35. LOCKWASHER

12. THRUST WASHER 24. PLANET CARRIER 36. CAPSCREW

AM

C 1

15

Figure 6-9 Swing Gear Reducer

6 - 14

3. Inspect the balls and races for scoring, spallingor other damage. If damage is found, the bearingmust be replaced.

6.3.1.10.3 Assembly

CAUTION

ENSURE ALL PARTS ARE CLEAN AND FREE OFDAMAGE PRIOR TO ASSEMBLY.

1. Lubricate the balls and races with grease(MIL-G-24139) EP1 or EP2 as appropriate.

CAUTION

ENSURE THE NUMBER OF BALLS EQUALS THENUMBER OF SPACERS BEFORE ATTEMPTING TOASSEMBLE THE BEARING.

2. Carefully assemble the bearing, alternating balls andspacers to prevent the balls from touching each other.

3. Lubricate the assembled bearing before use.

6.3.1.11 Swing Drive InstallationSee Figure 6-11.

1. Lift swing drive with a hoist and carefully lower intoposition in davit base opening. Place swing drive so pinionengages gear teeth on swing bearing, and align hydrauliclines.

2. Install eight capscrews (7) through flange in gearreducer (3) into tapped holes in mounting ring on turret.Leave the capscrews loose for now.

3. Adjust pinion gear backlash by moving the swing driveuntil the backlash is 0.000" on the bearing high spot.

4. Tighten eight capscrews (7) to 85 lb-ft.

5. Install hydraulic lines to motor and brake.

6.3.2 Boom System

6.3.2.1 Boom Lift Cylinder Removal

1. Lower the boom onto a support, capable of supportingat least 4800 lbs. Secure the HPU.

THE CYLINDER MUST BE UNLOADED BEFOREDISCONNECTING HOSES/PIPES. REMOVE ANYLOAD FROM THE CYLINDER INCLUDING THEWEIGHT OF THE BOOM AND SECURE THEHYDRAULIC POWER UNIT. FAILURE TO FOLLOWTHESE INSTRUCTIONS COULD RESULT INEQUIPMENT DAMAGE, SEVERE PERSONALINJURY OR DEATH.

2. Disconnect hoses/pipes from the load lockvalve manifold. Plug or cap all lines and portsto prevent contamination.

3. Suspend a cable operated hoist from the boom, andusing a suitable choker or sling, attach the hook end to theboom lift cylinder at its midpoint.

4. Remove the lock collar capscrews and nuts. Using aslide hammer puller or drift pin, remove the stem end pin.

5. Lower the boom lift cylinder until it is level and removethe base end pin.

6. The boom lift cylinder can now be safely lowered tothe deck.

6.3.2.2 Boom Lift Cylinder Disassembly

1. Remove capscrews from packing gland, and removepacking gland from barrel.

2. Pull the stem and eye assembly from the barrel. Be carefulto avoid marring the inner surface of the barrel.

3. Clean all metal components thoroughly.

4. Remove nut from rod assembly.

NOTE: Nut is torqued to 2000 lb-ft (2712 N-m).

5. Remove piston, spacer and packing gland.

6. Inspect all metal components for damage. Examinesealing surfaces of the rod end and barrel for cuts andscratches. Small scratches may be polished out with fine emerycloth. Deeply scratched or gouged components must bereplaced.

6 - 15

7. Replace all seals and O-rings on both packing gland andpiston. Never reuse old seals. Coat O-rings with petroleumjelly before installing.

6.3.2.2.1 Piston Seal Replacement

1. Remove old seal from piston by cutting it with aknife. 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 shownin Figure 6-12. Lubricate seal and installation cone withpetroleum jelly.

4. Turn the nut until the seal slides up the cone and dropsinto the seal groove in the piston.

AM

C2

02

VIEW A

VIEW B

LEGEND

1. HYDRAULIC MOTOR

2. BRAKE

3. GEAR REDUCER

4. PINION

5. PINION CAP

6. SHEAR BLOCK

7. CAPSCREW

8. CAPSCREW

9. CAPSCREW

9A. CAPSCREW

10. GASKET

11. GASKET

11

37

6

10

9A

4

5 8

1

AM

C 1

12

9

2

Figure 6-10 Swing Bearing Inspection


6.3.2.3 Boom Lift Cylinder AssemblyReassemble the boom lift cylinder in the reverseorder of disassembly.

6 - 16

1. Tighten the piston nut to 2000 lb-ft (2712 N-m).

2. Tighten the packing gland capscrews to210 lb-ft (285 N-m).

6.3.2.4 Boom Lift Cylinder Installation

1. Suspend the boom lift cylinder from the boom. Hoist itup to a level position and insert the base end pin.

2. Hoist the stem end of the boom lift cylinder intoposition and using a hoist, install the stem end pin.

3. Install lock collar capscrews and nuts. Tightencapscrews and nuts to 124 lb-ft (168 N-m).

4. Carefully connect hoses/pipes and verify properconnection before applying hydraulic power.

5. Perform boom system test in accordance with paragraph5.2.5.

6.3.3 Constant Tension Winch

6.3.3.1 RemovalSee Figure 6-13.

1. Remove the cable and cable wedge. Refer to paragraph6.3.3.9.

2. Relieve all pressure in the hydraulic system before anylines, fittings, or related items are disconnectedor removed.

3. Drain all the oil from the winch.

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

CAUTION

BEFORE HOSES AND LINES ARE REMOVED,MANIFOLDS, HOSES, LINES AND PORTS SHOULDBE TAGGED FOR IDENTIFICATION TO ENSUREPROPER REINSTALLATION. IF HYDRAULICPRESSURE AND RETURN LINES ARE REVERSED,THE WINCH WILL BE DAMAGED.

5. Secure a lifting chain or strap to the winch, and using asuitable overhead hoist with a lifting capacity of at least 1600lbs, support the winch. Remove the four mounting bolts (11)and nuts (12), and lower the winch. Move it to a clean work

area. A rotating holding fixture is recommended fordisassembly and assembly procedures.

DISASSEMBLY AND REPAIR OF THIS WINCHSHOULD NOT BE ATTEMPTED BY OTHER THANFACTORY TRAINED PERSONNEL. BECAUSE ITREQUIRES EXACT PROCEDURES AND THE USE OFSPECIAL TOOLS, IT IS RECOMMENDED THAT THEWINCH BE RETURNED TO THE FACTORY OR TOAN AUTHORIZED REPAIR FACILITY FOR MAJORREPAIRS. POTENTIAL FOR PERSONAL INJURYAND/OR DAMAGE TO WINCH COMPONENTSEXISTS.

NOTE: See Table 6-1 for special tools required forwinch repairs.

6.3.3.2 Disassembly

6.3.3.2.1 Constant Tension Motor EndDisassemblySee Figs. 6-22 and 6-23.

1. Mount winch to a suitable rotating workstand. Orientwinch so that constant tension end is up.

2. Remove four capscrews (47). Remove motor (4) andspacer (19).

3. Remove 10 capscrews (45) and removehousing (20) from frame (7).

4. Remove bearing (26) from housing (20) or fromhub (17) using bearing puller.

5. Remove oil seal (36) from housing (20). Remove anygasket sealant from housing.

NOTE: A new seal must be fitted at assembly.

6. Remove 10 capscrews (48) and remove hub (17) fromdrum (6). Jacking screw holes are provided.

6.3.3.2.2 Load Motor End DisassemblySee Figs. 6-17.

1. Orient winch so that the main hoisting motorend is up.

2. Install spring compressor. See Figure 6-14.

6 - 17

NUT

WEAR STRIP

PISTON

SEAL

PISTON

O-RING

STEM

BUSHING

EYE

SEAL

WIPER

RING

O-RING

SPACER

PACKING

GLAND

STEM & EYE

ASSEMBLY

FLATWASHER, 3/4

(P/N 00103346)

INSTALLATION SLEEVE

(P/N 33541)

SPLIT RING

(P/N 33544)

INSTALLATION CONE

(P/N 33545)

SEAL

PISTON

THREADED ROD

3/4 NC X 15"

(P/N 34197)

NUT, 3/4 NC

(P/N 00220081)

BARREL

BASEBUSHING

CAPSCREW

(10)

WEAR STRIP

AM

C1

84

SEAL REPLACEMENT TOOL KIT

NOTE: ENSURE SEAL LIP FACES DOWN

Figure 6-12 Boom Lift Cylinder

6 - 18

USE EXTREME CAUTION WHEN WORKING WITHCOMPRESSED SPRINGS. USE ONLYAUTHORIZED SPECIAL TOOLS/FIXTURES.

3. Remove the two nuts (13) and capscrews (43) and liftthe main hoist motor (1) off the studs (54).

4. Remove the studs (54).

5. Remove the brake (2).

6. Remove twelve capscrews (44) and removecover from reducer assembly (3). Remove twospacers (52 and 53).

7. Lift out gear reducer assembly (3). Remove any sealantfrom sealing surfaces.

8. Remove shim (56) from gear reducer (3).

9. Remove spacer (5) from winch. Remove any sealantfrom sealing surfaces.

10. Remove spacer (50) from inner step of spacer (5).

6.3.3.2.3 Spacer RemovalSee Figure 6-12.

1. Orient winch 180 degrees so that Constant Tension endis up.


2. Compress the springs using a port-a-power between thespring compressor and hub (17). See Figure 6-14.

3. Remove the hub retaining ring (33).

4. Install CT winch hub retainer. See Figure 6-12. Orientwinch 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 RemovalSee Figure 6-12.

1. Adjust screw on CT winch hub retainer, to retain hub.

2. Remove four capscrews (59) and cover (11).

NOTE: Record the position of oil ports forassembly.

3. Remove O-ring (40), backup rings (41), O-ring (38)and fittings (35) from cover (11).

4. Remove piston (12) from hub (8).

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) fromframe and drum assembly.

