Lt1 · ':> l=S,01

.1 TG811-AT-MM0-010

091 O-LP-523-3800

OPERATION AND MAINTENANCE MANUAL

FOR

CRANES, DECK AND BOOM

MANUFACTURED BY

UTILITY STEEL FABRICATION, INC.

137 CABIRAN RD

SLIDELL, LA 70480

HALTER MARINE INC.

T-AGS51/52

N00024-89-C-2079

DISTRIBUTION STATEMENT "C": DISTRIBUTION AUTHORIZED TO

U.S. GOVERNMENT AGENCIES AND THEIR CONTRACTORS; AD

MINISTRATIVE/OPERATIONAL USE: 01 MAY 1991. OTHER RE

QUESTS FOR THIS DOCUMENT SHALL BE REFERRED TO THE

COMMANDER, MILITARY SEALIFT COMMAND, CODE M-4E

WASHINGTON, DC 20390.

WARNING: THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE

EXPORT IS RESTRICTED BY THE ARMS EXPORT CONTROL ACT

(TITLE 22, U.S.C. SEC 2751 ET. SEC.) OR EXECUTIVE ORDER 12470.

VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECT TO SEVERE

CRIMINAL PENALTIES.

DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL

PREVENT DISCLOSURE OF CONTENTS OR RECONSTRUCTION OF

THE DOCUMENT.

MILITARY SEALIFT COMMAND

TG811-A T-HM!)-!)! i

· / !f!liilillllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllll F~R OFFICIAL USE ONL y .

, .lO'?l•)-LP-523-3,s,,; .. )*

·.:) TG811-AT-MM0-010

091 O-LP-523-3800

OPERATION AND MAINTENANCE MANUAL

FOR

CRANES, DECK AND BOOM

MANUFACTURED BY

UTILITY STEEL FABRICATION, INC.

137 CABIRAN RD

SLIDELL, LA 70480

HALTER MARINE INC.

T-AGS51/52

N00024-89-C-2079

DISTRIBUTION STATEMENT "C": DISTRIBUTION AUTHORIZED TO

U.S. GOVERNMENT AGENCIES AND THEIR CONTRACTORS: AD

MINISTRATIVE/OPERATIONAL USE: 01 MAY 1991. OTHER RE

QUESTS FOR THIS DOCUMENT SHALL BE REFERRED TO THE

COMMANDER, MILITARY SEALIFT COMMAND, CODE M-4E

WASHINGTON, DC 20390.

WARNING: THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE

EXPORT IS RESTRICTED BY THE ARMS EXPORT CONTROL ACT

{TITLE 22, U.S.C. SEC 2751 ET. SEC.) OR EXECUTIVE ORDER 12470.

VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECT TO SEVERE

CRIMINAL PENALTIES.

DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL

PREVENT DISCLOSURE OF CONTENTS OR RECONSTRUCTION OF

THE DOCUMENT.

MILITARY SEALIFT COMMAND

01 MAY 1991

~~111111111111111111111111111111111111111111111111111111111111111111111111111111111111111 FOR OFFICIAL USE ONL y

~0910-LF-523-3300•

A

TG811-AT-MMO-OIO

LIST OF EFFECTIVE INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

NOTE: The portion of the text affected by the changes is indicated by a vertical line in the OtJter margins of the page. Changes to illustrations are indicated by .. (miniature pointing hands). Changes to wiring diagrams are indicated by shaded areas.

Date(s) Of Original And Change Pages Are:

Original ... 0 . . . 1 MAY 1991

Total Number Of Pages In This Publication Is .6Z.Consisting Of The Following:.

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

A Record of Change . . O APR Page Validation Cert . . . . O Foreword ....... o :,va~ranty l·VII .•..• 1-1 - 1-5 2-1 - 2-4 3-1-3-2 4-1 - 4-4 5-1 • 5-3 6-1 • 6-3 .. 0 7-1 • 7-20 .. 0 8-1-8-12

• ZERO IN lHIS COLUMN INDICATES AN ORIGINAL PAGE.