8. Remove bearing cone (31) and bushing (16) fromhousing (14).

6 - 19

Figure 6-13 Manifold Installation

12

11WINCH MOUNTING

PLATE

AM

C4

82

8

410

3

1

4

6

9

2

7

5

6

3

LEGEND

1. ELECTRICALLY OPERATED RELIEF VALVE

2. CHECK VALVE

3. PRESSURE REDUCING VALVE

4. SEQUENCE VALVE

5. MANIFOLD

6. MANIFOLD

7. SUB PLATE

8. SHUTTLE VALVE

9. COUNTERBALANCE VALVE

10. SOLENOID VALVE

11. BOLTS (4)

12. NUTS (4)

6 - 20


6 - 21

6.3.3.2.5 Drum and Brake DisassemblySee Figure 6-17.

1. With the main hoist motor end up, install Main winchhub retainer. See Figure 6-15.

2. Orient winch so that constant tension motorend is up.

3. Remove ring (15).

4. Beginning with a friction disc (27), alternately removenine friction discs and eight separator plates (28).

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

6. With the constant tension end is up, remove drumassembly from frame (7).

7. Remove main winch hub retainer from main hoistmotor end of frame.

8. Clean exposed oil seal surface.

9. Remove oil seal (37) and clean off any excess gasketsealant.

10. Remove bearing cup (32) and spacer (18) fromdrum (6).

NOTE: Treat all unpainted mating surfaces withcosmoline if the winch is not to be reassembledimmediately.

DISASSEMBLY AND REPAIR OF THIS WINCHSHOULD NOT BE ATTEMPTED BY OTHER THANFACTORY TRAINED PERSONNEL. BECAUSE ITREQUIRES EXACT PROCEDURES AND THE USEOF SPECIAL TOOLS, IT IS RECOMMENDED THATTHE WINCH BE RETURNED TO THE FACTORY ORTO AN AUTHORIZED REPAIR FACILITY FORMAJOR REPAIRS. POTENTIAL FOR PERSONALINJURY AND/OR DAMAGE TO WINCHCOMPONENTS EXISTS.

NOTE: See Table 6-1 for special tools required forwinch repairs.

6.3.3.3 Assembly

NOTE: Treat all threaded fasteners with anti-seizecompound (MIL-A-907A).

HYDRAULIC

PORT-A-POWER

P/N P39/RCH202 (ENERPAC)

RETAINING

RING

SPRINGS

HUB

SPRING

COMPRESSOR

P/N 41729

AM

C1

56

CT WINCH

HUB RETAINER

P/N 41727

CONSTANT

TENSION

MOTOR

END UP

AM

C1

57

Figure 6-14 Spring Compresser Installation

Figure 6-15 Constant Tension Winch Retainer Installation

(6-20 blank)/ 6 - 21

6 - 22

6.3.3.3.1 Drum and Brake AssemblySee Figs. 6-17.

1. Mount frame (7) to rotating workstand.

2. Install fitting (55) in drum (6) and apply PST sealant.

3. Fit spacer (18) into drum (6). The lip on the spacermust 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 sealdriver. Seal with sealing compound(MIL-S-45180). Seal lip must face the inside of thedrum (6). Treat exposed oil seal surface with cosmoline.

6. Fit drum assembly into frame (7). Add three spacersunder drum to center. Install Main winch hub retainer, to mainhoist motor end of frame.

7. Orient frame so that constant tension motor end is up.

8. Insert hub (8), large end up, into drum (6). Rest smallend onto adjusting screw of hub retainer.

9. Beginning with a friction disc (27), alternately installnine friction discs and eight separator plates (28).

NOTE: Missing teeth in friction discs (27) must alignwith 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).

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 InstallationSee Figs. 6-23 and 6-24.

1. Drive bearing cone (31) onto housing (14). Pressbushing (16) into housing (14).

2. Treat exposed and mating surfaces with cosmoline.

3. Lubricate seal lip and fit housing assembly overhub (8) and into frame and drum assembly.

4. Orient housing (14) to align cover (11) mounting holesat 1:30, 4:30, 7:30 and 10:30 positions.

5. Secure housing to frame with 12 capscrews (46) treatedwith anti-seize compound (MIL-A-907A). Torque to45 lb-ft.

6. Install three springs (29) into housing (14), overhub (8). Place the first spring with the center high side facingdown, 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) ontopiston (12).

8. Fit piston assembly into the housing (14) so that it restssquarely on the springs (29).

9. Fit O-ring (40), backup rings (41), O-ring (38) andfittings (35) into cover (11).

10. Fit cover assembly (11) to housing (14); positionhousing oil ports at 3:30 and 9:30 positions. Secure with fourcapscrews (59). Torque to 36 lb-ft.

11. Tighten adjusting screw on CT winch hub retainer untilhub is at its highest point.

CAUTION

DO NOT OVER TIGHTEN.

6.3.3.3.3 Spacer InstallationSee Figure 6-24.

1. Install spacer (10) and drive bearing assembly (30) usingdriver.

NOTE: The larger ID of the bearing faces down.

2. Fit spacer (9) to hub (8) and secure with retainingring (34).

MAIN WINCH

HUB RETAINER

P/N 41721

MAIN

WINCH

MOTOR

END UP

AM

C1

58

Figure 6-15 Main Winch Hub Retainer Installation

6 - 23

3. See Figure 6-15. Install spring compressor. Orient winchso that constant tension motor end is up.


4. Remove the CT winch hub retainer and compress thesprings, using a port-a-power between the spring compressorand hub (8).

5. Secure the hub (8) with retaining ring (33).

6.3.3.3.4 Load Motor End AssemblySee Figure 6-24.

1. Orient winch so that the hoist motor end is up.

2. Remove spring compressor.

3. 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), firstremove the thrust washer cemented inside the newgear reducer cover.

6. Install spacer (53) and spacer (52).

7. Install gear reducer cover (3). Seal with Loctite “UltraBlue” and secure with 12 capscrews (44). Torque to35-40 lb-ft.

8. Install two studs (54) in gear reducer cover (3).

9. Install brake (2) over studs (54). Make sure that thereis a new gasket and O-ring at each end of the brake.

10. Install main hoist motor (1) over studs (54) and securewith two nuts (13) and two capscrews (43). Torque to45 lb-ft.

6.3.3.3.5 Constant Tension Motor End AssemblySee Figure 6-24.

1. Orient winch so the constant tension motor 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 tencapscrews (48). Torque to 20 lb-ft.

4. Fit oil seal (36) into housing (20). Coat OD of seal withsealant (MIL-S-45180) before installation. Lubricate seal lipbefore installation.

5. Fit housing assembly (20) into frame (7) and securewith ten capscrews (45). Torque to 20 lb-ft.

NOTE: Orient housing so that the motor mountinghole pattern is aligned with the frame mountingsurface.

6. Drive bearing (26) into housing (20) and onto hub (8)using driver.

7. Install spacer with larger diameter up (19).

8. Coat mating surface of constant tension motor (4) withLoctite “Ultra Blue” sealant. Install motor (4) and securewith four capscrews (47). Torque to 45 lb-ft.

NOTE: Treat any unpainted surfaces withcosmoline.

BRAKE RING

RETAINER

P/N 41726

CONSTANT

TENSION

MOTOR

END UP

AM

C1

59

Figure 6-17 Brake Ring Retainer Installation

6 - 24

6.3.3.4 Load Motor

6.3.3.4.1 DisassemblySee Figure 6-18.

CAUTION

IF PRYING SECTIONS APART IS NECESSARY,AVOID MARRING OR DAMAGING MACHINEDSURFACES. EXCESSIVE FORCE WHILE PRYINGCAN RESULT IN MISALIGNMENT AND SERIOUSLYDAMAGE PARTS.

GEARS ARE CLOSELY MATCHED ANDTHEREFORE MUST BE KEPT TOGETHER AS SETSWHEN REMOVED FROM A UNIT. HANDLE WITHCARE TO AVOID DAMAGE TO THE JOURNALS ORTEETH.

1. Mount the motor in a vise with the shaft end pointingdown. Index mark all sections with a punch. Be sure to alignthese marks when reassembling.

2. Remove the four capscrews (16) and washers (17) with asocket 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 thegear housing (3), it can be tapped out later with a woodenhammer handle. Be careful not to distort the thrust plate.

4. Pry the gear housing (3) from the gears (2) and off thedowels (14) from opposite sides taking care not to damagemachined 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 thrustplates for wear or damage and replace if necessary. Removeand 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 bearingswith a bearing puller.

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

11. THRUST PLATE

12. POCKET SEALS

13. GASKET SEAL

14. DOWEL PIN

15. SEAL RETAINER

16. CAPSCREW

17. WASHER

2

4

7

13

15

6

5

8

11

10

12

1

9

14

3

13

14

11

12

10

9

17

14

16

14A

MC

14

9

Figure 6-18 Load Motor

6 - 25

7. It is generally advisable to replace ring seals (9) whenrebuilding unit. To replace, remove the drive gearbearing (10) with a bearing puller and remove ring seal fromthe bottom of bearing bore.

8. Place the shaft end cover (1) in a vise with the mountingface up. Remove the bearing snap ring (5) with a smallscrewdriver or awl.

9. Use a bearing puller to remove outboard bearing (6).

10. Grip the shaft end cover (1) in a vise with the mountingface down. Remove the double lip seal (7). Tap the seal outand discard.

6.3.3.4.2 InspectionSee Figure 6-18.

1. Gear Housing (3) - Wear in excess of 0.005" cutoutnecessitates replacement of the gear housing. Place astraightedge across bore. If you can slip a 0.005" feeler gageunder the straightedge in the cutout area, the gear housingrequires replacement. Where wear is moderate, 0.005" orless, gear housing is in good condition, and both ports are ofthe same size, housing may be flopped over and reused.

2. Gear Sets (2)- Any wear on gear hubs detectable bytouch, or in excess of 0.002" necessitates replacement.Scoring, grooving, or burring of outside diameter of teethrequires replacement. Nicking, grooving, or fretting of teethsurfaces also necessitates replacement. Wear in the shaft sealareas indicate oil contamination. Wear or damage to splinesnecessitates replacement.

3. Thrust plates (11) - The thrust plates seal the gearsection at the sides of the gears. Wear here will allow internalslippage, that is, oil will bypass within the pump. Maximumallowable wear is 0.002". Replace thrust plates if they arescored, eroded or pitted. Check center of thrust plates wherethe gears mesh. Erosion here indicates oil contamination.Pitted thrust plates indicate cavitation or oil aeration.Discolored thrust plates indicate overheating, probablyinsufficient oil.

4. Dowel pins (14) - If either the dowel pin or dowel holeis damaged, the pin or machined casting, or both, must bereplaced. If more than reasonable force is required to seatdowels, 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, bearingsmust be replaced. Bearings should fit into bore with a lightpress fit. A neat hand fit is allowable. If bearings can fallout, bore may be oversize.

6. Seals and gaskets - Replace all rubber and polymer sealswhenever disassembling pump. Include all O-rings, pocket

seals behind thrust plates, shaft seal and gasket seals.

7. Check valve (8) - Examine small check valve in shaft endcover (1) to ensure it is intact and functioning.

6.3.3.4.3 AssemblySee Figure 6-18.

CAUTION

IF PARTS ARE STUBBORN DURING ASSEMBLY,DO NOT FORCE THEM AND NEVER USE AN IRONHAMMER.

NEVER HAMMER ROLLER BEARINGS INTOBORES. USE ONLY AN ARBOR PRESS OR OTHERSUITABLE TOOL.

1. Stone off all machined surfaces with a medium gritcarborundum stone.

2. If bearings (6,10) have been removed, deburr bearingbores. Rinse parts in a solvent. Air blast all parts and wipewith a clean lint free cloth before starting assembly. Reinstallbearings by pressing them into bearing bores with an arborpress.

3. Grip shaft end cover (1) in vise with mounting facedown. Examine check valves (8) to be sure they're tightly inplace. 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 bottomof drive gear (2) bearing bore. The notch in the ring sealmust be visible. This is a check to be certain the notchedside is next to the bearing.

5. Before inserting a new lip seal (7) in the shaft endcover (1), coat the outer edge of the lip seal and its recesswith Permatex Aviation Form-A-Gasket No. 3 non-hardeningsealant or equivalent. With the metal side of the lip seal up,press it into the mounting flange side of the shaft end coverwith an arbor press and bar. Do not attempt to bottom-outseal; 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.

7. Grip the shaft end cover (1) in a vise with the mountingface down. Cut two pocket seals (12) 7/32" long from thepocket seal strip. Grease these pocket seals well and insertthem into the middle slots on the reverse side of the thrustplate (11).

6 - 26

8. With the pocket seals (12) facing down, place the thrustplate (11) over the bearings in the shaft end cover (1). Tapthrust plate with a soft hammer to about 1/32" from themachined surface.

9. Cut four pocket seals (12) approximately 1/4" long fromthe pocket seal strip. Insert one pocket seal into each of theslots in the thrust plate. Push each pocket seal all the way inso that it touches the roller bearings. Tap the thrust platedown firmly against the machined surface with a softhammer. Use a sharp razor blade to trim exposed end of thepocket seal square and flush with the thrust plate.

CAUTION

TEMPORARILY COVER THE SPLINED PORTIONOF THE INTEGRAL GEAR AND DRIVE SHAFT (2)WITH A PROTECTIVE SLEEVE BEFOREINSERTING SHAFT THROUGH DOUBLE LIPSEAL (7). FAILURE TO DO SO WILL DAMAGE THELIP SEAL.

10. Insert the integral gear and drive shaft (2) with sleeveinto the shaft end cover (1) with a twisting motion. Be carefulnot to damage the double lip seal. Push down carefully untilthe gear rests against the thrust plate (11). Remove thesleeve. Insert the driven gear.

11. Grease the new gasket seals (13) and insert them intothe grooves in both sides of the gear housing (3). Examineall dowel pins (14). Before inserting a pin, make certain thehole is clean and free from burrs. Start pin into hole gentlyand straight, tapping lightly with a soft hammer.

12. Slide gear housing (3) over the gears (2) and tap it witha soft hammer until it rests tightly against the shaft endcover (1). Be careful not to pinch the gasket seal (13). Squirtoil over the gears to provide initial lubrication when pumpis started. Line up the dowels (14) with the matching holes.When parts are parallel, squeeze them together or gentlytap alternately over dowels with a plastic hammer until theparts become parallel and move smoothly together. Do notforce.

13. Place the port end cover (4) over the gear journals andtap tightly against the gear housing (3). Be careful not topinch the gasket seal (13). Align the dowels with the holesin the mating casting. Being careful not to pinch the gasketseal, tap the port end cover lightly in the center betweenbearing bores to engage the dowels and to move partstogether in final seating.

14. Thread the four cap screws (16) and washers (17) intothe shaft end cover and tighten alternately or cross-corner.Rotate the drive shaft with a 6" wrench to make certain thereis no binding in the pump.

15. Guide the outboard bearing (6) into its recess in the shaftend 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, torquediagonally opposed fasteners to 200 lb-ft.

6.3.3.5 Constant Tension Motor


1. Remove snap ring (1).

2. Pry out seal plate (2) with two screwdrivers. Removeseal 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 beinstalled upside down. Secure the motor and loosen andremove the 5/8" bolts (9).

4. Remove front housing (10).

NOTE: Two 5/32" ball checks (22) and one mainbody O-ring (12) may fall out.

5. Press shaft (8) and ball bearing (7) out of fronthousing (10).

6. Remove snap ring (6) from shaft (8). Press shaft out ofbearing.

7. Lift up rotor/stator assembly (15 - 21) and remove fromthe rear housing (24).

8. Place assembly on any object which will hold it off thetable. Remove two each plate screws (13). Remove timingplate (14).

9. Remove O-ring (12) and springs (16, 20, 21) with a smallscrew 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 InspectionSee Figure 6-19.

1. If any wear on either seals or springs is detected, replacewith new parts.

2. Inspect all parts and replace any which obviously showexcessive wear or damage.

6 - 27

3. Inspect the vanes (17 and 19) for excessive wear. Normalwear results in slight flattening of vane tips, which does notimpair motor performance. Replace vane if outside radius isreduced by 50%.

NOTE: There is normally 0.010" clearance betweena vane and a vane slot.

4. Inspect the timing plates (14) for excessive wear.Normal wear results in marking of timing plates which doesnot impair motor performance.

5. Inspect the rotor (18) for excessive wear or damage.Normal wear results in polishing of rotor faces which doesnot impair motor performance.

6. Inspect the stator (15) for excessive wear or damage.Normal wear results in polishing of cam form which doesnot impair motor performance.

7. Measure the rotor and stator length to the fourthdecimal point, and supply measurement when ordering rotor,stator, or vanes.


1. Place the stator (15) on a raised surface, and place therotor (18) inside the stator. Install stator vanes (17) and rotorvanes (19) in their slots.

NOTE: Make sure that the radiused edge of eachstator vane points to the rotor, and the radiusededge of each rotor vane points to the stator.

2. Install two front dowel pins (11) in the stator. Using asmall screw driver, install the vane springs.

NOTE: Make sure springs are seated in the bottomof the spring pocket in both the rotor and stator.

3. Install O-ring (12) and timing plate (14). Install twotiming plate screws (13).

4. Turn assembly over and repeat steps 1 through 3, exceptinstall rear dowel pins (5).

5. Install ball checks (22) into rear housing. Install mainbody O-ring (12).

Figure 6-19 Constant Tension Motor

6 - 28

6. Place rotor/stator assembly onto rear housing (24).

NOTE: Ensure assembly marks from disassemblyprocedure are aligned.

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 fronthousing (10). Press seal plate (2) into front housing. Installsnap ring (1).

10. Install main body O-ring (12) into front housing (10).Install ball checks (22) into front housing. Place a smallamount of grease over ball checks and O-ring. Wipe off anyexcess grease.

11. Pour a small amount of clean hydraulic oil into therotor/stator assembly. Install front housing (10) onto therotor/stator assembly. Make sure the alignment marks fromdisassembly are lined up.

12. Install 5/8" bolts (9) and tighten to 50 lb-ft. Rotate theshaft in both directions to assure that the shaft turnssmoothly. Now tighten the bolts (9) to 175 lb-ft. Rotate theshaft again in both directions to verify that the shaft stillturns smoothly.

6.3.3.6 Winch Brake


1. Remove two capscrews (4). A suitable holding fixtureis useful to keep brake in position.

2. Tap female end of spline shaft assembly (7 - 13) andspring plate (20) with soft mallet to separate cover. If sectionswill not separate, use a screwdriver to carefully pry sectionsapart.

3. Remove retaining ring (2) from spline shaftassembly (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) isrequired, 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 removedfrom spline shaft (13) as a subassembly.

7. Remove retaining ring (8) from outer spline (11) thenslide bearing (9) and sprag bearing (10) out of outerspline (11). Noting direction of individual sprags in spragbearing (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 outerspline (11) is not recommended. If needle bearingrequires servicing, contact factory for furtherinformation.

8. Remove retaining ring (1) from cover (6) and press outoil seal (5) and bearing (3) if required.

9. Remove four capscrews (14). A suitable holding fixtureis useful to hold brake in position.

CAUTION

DO NOT REMOVE CAPSCREWS (14) WITHOUTPRESSURIZING BRAKE TO APPROXIMATELY 300PSI.