RECORD OF CHANGES

Change No. Date Title Or Brief Description Entered By

<J

C)

APPROVAL AND PROCUREMENT RECORD PAGE

APPROVAL DATA FOR: TG811-AT-MM0-010

TITLE OF MANUAL: CRANES, DECK AND BOOM

APPROVAL AUTHORITY: SUPERVISOR OF SHIPBUILDING, CONVERSION AND REPAIR,

USN, PASCAGOULA

CONTRACT NO. APPLICABILITY QTY BUILDING YARD

N00024-89-C-2079 TAGS51/52 2PERHULL HALTER MARINE INC.

REMARKS:

CERTIFICATION

IT IS HEREBY CERTIFIED THAT TG811-AT-MM0-010 TO BE PROVIDED UNDER CONTRACT NUM

BER N00024-89-C·2079, HAS BEEN APPROVED BY THE ~ORITY SHOWN ABOVE.

C) . TECHNICAL MANUAL VALIDATION CERTIFICATE

NAVSEA 4160/3 (4-82)

TECHNICAL MANUAL TITLE:

CRANES, DECK AND BOOM

NAVESA TECHNICAL MANUAL NUMBER: DATE: 1 MAY 1991

TG811-AT-MM0-010

CONTRACT/TMCR NO. :

N00024-89-C-2079

I -VALIDATION

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

II- EXCEPTIONS

EXCEPTIONS

NONE

BLICATIONS QUALITY ASSURANCE OFFICER:

AUTHORIZED BY

T0811-AT-MM0-010

FOREWORD-

This NA VSEA technical manual includes installation, operation, maintenance, and repair instruc tions, with a parts list for the Cranes, Deck and Boom. The manual covers the following:

CHAPTER

1. General Information

2. Operation

3. Functional Description

4. Scheduled Maintenance

5. Troubleshooting

6. Corrective Maintenance

7. Parts Lists

8. Installation

Ships, training activities, supply points, depots, and Supervisors of Shipbuilding are requested to arrange for the maximum practical use and evaluation of MSC technical manuals. All errors, omissions, descrepancies, and suggestions for improvement to MSC technical manuals shall be reported to the Commander, Military Sealift Command, Code M-4E, Washington, DC 20309.

TG811-AT-MM0-010

WARRANT{

The Manufacturer will warranty this equipment against any defects or deficiencies in workmanship and/or material through the period of time that the vessel this equipment is installed on is completed, finally accepted by the Navy, and subsequently performs nine

(9) months continuous service or nine (9) months of cumulative service in the event the vessel is disabled because of any equipment failure.

/J

TG8I l-AT-MM0-010

TABLE OF CON'{ENTS

CHAPTER DESCRIPTION PAGE

1 GENERAL INFORMATION AND SAFETY

PRECAUTIONS ........................ 1-1

1-1 INTRODUCTION ............... , ... 1-1

1-2 SAFETYPRECAUTIONS ............... 1-1

1-3 GENERAL ....................... 1-1

1-4 REFERENCEDATA .................. 1-1

1-5 TOOLS AND TEST EQUIPMENT .......... 1-2

1-6 ENVIRONMENTAL AND STORAGE

REQUIREMENTS ................... 1-2

2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-7.1 2-7.2 2-7.3 2-7.4 2-7.5

INTRODUCTION ................... 2-1

INITIAL START-UP . . . . . . . . . . . . . . . . . . 2-1

ROUTINE PRE-START CHECKS ........... 2-2

SWING OPERATION . . . . . . . . . . . . . . . . . 2-2

BOOM OPERATION . . . . . . . . . ......... 2-2

WINCHOPERATION ................. 2-3

HYDRAULIC POWER UNIT . . . . . . . . . . . . . 2-3

Pre-Start-Up Precautions . . . . . . . ......... 2-3 Filling the Reservoir . . . . . . . . . . . . . . . . . . . 2-4 Motor Rotation . . . . . . . . . . . . . . . . . . . . . 2-4 Running the System . . . . . . . . . . . . . . . . . . . 2-4 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 2-4

3 FUNCTIONAL DESCRIPTION ................ 3-1

3-1 3-2 3-2.1 3-2.2 3-2.3 3-2.4 3-2.5 3-2.6 3-2.7

INTRODUCTION ................... 3-1

CRANE ......................... 3-1

Pedestal . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Turret . . . . . . . . . . . . . . . . . . . . . ..... 3-1 Boom .......................... 3-1 Operators Platform . . . . . . . . . . . . . . . . . . . 3-1 Proportional Control Valve . . . . . . . . . . . . . . . 3-1 Swing System . . . . . . . . . . . . . . . . . . . . . . 3-1 Luffing System . . . . . . ............... 3-2