10. Before removing primary disc (15), rotor discs (16) andstator discs (17), note pattern for assembly purposes.

11. Release the pressure to brake before removing the fourcapscrews (18).

12. Remove spring plate (20).

13. Remove gasket (19) from spring plate (20).

14. Before removing springs (21), note pattern and colorfor reassembly purposes.

15. Remove piston (22) by carefully exerting hydraulicpressure through brake release port on pressure plate (27).

16. Remove O-rings (24 and 26) and backuprings (23 and 25) from piston (22).

NOTE: Avoid scratching or marring piston.

17. Remove gasket (19) from pressure plate (27).


NOTE: Lubricate all rubber components from repairkit with clean hydraulic fluid of the same type usedin the hydraulic system.

6 - 29

1. Clean all parts thoroughly before assembling.

2. Press seal (5) into bore until it is flush with bearingshoulder. Seal (5) must be installed with closed side facingpilot end of cover (6).

3. Press bearing (3) into position until it bottoms out onoil 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) toform outer spline subassembly.

6. With spline shaft (13) sitting upright on a flat surface,take outer spline subassembly and carefully place over splineshaft (13) making sure that sprag bearing (10) slides freelyover spline shaft (13).

7. While holding outer spline (11) stationary, splineshaft (13) must rotate freely in the counterclockwise directionwhen 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).

9. Install retaining ring (7) onto spline shaft (13) andretaining ring (8) into outer spline (11) to complete splineshaft assembly (7 - 13).

10. Press spline shaft assembly (7 - 13) into bearing (3)until shaft bottoms on shaft shoulder. Bearing inner racemust be supported during this operation.

11. Install retaining ring (2) on spline shaftassembly (7 - 13).

12. Install backup rings (23 and 25) on piston (22) towardsspring pockets.

13. Install O-rings (24 and 26) on piston (22). EnsureO-rings are flat and all twists removed.

NOTE: Avoid scratching or marring piston.

14. Lubricate piston (22) with clean hydraulic fluid of thesame type as is used in the hydraulic system. Carefully presspiston into pressure plate (27). Be sure piston is orientedsuch that threaded holes in piston are in alignment withthrough holes in spring plate (20) when installed.

NOTE: Alternate different colored springs.

1

5

3029

23

4

286

78

910

1112

13

1415

1617

27

19

2625

2423

22

21

20

19

18

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 AM

C1

53

Figure 6-20 Winch Brake

6 - 30

15. Affix gaskets (19) to pressure plate (27) and springplate (20).

16. Place unit on a press. Using a suitable fixture, depressand install four shouldered capscrews (18) with two dropsof thread locking compound (MIL-S-22473E) applied toeach capscrew. Torque bolts to 35 - 40 lb-ft. A suitable holdingfixture is useful to hold brake in position.

17. Install stator discs (17) and rotor discs (16) in samesequence 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 shoulderedcapscrews (14) with two drops of thread locking compound(MIL-S-22473E) applied to each capscrew. Inspect for freemovement of stack. Pressurize brake release port toapproximately 300 psi to release discs. Torque shoulder boltsto 15 - 18 lb-ft and release pressure. A suitable holding fixtureis useful to hold brake in position.

20. Install cover (6) using capscrews (4) with two drops ofthread locking compound (MIL-S-22473E) applied to eachcapscrew. Torque bolts to 9 - 11 lb-ft.

CAUTION

IF HYDROSTATIC BENCH TESTING ISPERFORMED ON THE BRAKE ASSEMBLY,RELEASE PRESSURE SHOULD NOT EXCEED1000 PSI UNLESS FOUR ADDITIONAL BOLTS AREUSED FOR SUPPLEMENTAL CLAMPING.

6.3.3.7 Winch Gear Reducer

6.3.3.7.1 Gear Reducer DisassemblySee Figure 6-21.

1. Remove cover (22) and spacer (25).

2. Remove sun gear (21) and spacer (26).

3. Remove primary carrier assembly (11).

4. Remove secondary carrier assembly (2).

6.3.3.7.2 Primary Carrier DisassemblySee Figure 6-21.

1. Remove retaining ring (19) holding a pinion shaft (15).Mark the serrated pin on each shaft so they may be replacedas described at reassembly.

2. Catch planet gear (13), needle bearings (18) and thrustwashers (14) as each pinion shaft (15) is removed.


4. Remove the retaining ring (16) from sun gear (12)groove inside primary planet carrier (20). Pull sun gear fromcarrier splines.

6.3.3.7.3 Secondary Carrier DisassemblySee Figure 6-21.

1. Remove retaining ring (10) retaining a pinion shaft (8).Mark the serrated pin on each shaft so they may be replacedas described at reassembly.

2. Catch planet gear (7), needle bearings (5),separator (6), and thrust washers (4) as each pinion shaft(8) is removed.


6.3.3.7.4 Primary Carrier AssemblySee Figure 6-21.

1. Install the larger diameter retaining ring (17) againstsun gear (12) shoulder. Slide sun gear splines into primaryplanet carrier (20), then insert the smaller diameter retainingring (16) in sun gear groove inside of the primary planetcarrier.

2. Use a low melting point grease to hold the sixteenneedle bearings (18) as they are inserted into planet gearbore. Centering pinion shaft (15) in planet gear bore willhelp align needle bearings.

3. Install a thrust washer (14) between gear (13) andcarrier faces as gears are assembled into carrier (20).

4. Align thrust washer tang with recess cast into carrier.

5. Insert pinion shafts (15) into carrier and through eachgear (13). Install retaining ring (19) to secure shaft. Installpinion shafts in the exact position from which they wereremoved.


6.3.3.7.5 Secondary Carrier AssemblySee Figure 6-21.

1. Install thrust washer (9) in recess inside of carrier (3).

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

6 - 31

3. Install a separator (6) and a second set of sixteen needlebearings (5) into the other end of the planet gear bore.

4. Insert pinion shafts (8) into carrier and through eachgear (3). Install retaining ring (7) to secure shaft. Installpinion shafts in the exact position from which they wereremoved.


6.3.3.7.6 Gear Reducer AssemblySee Figure 6-21.

1. Place ring gear (1) on clean work surface.

2. Place secondary carrier assembly (2) into bore of ringgear, 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 thesecondary carrier assembly (2).

4. Install spacer (26) into bore of small sun gear (21) andinstall spacer (25) over other end of small sun gear. Installthis assembly, with teeth of small sun gear meshing withplanet gears (13) into primary carrier assembly (11).

5. Install the shim (27) and cover (22). Do not use sealantat this time. Temporarily bolt the assembly together using5-1/2" long capscrews and nuts.

6.3.3.8 Winch InstallationSee Figure 6-13.

1. Secure a lifting chain or strap to the winch, and using asuitable overhead hoist with a lifting capacity of at least 1600lbs, lift the winch and move it into position on the davit.Install the four mounting bolts (11) and nuts (12) and tightento 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 paragraph6.3.3.9.

3. Fill winch with the proper oil. Refer to Chapter 4.

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

2 (ITEMS 3-10)

15

11

(ITEMS 12-20)1

10

23

56

57

4

8

14

19

1814

16

3

9

1217

20

13

4

26

21

27

2224 25

AM

C 1

54

Figure 6-21 Winch Gear Reducer

6 - 32

4. Install all hydraulic lines. Start davit and allow system towarm up and air to pass through the lines to the tank. Checksystem for leaks.

5. Install the hook and related reeving components.

6.3.3.9 Winch Cable InstallationSee Figure 6-22.

CABLE CLAMPS ALONE ARE NOT DESIGNED TOHOLD RATED LOADS. NEVER OPERATE THEDAVIT WITH FEWER THAN THREE COMPLETEWRAPS OF CABLE ON THE DRUM.

NOTE: The winch cable should not be installed ontothe drum until initial adjustments have been madeas instructed in paragraph 6.2.3.

1. Insert the cable from the inside of the drum into thesmall hole in the drum flange and pass the free end throughthe small opening in the wedge pocket.

2. Loop cable by pushing the free end back through thepocket and install a cable clamp on the dead end.

3. Insert the cable wedge in the loop with the small endtoward the drum and pull slack out of the cable through thedrum.

4. The cable wedge will slip into the pocket to secure thecable onto the drum.

AM

C2

93

CABLE CLAMP

LOAD

HYDRAULIC

MOTOR

CABLE DRUM

CABLE

WEDGE

CABLE

WEDGECONSTANT

TENSION

HYDRAULIC

MOTOR

Figure 6-22 Winch Cable Installation

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


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

6 - 33 / (6 - 34 blank)


AM

C4

40

3329

3

1

44

3

5556

505

43

13

53

54

59

39

52

8

42

6

2

3839

41

12

58

40

10

38

41

35

38

30

29

11

37

18

16

45934

14

19

27

31

32

28

46

1560

17

36

26

47

20

4

48

7


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



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

6 - 35 / (6-36 blank)

Figure 6-23 Constant Tension Winch Sectional View

14

3

44

56

55

93

73

1,3

21

74

84

0,4

15

0

33

51

11

64

5 20

26

55

58

8

13

,54

2

38

39

53

34

93

01

2

35

10

46

14

29

18

28

27

15

33

36

47

4

19

52

42

6

7

VIE

W A

-A

AA

AM

C4

41

Figure 6-24 Constant Tension Winch Sectional View

7 - 1

CHAPTER 7PARTS LIST

“A/R” (as required) identifies bulk items whose length or otherdimension must be specified when requisitioning.

“Ref” identifies items shown for reference purposes onlyto illustrate their relationship to other systems.

“NSS” (not sold separately) identifies items such as valvehousings and spools, ring gears and pinions, etc., which mustbe ordered as a set because they are closely mated atmanufacture.

7.2.5 DescriptionThis column lists the item nomenclature along with thosemodifiers necessary to identify the item. Additionally, crossreferences for repairable subassemblies are listed in thiscolumn.

One dot preceding the description indicates that the item isa component part of the previously listed item or assemblywith no dot. Two dots indicate that the item is part of thepreviously 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 ofthe Electric Swivel as indicated with one dot. The Screwand the Brush Holder Assembly are second level componentsof the Collector Ring Assembly as indicated by the two dots.The Brush Spring is a third level component of the BrushHolder Assembly which is indicated with three dots.

7.2.6 IllustrationsParts location illustrations may differ from engineeringdrawings because they have been altered to fit on the pageor to improve clarity by omitting items that are notreplaceable components such as weld-ons.

7.1 INTRODUCTIONThis illustrated parts list contains all components of the davitthat can be separately identified as well as parts necessaryfor equipment support.

7.1.1 Major SubassembliesFigure/Table 7-1 identifies all major subassemblies of thedavit. Quantities indicated are total per davit exceptindented items which indicate total per subassembly.Equipment specifications (such as power requirements,dimensions, etc.) for major subassemblies are contained inChapter 1.

7.1.2 Special NotesEssential information regarding the interchangeability ofparts, initial condition settings or special installationprocedures are offset in italicized text in the parts breakdownillustrations when necessary.

7.2 FORMATComponent parts lists (Pages 7-5 through 7-75) are presentedin 5-column format.

7.2.1 ItemIndex numbers found in this column correspond to thenumbers found on the respective parts location illustration.Some items are shown for reference purposes only toillustrate their relationship to other systems.

7.2.2 NotesThis column identifies footnotes applicable to specifieditems.

7.2.3 ASC P/NThis column lists the Allied Systems Company Part Number.

7.2.4 QtyThis column lists the total number of a specific item requiredper assembly or subassembly. This number may notnecessarily be the number of items used in the end item orsystem. Only one set of components is listed whenever thecomponents of two assemblies are the same.

7 - 2

Figure 7-1 D5700CT Boat Davit

9

5

7

11

8

1

4

3

2

6

10

7 - 3

ITEM ASC P/N QTY DESCRIPTION PAGE

D5700CT Boat Davit 7-21 48850 1 . Davit Assembly 7-5

49233 1 . . Remote Lube Assy 7-62 1 . . Pedestal Assembly (Ref)

Customer Supplied3 27164 1 . Swing Stop Installation 7-74 47045 1 . Boom Lift Cylinder 7-85 52197 1 . Jib Boom Assembly 7-96 42269 2 . Swing Drive 7-10

236945 1 . . Swing Motor 7-1123939 1 . . Swing Gear Reducer 7-12240247 1 . . Swing Brake 7-14

7 1 . Control Console (Ref) Customer Supplied

8 48857 1 . Swing System 7-1649100 1 . . Swing Junction Block 7-1825829 1 . . Swing Stop Valve 7-1938693 1 . . Swing Dual Counterbalance

Valve 7-2048855 1 . Boom System 7-2148856 1 . Winch System 7-2248860 1 . Bulkhead Plate 7-23

Table 7-1 List of Major Components

ITEM ASC P/N QTY DESCRIPTION PAGE

9 46450 1 . Reeving Components 7-2445675 1 . . Constant Tension Winch 7-2645670 1 . . . Manifold Installation 7-2839163 1 . . . . Winch Electrically Operated

Relief Valve 7-30235621 1 . . . . Winch Check Valve 7-31235622 1 . . . . Winch Pressure Reducing

Valve 7-33235623 1 . . . . CT Sequence Valve 7-34234728 1 . . . . Counterbalance Valve 7-35237425 1 . . . . Winch Solenoid Valve 7-36236421 1 . . . Load Hydraulic Motor 7-37235378 1 . . . Winch Brake 7-38235377 1 . . . Winch Gear Reducer 7-39235411 1 . . . CT Hydraulic Motor 7-40

10 52201 1 . Electrical System 7-4252202 1 . . Junction Box 7-4447220 1 . . Anti-2-Block Control 7-4547221 1 . . Downstop Control 7-4647222 1 . . Cable Tension Sensor 7-47

11 45362 1 . Hydraulic Power Unit (Ref) (Customer Supplied)

7 - 4

Figure 7-2 Davit Assembly

7 - 5

Table 7-2 Davit Assembly Parts List

ITEM NOTES ASC P/N QTY DESCRIPTION

Fig. 7-2 48850 Davit Assembly1 48853 1 . Davit Weldment2 49233 1 . Remote Lube System - See Table 7-33 27164 1 . Swing Stops Installation - See Table 7-44 46157 2 . Plate, Cover5 36681 2 . Gasket6 234130 8 . Capscrew7 44050 1 . Nameplate8 38340 2 . Plate, Cover9 233866 4 . Capscrew

10 245098 26 . Capscrew11 226684 1 . Bearing12 245097 31 . Capscrew13 25097 1 . Pin14 229324 1 . Capscrew15 233852 1 . Nut, Esna16 R13802633 46 . Washer, Flat17 25450 1 . Gasket

7 - 6


Fig. 7-3 49233 Remote Lube System1 46541 1 . Tube Assembly2 237800 1 . Fitting3 239617 1 . Fitting4 10643 1 . Fitting, Lube5 233858 1 . Fitting

Figure 7-3 Remote Lube System

Table 7-3 Remote Lube System Parts List

7 - 7

Table 7-4 Swing Stop Installation Parts List


Fig. 7-4 27164 Swing Stop Installation1 25810 1 . Swing Stop, LH2 26061 1 . Swing Stop, RH3 245100 6 . Capscrew

Figure 7-4 Swing Stop Installation

23

1

120°TYP

7 - 8

Table 7-5 Boom Lift Cylinder Parts List


Fig. 7-5 47045 Boom Lift Cylinder1 47073 1 . Barrel Weldment2 25314 1 . Stem & Eye Weldment3 25317 1 . Piston4 25318 1 . Packing Gland5 09419545 1 . Nylock Nut6 25319 1 . Spacer7 * 21865 1 . Wear Strip (Bearing Pad)8 * 25320 1 . Wear Strip (Bearing Pad)9 * 21866 1 . Seal

10 * 25333 1 . Seal11 * 25334 1 . Wiper Ring12 223390 10 . Capscrew13 * 26586 1 . O-Ring14 * 25360 1 . O-Ring15 25075 2 . Bushing

34196 Seal Installation Tool Kit* 25417 Service Kit

Figure 7-5 Boom Lift Cylinder

7 - 9

Figure 7-6 Jib Boom Assembly


Fig. 7-6 52197 Jib Assembly1 52198 1 . Jib Weldment2 228458 1 . Nut, Esna3 25098 1 . Pin4 233864 1 . Capscrew5 25076 2 . Bushing6 25093 1 . Sheave Case Assembly7 25099 1 . Pin Assembly, Sheave8 25322 1 . Sheave Assembly

25303 2 . Washer25077 1 . Bushing

9 226846 1 . Capscrew10 231851 1 . Nut, Esna11 25096 1 . Pin12 25020 2 . Bushing13 225788 1 . Capscrew14 228460 1 . Nut, Esna15 25097 1 . Pin16 229324 1 . Capscrew17 233852 1 . Nut, Esna18 12977 1 . Lock Collar19 241239 1 . Washer, Flat

Figure 7-6 Jib Boom Assembly

7 - 10

Table 7-7 Swing Drive Parts List



Fig. 7-7 42269 Swing Drive1 * 236945 1 . Swing Motor - Table 7-82 * 240247 1 . Swing Brake - Table 7-93 * 23939 1 . Swing Gear Reducer - Table 7-104 * 31475 1 . Pinion5 24014 1 . Pinion Cap7 233853 8 . Capscrew8 233854 2 . Capscrew9 233855 4 . Capscrew

10 516672 1 . Gasket11 ------ Ref Gasket - Table 7-9

* Recommended Spare Part - Qty 1

9

9

5

1

11

10

2

3

8

4

7

7 - 11

Table 7-8 Swing Motor Parts List

Figure 7-8 Swing Motor

18

6

4

1

2

3

7

8

10

11

9

13

12

19

14

15

16

17

5


Fig. 7-8 236945 Swing Motor1 * 236722 1 . Dust Seal2 * 236723 1 . Snap Ring3 * 236724 1 . Backup Shim4 * 236725 1 . Housing Seal (High Pressure)5 * 236726 3 . Body Seal6 236727 1 . Seal Spacer Assembly

236728 1 . . Seal Carrier* 236729 1 . . Shaft Seal* 236730 1 . . Teflon Backup* 236731 1 . . Backup Shim

7 * 236732 1 . Thrust Washer8 236733 1 . Thrust Bearing9 ------ 1 . Housing

10 236735 1 . Spline Shaft11 236736 1 . Cooling Plug12 236737 1 . Drive Link13 236738 1 . Wear Plate14 236739 1 . Rotor Set Assembly15 236740 1 . Pin, Drive Link16 236741 1 . Ball17 236742 1 . End Cover18 ------ 1 . Identification Tag19 236743 4 . Bolt

* 25408 Service Kit

7 - 12

Figure 7-9 Swing Gear Reducer

3

20

SEE DETAIL B

6

5

2

13

4

1

34

36

11

SEE DETAIL A

8

10

32

31

33

7

14

1315

23

12

12

16

17

18

19 DETAIL A

2221

2821

2726

25

30

24

29DETAIL B

9

35

7 - 13


Fig. 7-9 23939 Swing Gear Reducer1 25414 1 . Output Shaft2 * 225334 1 . Seal3 * 225335 1 . Bearing Cone4 * 225336 1 . Bearing Cup5 225337 1 . Hub6 * 225338 1 . Bearing Cup7 * 225339 1 . Bearing Cone8 * 228886 1 . Thrust Washer9 225341 1 . Retaining Ring