TGSll-AT-MM0-010

C) TABLE OF CONTENTS (Cont'd)

CHAPTER DESCRIPTION PAGE

3-2.8 Boom Extension System . . . . . . . . . . . ..... 3-2 3-2.9 Winch . . . . . . . . . . . . . . . . . . . . . ..... 3-2

3-3 HYDRAULIC POWER UNIT . . . . . . . . . . ... 3-2

4 SCHEDULEDMAINTENANCE ................ 4-1

4-1 INTRODUCTION ................... 4-1

4-2 MAlNTENANCEPLAN ................ 4-1

4-3 HYDRAULIC OIL CHANGE ............. 4-1

4-4 RETURNFIL1ERREPLACEMENT ......... 4-2

4-5 SWINGDRIVELUBRICATION ........... 4-2

4-6 TURNTABLEBEARING ............... 4-3

4-7 BOOMLIFTCYLINDER ............... 4-3

4-8 BOOM EXTENSION CYLINDER . . . . . . . . ... 4-3

0 5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . ... 5-1

/J

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

5-2 TROUBLESHOOTING CHART . . . . . ....... 5-1

6 CORRECTIVEMAIN1ENANCE ............... 6-1

6-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . 6-1

6-2 MAINTENANCE .................... 6-1

6-3 HYDRAULIC POWER UNIT . . . . . . ....... 6-1

6-3.1 Removal . . . . . . . . . . . . . . . . . . ....... 6-1 6-3.2 Installation . . . . . . . . . . . . . . . . . . . ..... 6-2

6-4 WINCH REPLACEMENT ............... 6-2

6-4.1 Removal . . . . . . . . . . . . . . . . . . . . . . ... 6-2 6-4.2 Installation . . . . . . . . . . . . . . . . . ....... 6-3

7 PARTS LIST .......................... 7-1

7-1 INTRODUCTION ................... 7-1

7-2 PARTS LIST .........•............ 7-1

7-2.1 Figure and Item Number . . . . . . . . . . . . . . . . 7-1 7-2.2 Description . . . . . . . . . . . . . . . . . . . . . . . 7-1 ii

(J TABLE OF CONTENTS (Cont'd)

CHAPTER DESCRIPTION PAGE.

7-2.3 Qty/Unit ......................... 7-1

.7-2.4 FSCM .......................... 7-1

7-2.5 Part Number ....................... 7-1

8 INSTALLATION ........................ 8-1

8-1 INTRODUCTION ................... 8-1

8-2 GENERAL INFORMATION .............. 8-1

8-2.1 Crane • . . . • • . . . . . . . • . . . . • . . . . .•. 8-1 8-2.2 Pedestal . . . . . . . . . . . . . . . . . . . . ..... 8-1 8-2.3 Turret .......... _ ............... 8-1 8-2.4 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-3 HYDRAULIC POWER UNIT ............. 8-1

8-4 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . 8-1

8-5 HYDRAULIC PIPING ................. 8-1

iii

TG811-AT-MM0-010

LIST OF ILLUSTRi\. TIONS

FIGURE TITLE PAGE

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

BOOMCRANE .................... 1-3

HYDRAULIC POWER UNIT . . . . . . . . . ... 1-4

ELECTRIC MOTOR ................. 7-4

HYDRAULIC PUMP (SHEET 1 OF 3) ....... 7-8

HYDRAULIC PUMP (SHEET 2 OF 3) . . . . . . . 7-9

HYDRAULIC PUMP (SHEET 3 OF 3) ....... 7-10

HYDRAULIC POWER UNIT ............ 7-12

LIFTCYLINDER ................... 7-14

EX1ENSION CYLINDER .............. 7-16

WINCH ........................ 7-20

HYDRAULIC SCHEMATIC ............. 8-2

INSTALLATION DRAWINGS (Sheet 1 of 10) ... 8-3 INSTALLATION DRAWINGS (Sheet 2 of 10) ... 8-4 INSTALLATION DRAWINGS (Sheet 3 of 10) ... 8-5 INSTALLATION DRAWINGS (Sheet 4 of 10) ... 8-6 INSTALLATION DRAWINGS (Sheet 5 of 10) ... 8-7 INSTALLATION DRAWINGS (Sheet 6 of 10) ... 8-8 INSTALLATION DRAWINGS (Sheet 7 of 10) ... 8-9 INSTALLATION DRAWINGS (Sheet 8 of 10) ... 8-10 INSTALLATIONDRAWINGS (Sheet9of10) ... 8-11 INSTALLATION DRAWINGS (Sheet 10 of 10) . . 8-12 iv