10 225342 1 . Ring Gear11 225343 1 . Secondary Carrier Assembly12 * 228887 6 . . Thrust Washer13 * 228888 96 . . Needle Bearing14 * 228889 3 . . Separator15 NSS 3 . . Planet Gear16 NSS 3 . . Retaining Ring17 NSS 1 . . Planet Carrier18 * 228890 1 . . Thrust Washer19 * 228891 3 . . Pinion Shaft20 225344 1 . Primary Carrier Assembly21 * 228887 6 . . Thrust Washer22 NSS 3 . . Planet Gear23 * 228893 48 . . Needle Bearing24 NSS 1 . . Planet Carrier25 NSS 1 . . Retaining Ring26 NSS 1 . . Sun Gear27 NSS 3 . . Retaining Ring28 NSS 1 . . Retaining Ring29 * 228894 3 . . Pinion Shaft30 225345 1 . Sun Gear31 * 225346 1 . Thrust Washer32 225348 1 . Cover33 ------ 1 . Pipe Plug34 ------ 1 . Pipe Plug35 ------ 12 . Lockwasher36 ------ 12 . Capscrew

* 33276 Service Kit

Table 7-9 Swing Gear Reducer Parts List

Table 7-10 Swing Brake Parts List


Fig. 7-10 240247 Swing Brake1 237407 1 . Case2 ------ 1 . Cover3 229607 1 . Piston4 225332 1 . Shaft5 *b 225331 1 . Bearing, Output6 *b 225333 1 . Bearing, Input7 232508 4 . Capscrew8 228076 1 . Plug9 225174 5 . Spring

10 *b 237698 1 . Friction Disc Kit (includes 8 discs)11 *b 226559 7 . Plate, Separator12 *a 27356 1 . Backup-Ring13 *a 27359 1 . Backup-Ring14 *a 27357 1 . O-Ring15 *a 27358 1 . O-Ring16 *a 240208 1 . O-Ring17 *a 27192 1 . Seal18 *a 239736 1 . Gasket19 ------ Ref Gasket - Table 7-6

*a 27171 Seal Kit*b 31077 Disc & Bearing Kit

Figure 7-10 Swing Brake

3

18

6

12

11

19

15

13

2

1614

10

4

17

9

7

8

1

5

7 - 14

7 - 15


7 - 16

Figure 7-11 Swing System

(7 - 15 blank) / 7 - 16

7 - 17


Fig. 7-11 48857 Swing System1 49100 1 . Swing Manifold Assembly - Table 7-122 25829 1 . Valve, Stop - Table 7-133 233867 2 . Capscrew4 228413 2 . Nut, Hex5 49030 2 . Tube Assembly6 49031 3 . Tube Assembly7 49032 1 . Tube Assembly8 49033 1 . Tube Assembly9 49034 1 . Tube Assembly

10 49035 1 . Tube Assembly11 49036 1 . Tube Weldment12 38693 2 . Counterbalance Assembly,Dual - Table 7-1413 237764 9 . Fitting14 237765 3 . Fitting15 237766 7 . Fitting16 228490 1 . Fitting

Table 7-11 Swing System Parts List

7 - 18

Table 7-12 Swing Junction Block Parts List

Figure 7-12 Swing Junction BlockITEM NOTES ASC P/N QTY DESCRIPTION

Fig 7-12 49100 Swing Manifold Assembly1 49101 1 . Manifold2 25903 1 . Retainer,Ball3 25905 2 . Check, Shuttle4 25906 1 . Ball, Steel5 25907 1 . Fitting6 25908 2 . Fitting7 26982 2 . Spring, Comp8 203430 1 . O-Ring9 25911 1 . Backup Ring

10 203425 1 . O-Ring11 26266 1 . Valve Weldment, Needle12 27044 1 . Valve, Check13 27018 1 . Fitting14 209744 1 . O-Ring

7 - 18

S2 S1

S3 S4

SB

V2 V1

4

5

6

2

3 3 77

6

1110

89

121314

11

7 - 19

Table 7-13 Swing Stop Valve Parts List

28

2527

24

29

22

21

26

20

1918

30

23

3

10

4

15

9

21

11


Fig. 7-13 25829 Swing Stop Valve1 231327 1 . Handle2 ------ 2 . Setscrew3 ------ 4 . Capscrew4 ------ 4 . Lockwasher9 232150 1 . Centering Spring

10 ------ 1 . Pin11 ------ 1 . Housing15 ------ 1 . Stop Pin18 * ------ 1 . Thrust Washer19 * ------ 1 . Thrust Bearing20 233632 1 . Detent Disc21 ------ 1 . Rotor22 ------ 1 . Shaft23 * ------ 1 . O-Ring24 * ------ 1 . O-Ring25 * ------ 3 . Seat, Shear Seal26 * ------ 3 . O-Ring27 * ------ 3 . Backup Ring28 * ------ 1 . Washer, Spring Seat29 ------ 1 . Body30 ------ 1 . Dowel Pin

* 27203 Service Kit

Figure 7-13 Swing Stop Valve

7 - 20

1

8

3

64

57

10

9

2

Table 7-14 Swing Dual Counterbalance Valve Parts List

Figure 7-14 Swing Dual Counterbalance Valve ITEM NOTES ASC P/N QTY DESCRIPTION

Fig. 7-14 38693 Swing Dual Counterbalance Valve1 38694 1 . Manifold2 *b 230404 2 . Cartridge3 *a ------ 1 . . O-Ring4 *a ------ 1 . . O-Ring5 *a ------ 1 . . O-Ring6 *a ------ 2 . . Backup-Ring7 *a ------ 2 . . Backup-Ring8 233843 2 . Square Ring9 230794 4 . Capscrew

10 201566 4 . Lockwasher

*a,b 234650 Seal KitNOTE: One Seal Kit Required Per Cartridge

*b Recommended Spare Part - Qty 2

SERVICE NOTE

See Hydraulic Schematic for

correct pressure setting

7 - 21

Table 7-15 Boom System Parts List

Figure 7-15 Boom SystemITEM NOTES ASC P/N QTY DESCRIPTION

Fig 7-15 48855 Boom System1 41426 1 . Manifold2 234728 1 . Cartridge, Valve - Table 7-253 R13811044 4 . Capscrew4 203443 1 . O-Ring5 49021 1 . Tube Assembly6 49022 1 . Tube Assembly7 49023 1 . Tube Assembly8 49024 1 . Tube Assembly9 25908 1 . Fitting

10 246885 2 . Fitting11 237799 1 . Fitting12 245956 2 . Fitting13 241986 1 . Fitting14 237764 2 . Fitting15 237797 1 . Fitting16 247217 1 . Hose Assembly17 247218 1 . Hose Assembly18 247219 1 . Hose Assembly

7 - 22

Table 7-16 Winch System Parts List


Fig. 7-16 48856 Winch System1 49025 1 . Tube Assembly2 49026 1 . Tube Assembly3 49027 1 . Tube Assembly4 49028 1 . Tube Assembly5 49029 1 . Tube Assembly6 237765 1 . Fitting7 241477 1 . Fitting8 244075 3 . Fitting9 241986 1 . Fitting

10 237775 1 . Fitting11 242320 1 . Fitting12 508253 1 . Spacer13 508254 2 . Flange, Split14 201617 4 . Capscrew15 201568 4 . Washer, Lock16 237779 1 . Fitting17 247215 1 . Hose Assembly18 244040 2 . Hose Assembly19 247232 1 . Hose Assembly20 247216 1 . Hose Assembly

Figure 7-16 Winch System

7 - 23Table 7-17 Bulkhead Plate Part List


Fig. 7-17 48860 Bulkhead Plate Assembly1 49073 1 . Plate, Bulkhead2 49074 2 . Tube3 49075 1 . Tube4 49076 1 . Tube5 49077 2 . Tube6 49078 2 . Tube7 243862 3 . Fitting8 243863 1 . Fitting9 243861 2 . Fitting

10 246886 2 . Fitting11 242510 3 . Fitting12 242511 1 . Fitting13 241246 4 . Fitting14 241969 1 . Flange, Weld

Figure 7-17 Bulkhead Plate

7 - 24

Figure 7-18 Reeving Components

1,2,3

4

17

6,7 15

14

16

10,11,12

8,9

14,15

7 - 25

Table 7-18 Reeving Components Parts List


Fig. 7-18 46450 Reeving Components1 45675 1 . Constant Tension Winch - Table 7-204 34220 1 . Wire Rope Assembly6 223945 4 . Capscrew7 223188 4 . Locknut8 39119 1 . Reeving Chart9 237034 4 . Drive Screw

10 43608 1 . Pin11 243298 2 . Cotter Pin12 243297 4 . Flat Washer14 ------ Ref Downstop Control - Table 7-3415 ------ Ref Anti-2-Block Control - Table 7-3316 241364 1 Quick Release Hook17 ------ Ref Sheave Case18 247398 1 Fitting19 237614 1 Fitting

7 - 26


5

3

44

5

21

5556

507

43

15

53

54

59

39

52

10

42

8

4

3839

41

14

58

40

12

38

41

35

38

30

29

13

37

20

18

45

33

1134

1621

27

31

32

28

46

1719

36

26

47

22

6

48

9

60

7 - 27

Table 7-19 Constant Tension Winch Parts List


Fig. 7-19 45675 Constant Tension Winch Assembly1 45670 1 . Manifold Installation - Table 7-202 41661 1 . Constant Tension Winch3 236421 1 . . Load Hydraulic Motor - Table 7-214 235378 1 . . Winch Brake - Table 7-285 235377 1 . . Winch Gear Reducer - Table 7-296 237411 1 . . CT Hydraulic Motor - Table 7-307 37303 1 . . Spacer8 48209 1 . . Drum Weldment9 41662 1 . . Frame Weldment

10 37306 1 . . Hub11 37307 1 . . Spacer12 37308 1 . . Spacer13 37309 1 . . Cover14 37345 1 . . Piston15 223587 2 . . Nut16 37312 1 . . Housing17 37319 1 . . Ring18 37322 1 . . Bushing19 37315 1 . . Hub20 37320 1 . . Spacer21 37317 1 . . Spacer22 37318 1 . . Housing26 235384 1 . . Roller Bearing27 235422 9 . . FrictionDisc28 235423 8 . . Separator Plate29 235374 3 . . Spring30 235382 1 . . Thrust Bearing31 235383 1 . . Tapered Roller Bearing32 201138 1 . . Bearing Cup33 235385 1 . . Retaining Ring34 235386 1 . . Retaining Ring35 235387 4 . . Fitting36 * 235388 1 . . Seal37 * 236275 1 . . Seal38 * 203560 3 . . O-Ring39 * 235390 2 . . Backup Ring40 * 203475 1 . . O-Ring41 * 235391 2 . . Backup Ring42 237613 1 . . Wedge43 R13811089 2 . . Capscrewl44 240751 12 . . Capscrew45 235628 10 . . Capscrew46 R13811076 12 . . Capscrew47 R13801842 4 . . Capscrew48 R13811804 10 . . Capscrew50 37872 1 . . Spacer52 37870 1 . . Spacer53 37871 1 . . Spacer54 37869 2 . . Stud55 234712 1 . . Fitting56 37311 1 . . Shim58 240405 1 . . Relief Valve59 00138243 4 . . Capscrew60 46086 1 . . Decal, CT5 Serial No.61 47231 A/R . . Shim

* 39797 Service Kit

7 - 28

Figure 7-20 Manifold Installation

21

26

45

25

15

22

36

34

17

3

37

40

7

29

27

,43

24

44

1 4

11

16

19

41

20

39

33

35

,42

18

10

2

8,1

2

5

69 14

13

,14

31

32

46

47

28

22

27

22

30

31

47

44

7 - 29

Table 7-20 Manifold Installation Parts List


Fig. 7-20 45670 Manifold Installation1 39163 1 . Winch Electrically Operated

Relief Valve - Table 7-212 235621 1 . Winch Check Valve - Table 7-223 235622 1 . Winch Pressure Reducing

Valve - Table 7-234 235623 1 . CT Sequence Valve - Table 7-245 37497 1 . Winch Manifold6 37498 1 . Manifold7 37499 1 . Tube Assembly8 37503 1 . Subplate9 230895 4 . Capscrew

10 242953 4 . Capscrew11 228177 1 . Fitting12 228198 4 . Capscrew13 230095 4 . Capscrew14 203446 6 . O-Ring15 39067 1 . Tube Assembly16 46390 1 . Tube Assembly17 38316 1 . Tube Assembly18 38319 1 . Tube Assembly19 39069 1 . Tube Assembly20 39070 1 . Tube Assembly21 224303 1 . Shuttle Valve22 228403 6 . Fitting24 237436 1 . Fitting25 232916 1 . Fitting26 209766 1 . Fitting27 233840 4 . Fitting28 39068 1 . Tube Assembly29 228214 1 . Fitting30 232848 2 . Fitting31 228492 2 . Fitting32 19759 1 . Fitting33 228315 1 . Fitting34 521926 1 . Flange, Gauge Port35 45656 1 . Manifold36 237425 1 . Winch Solenoid Valve - Table 7-2637 235734 1 . Fitting39 231483 1 . Fitting41 203443 1 . O-Ring42 234728 1 . Counterbalance Valve - Table 7-2543 209768 1 . Fitting44 228221 1 . Fitting45 45669 1 . Tube Assembly46 236859 1 . Fitting47 243469 2 . Fitting

7 - 30


Fig. 7-21 39163 Winch Electrically Operated Relief Valve1 39164 1 . Valve Shield2 228410 4 . Capscrew

235379 1 . Relief Valve, Reworked3 238012 1 . . Pressure Relief Valve, Proportional4 238013 2 . . . Seal5 ------ 4 . . . Capscrew6 39165 1 . . Cover Plate Rework7 235650 4 . . . Capscrew8 238015 1 . . Poppet Assembly9 * ------ 1 . . . Seal

10 * ------ 1 . . . Backup Ring11 * ------ 1 . . . Seal12 NSS 1 . . . Cap13 NSS 1 . . . Spring14 NSS 1 . . . Piston15 * ------ 2 . . . Seal16 NSS 1 . . . Poppet17 ------ Ref Winch Manifold - Table 7-31 (5)

* 238016 Seal Kit

Table 7-21 Winch Electrically Operated Relief Valve Parts List

6

2

8

1

3

5

4

7

11

10

9

12

13

14

15

17

15

16

Figure 7-21 Winch Electrically Operated Relief Valve

7 - 31

Table 7-22 Winch Check Valve Parts List


Fig. 7-22 235621 Winch Check Valve1 * ------ 1 . O-Ring2 * ------ 1 . Backup-Ring3 * ------ 1 . Backup-Ring4 * ------ 1 . O-Ring

* 237511 Seal Kit

Figure 7-22 Winch Check Valve

1

3

2

4

7 - 32


7 - 33

Table 7-23 Winch Pressure Reducing Valve Parts List


Fig. 7-23 235622 Winch Pressure Reducing Valve1 * ------ 1 . Backup Ring2 * ------ 1 . O-Ring3 * ------ 1 . O-Ring4 * ------ 1 . Backup Ring5 * ------ 2 . Backup Ring6 * ------ 1 . O-Ring

* 234655 Service Kit

Figure 7-23 Winch Pressure Reducing Valve

SERVICE NOTE



(7 - 32 blank) / 7 - 33

7 - 34

SERVICE NOTE



Table 7-24 CT Sequence Valve Parts List


Fig. 7-35 235623 CT Sequence Valve1 * ------ 1 . Backup Ring2 * ------ 1 . O-Ring3 * ------ 1 . O-Ring4 * ------ 1 . Backup Ring5 * ------ 2 . Backup Ring6 * ------ 1 . O-Ring


Figure 7-24 CT Sequence Valve

7 - 35

Table 7-25 Winch Counterbalance Valve Parts List

Figure 7-25 Winch Counterbalance Valve

SERVICE NOTE




Fig. 7-25 234728 Counterbalance Valve1 ------ 1 . Cartridge2 * ------ 1 . . O-Ring3 * ------ 1 . . Backup Ring4 * ------ 1 . . O-Ring5 * ------ 1 . . Backup Ring6 * ------ 1 . . O-Ring


2

4

6

1

5

3

7 - 36

Table 7-26 Winch Solenoid Valve Parts List


Fig. 7-26 237425 Winch Solenoid Valve1 ------ 1 . Nut2 237858 1 . Coil3 ------ 1 . Washer4 237859 1 . Cartridge5 237860 1 . Body

237861 Complete Seal Kit

Figure 7-26 Winch Solenoid Valve

7 - 37

Table 7-27 Load Hydraulic Motor Parts List

Figure 7-27 Load Hydraulic MotorITEM NOTES ASC P/N QTY DESCRIPTION

Fig. 7-27 236421 Load Hydraulic Motor1 226233 1 . Shaft End Cover2 ------ 1 . Gear Set3 ------ 1 . Gear Housing4 222939 1 . Port End Cover5 226230 1 . Snap Ring6 228108 1 . Bearing7 * 27195 1 . Lip Seal8 223855 1 . Check Assembly9 * ------ 2 . Ring Seal

10 224622 4 . Roller Bearing11 ------ 2 . Thrust Plate12 * 222743 1 . Pocket Seal Strip13 * 224629 2 . Gasket Seal14 222938 4 . Dowel Pin15 ------ 1 . Seal Retainer16 ------ 4 . Capscrew17 ------ 4 . Washer

* 27193 Service Kit

7 - 38


Fig. 7-28 235378 Winch Brake1 235765 1 . Retaining Ring2 238353 1 . Retaining Ring3 *c 238354 1 . Bearing4 235768 2 . Capscrew5 *a*c 238355 1 . Seal6 238356 1 . Cover7 238357 1 . . Retaining Ring8 238358 1 . . Retaining Ring9 *c 238359 1 . . Bearing

10 *c 238360 1 . . Bearing Sprag11 238361 1 . . Outer Spline12 *c 238362 1 . . Bearing, Needle13 238363 1 . . Spline Shaft14 238364 4 . Capscrew15 *b 229483 1 . Primary Disc16 *b 227487 5 . Rotor Disc17 *b 227489 4 . Stator Disc18 235761 4 . Capscrew19 *a,b,c,d 238365 2 . Gasket20 235762 1 . Spring Plate21 *d 226013 6 . Spring22 227491 1 . Piston23 *a 238366 1 . Backup-Ring24 *a 238367 1 . O-Ring25 *a 238368 1 . Backup-Ring26 *a 238369 1 . O-Ring27 238370 1 . Pressure Plate28 238371 4 . Plug (O-Ring)29 *a,b,c,d 238372 2 . Gasket30 *a,b,c,d 229484 2 . O-Ring

*a 238373 Seal Kit*b 238374 Lining Kit*c 238375 Bearing Kit*d 238376 Spring Kit

Table 7-28 Winch Brake Parts List

Figure 7-28 Winch Brake

7 - 39

Table 7-29 Winch Gear Reducer Parts List


Fig. 7-29 235377 Winch Gear Reducer1 225342 1 . Ring Gear2 225343 1 . Secondary Carrier Assembly3 ------ 1 . . Carrier4 238260 6 . . Thrust Washer5 228888 96 . . Needle Bearing6 228889 3 . . Separator7 238261 3 . . Planet Gear8 228891 3 . . Pinion Shaft9 228890 1 . . Thrust Washer

10 229745 3 . . Retaining Ring11 225344 1 . Primary Carrier Assembly12 238263 1 . . Large Sun Gear13 238265 3 . . Planet Gear14 238260 6 . . Thrust Washer15 228894 3 . . Pinion Shaft16 ------ 1 . . Retaining Ring17 238264 1 . . Thrust Washer18 228893 48 . . Needle Bearing19 229745 3 . . Retaining Ring20 ------ 1 . . Carrier21 228313 1 . Small Sun Gear22 238267 1 . Cover23 ------ 1 . Filler Plug24 226108 1 . Drain Plug, Magnetic25 ------ Ref Spacer - Table 7-30 (52)26 ------ Ref Spacer - Table 7-30 (53)27 ------ Ref Shim - Table 7-30 (56)

Figure 7-29 Winch Gear Reducer

7 - 40

Table 7-30 CT Hydraulic Motor Parts List


Fig. 7-30 237411 CT Hydraulic Motor1 * 238060 1 . Snap Ring2 * 240967 1 . Seal Plate3 * 240872 1 . Shaft Seal4 * ------ 1 . O-Ring5 238080 2 . Dowel Pin, Rear6 238062 1 . Snap Ring7 238063 1 . Ball Bearing8 238064 1 . Shaft9 238065 4 . Bolt

10 238066 1 . Front Housing11 238067 2 . Dowel Pin, Front12 ------ 4 . O-Ring13 238068 4 . Screw14 238069 2 . Plate15 238070 1 . Stator16 238071 8 . Vane Spring17 238072 4 . Stator Vane18 238073 1 . Rotor19 238074 10 . Rotor Vane20 238075 20 . Vane Spring, Outer21 238076 20 . Vane Spring, Inner22 238077 4 . Ball Checks23 238078 1 . Needle Bearing24 238079 1 . Rear Housing

* 39574 Seal Kit

Figure 7-30 CT Hydraulic Motor

7 - 41


7 - 42

Figure 7-31 Electrical System

(7 - 41 blank) / 7 - 42

7 - 43

Table 7-31 Electrical System Parts List


Fig. 7-31 52201 Electrical System1 52202 1 . Junction Box Assembly - Table 7-322 238442 1 . Housing3 238440 1 . Terminal, Female4 238441 1 . Plate5 230840 1 . Connector, Cord8 239304 10' . Cable, Shielded9 240880 50' . Cable, Shielded

10 230839 1 . Connector, Cord11 238438 1 . Hood, Side Entry12 238439 1 . Terminal, Male13 47220 1 . Anti-2-Block Assembly - Table 7-3314 47221 1 . Downstop Assembly - Table 7-3415 47222 1 . Switch Assembly,Tension - Table 7-3516 233572 4 . Washer, Lock17 230337 4 . Capscrew18 231851 18 . Nut, Esna19 234214 4 . Capscrew20 241983 3 . Clamp21 241981 6 . Clamp22 241980 13 . Clamp23 247275 1 . Adapter, Thread24 240811 9 . Stud, Weld

7 - 44

Table 7-32 Junction Box Parts List


Fig. 7-32 52202 Junction Box1 52203 1 . Junction Box, Rework2 23475 1 . Panel3 231827 1 . Connector4 27663 4 . Connector5 27054 5 . Ring Nut6 236827 11 . Terminal Block7 236828 1 . End Plate8 222257 2 . Capscrew9 22628 A/R . Rail

12 241761 2 . End Stop13 232239 3 . Jumper14 232242 1 . Card, Marker15 230839 1 . Connector16 27055 1 . Ring Nut

Figure 7-32 Junction Box

7 - 45

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


Fig 7-33 47220 Anti-2-Block Assembly1 46311 1 . Switch Assembly,A-2-B2 234552 2 . Capscrew3 231853 3 . Washer, Flat4 231660 2' . Wire Rope5 231658 2 . Clip, Cable6 40819 1 . Weight Assembly7 225669 2 . Capscrew8 231851 5 . Nut, Esna9 231593 1 . Clamp

Figure 7-33 Anti-2-Block Control

7 - 46

Table 7-34 Downstop Control Parts List


Fig. 7-34 47221 Downstop Control1 244112 1 . Switch, Prox2 40836 1 . Downstop Weldment3 234129 3 . Capscrew4 234051 1 . Capscrew5 40837 1 . Arm Weldment6 34330 1 . Roller7 25002 4 . Bearing, Nyliner8 228461 1 . Nut, Esna9 233882 4 . Washer, Flat

10 226849 4 . Washer, Flat11 226848 2 . Nut, Esna12 231893 1 . Spring, Ext13 233888 2 . Capscrew14 234170 2 . Nut, Esna15 40838 1 . Plate16 232518 1 . Capscrew17 234216 1 . Capscrew

Figure 7-34 Downstop Control

7 - 47

Table 7-35 Cable Tension Sensor Part List


Fig. 7-35 47222 Cable Tension Sensor1 45910 1 . Switch Base Weldment2 45900 1 . Tension Weldment3 45898 1 . Rod4 45897 1 . Rod5 243751 2 . Spring, Ext6 45899 1 . Roller7 226849 4 . Washer, Flat8 226848 4 . Nut, Esna9 244112 1 . Switch, Proximity

Figure 7-35 Cable Tension Sensor

8 - 1

CHAPTER 8INSTALLATION

8.1 INTRODUCTIONThis chapter is provided to assure a smooth and satisfactoryinstallation of the boat davit, model D5700CT.

1. Have a crane available that will safely lift the davit andjib boom (3,400 lbs).

2. Ensure adequate swing clearance between the davit andship’s structures or other deck mounted equipment.

8.2 DAVIT INSTALLATIONFigure 8-1 shows the swing stops in place on the undersideof the davit’s mounting surface. Each swing stop is held inplace by three capscrews, which also serve as davit mountingbolts. They are set at the factory for 180 degrees of rotationin each direction from center. Moving the stop one bolt holewill change the swing arc by 11 degrees and 15 minutes.

1. Install swing stops as shown in Figure 8-1.

2. Remove the davit inspection plate, and install lines ontohydraulic lid.

3. Lift the davit assembly over the mounting flange onthe pedestal so that the cable will be centered over the boat.Guide any hydraulic or electrical lines down through thepedestal flange to below deck.

4. Position the davit so that its center line is aligned withthe pedestal, and that the swing stops are centered on thedavit’s proposed swing arc. Install 26, capscrews (six capscrewsthrough swing stops) with 3/4" hard washers under eachcapscrew and tighten as indicated in Figure 8-1, DavitInstallation.

5. Mount the control console in its position on the deck.Make openings in the deck for hydraulic and electrical linerouting between the hydraulic power supply, control consoleand davit as necessary.

6. Connect hydraulic lines between control console,hydraulic power supply and davit installation as shown inHydraulic Schematic Diagram, and Figure 8-2, PlumbingDiagram.

7. Flush all lines and fittings to prevent damage to thedavit's hydraulic system.

a. Use couplings to connect lines from the hydraulicpower unit (HPU) together.

b. Start the HPU and flush lines for a period of at least5 minutes to carry any debris left in the lines to the HPUtank return filter.

Figure 8-1 Davit Installation

AM

C5

33

CAPSCREWS (6)

3/4NC x 4-1/2 FERRY HEAD

WITH FLATWASHERS

TORQUE 335 LB-FT, LUBRICATED

TORQUE 330-335 LB-FT, LUBRICATED


WELD

TO DECK

SWING STOPS

SHOWN SET

FOR 120 EACH

DIRECTION

CAPSCREWS (26)¾ UNRC

X 2-1/2 FRY HD 12PT BLK

CERTS WITH HARDWASHERS


135

c. Secure the HPU, disconnect the lines from oneanother, and connect them to the control valve in the controlconsole.

d. Connect the SWING lines from the davit installationto the control valve. Disconnect the SWING lines at thehydraulic lid and connect them together with a hose nipple.

e. Start the HPU and operate the SWING control leverin both directions for about 5 minutes to carry any debris tothe HPU tank return filter.

f. Repeat steps c through e for both the WINCH andBOOM systems.

8.3 PREPARATION FOR OPERATION

1. Check all lines, fittings and bolts for security.

NOTE: Refer to the Hydraulic and ElectricalSchematics to verify hydraulic and electricalconnections.

2. Trace all hydraulic and electrical circuits. Ensure allconnections 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 operatingtemperature 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 thatthe davit stops at the correct points in its swing arc.

NOTE: The winch should have at least 100 lbs ofweight on the hook to perform its functions.

8. Carefully operate the winch control lever, and ensurethat the winch stops at the correct points. When raising aload, it should stop just before the hook block reaches thesheave. When lowering a load, it should stop when there areat least three wraps of cable remaining on the drum. If thewinch 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 BOOMCYLINDER PRESSURE SWITCH BE PROPERLYADJUSTED. INCORRECT ADJUSTMENT COULDCAUSE EQUIPMENT DAMAGE, SEVEREPERSONAL INJURY OR DEATH.

8.4 PREPARATION FOR RESHIPMENTTo prepare the davit for reshipment, perform the following:

1. Remove the hook. Wind the cable neatly onto the drumand secure the end of the cable to the drum.

2. Secure electrical and hydraulic power.

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

ENSURE THAT THE POWER TO THE EQUIPMENTIS OFF BEFORE ATTEMPTING TO DISCONNECTTHE CABLES. AN ELECTRICAL SHOCK COULDBE FATAL.

4. Tag and disconnect hydraulic lines and electrical wiringbetween the davit , control console and HPU.

CAUTION

DISCONNECTED HYDRAULIC LINES MUST BECOVERED TO PREVENT HYDRAULIC SYSTEMCONTAMINATION. MAKE SURE OPEN PORTS ONHYDRAULIC COMPONENTS, INCLUDING HOSES,TUBING, AND FITTINGS, ARE EITHER CAPPED ORPLUGGED DURING INSTALLATION, SERVICE ANDREPAIR PROCEDURES.

5. Support the davit with an overhead crane that cansafely lift at least 3,400 lbs, and remove the pedestal flangemounting bolts. Stand clear when the davit becomes free, incase it is not well balanced with the rigging being used. Movethe davit to a safe location.

6. Similarly remove the control console. The consoleweighs 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)

80_713

Documents

lever forward

warning symbol

lever forward

lever rearward

constant tension

lever rearward

authorized

improper hosepipe