0 LIST OF TABLES

TABLE TITLE PAGE

1-1 REFERENCEDATA ................. 1-1

1-1 REFERENCEDATA ................. 1-2

1-2 LIST OF TOOLS AND TEST EQUIPMENT .... 1-5

4-1 MAINTENANCE PLAN . . . . . . . . . . . . . . .4-4

5-1 TROUBLESHOOTING CHART ........... 5-2

5-1 TROUBLESHOOTING CHART . . . . . . . . . . 5-3

7-1 ELECTRICMOTORPARTS ............. 7-2

7-1 ELECTRICMOTORPARTS ............. 7-3

7-1 HYDRAULIC PUMP PARTS ............ 7-5

7-2 HYDRAULIC PUMP PARTS ............ 7-6

7-2 HYDRAULICPUMPPARTS ............ 7-7

7-3 HYDRAULICPOWERUNITPARTS ........ 7-11

7-4 LIFTCYLINDERPARTS .............. 7-13

7-5 EX1ENSI0N CYLINDER PARTS .......... 7-15

7-6 WINCH PARTS .................... 7-17

7-6 WINCH PARTS .................... 7-18

7-6 WINCH PARTS .................... 7-19

V

C)

TG811-AT-MM0-010

SAFETY SUMMARY

The following are general safety precautions that are not related to any specific proce dures and therefore do not appear elsewhere in this publication. These are recom mended precautions that personnel must understand and apply during many phases of operation and maintenance.

WARNING notices are used to warn personnel about procedures which must be fol lowed for the protection of personnel. Failure to comply may result in injury or death to personnel.

CAUTION notices are used to warn personnel about procedures which must be fol lowed for protection of equipment. Failure to comply may result in damage to equip ment.

KEEP AWAY FROM LIVE CIRCUITS

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

DO NOT SERVICE OR ADJUST ALONE

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

REDUCE RISK OF ACCIDENTAL SHOCK

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

RESUSCITATION

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

WARNING AND CAUTIONS

The following warnings and cautions appear in this technical manual, and are repeated here for emphasis.

vi n WARNING n The equipment Is not designed or intended for lifting or moving people.

n WARNING n Maintain at least five dead wraps of wire rope on the drum at all times.

n WARNING n The start-up of this power unit should only be done by qualified technicians who are ex perienced in the operation of this equipment.

CAUTION I

Failure to open suction gate valve can cause premature pump failure.

CAUTION I

The on bypass setting in the return filter is 25 psi.

The filter element must be replaced before the pressure drop across the filter reaches 25 psi or contamination may enter the hydraulic pump and other critical components.

n WARNING n Before attempting to change oll make sure the system Is de-energized and tagged "Out-of-Ser vice."

n WARNING n Since troubleshooting sometimes requires the equipment to be operating, extreme care must be taken to avoid electrical circuits and moving parts.

n WARNING n Before attempting any maintenance on this equipment, disconnect all incoming power, relieve all pressure on the hydraulic lines and tag the equipment "Out of Service."

vii

Q

1-1

TGSll-AT-MM0-010

CHAPTER!

GENERAL INFORMATION AND SAFETY

PRECAUTIONS

INTRODUCTION

This manual provides information on the Boom Crane shown in Figure 1-1. It provides general information, operating instructions, functional description, scheduled maintenance, troubleshooting, corrective maintenance, parts listings and installation instructions.

1-2 SAFETY PRECAUTIONS

There are warnings and cautions placed throughout this manual. Every effort has been made to place these in the most appropriate place in the text It is recommended that personnel, not completely familiar with the equipment, read a complete procedure before operating or maintaining this equipment The warnings and cautions are also listed in the Safety Summary in the front of this manual.

1-3 GENERAL

The Boom Crane is a general purpose crane. It is used for loading and unloading miscellaneous equipment and supplies on and off the ship. The crane is powered by a hydraulic power unit (Figure 1-2) which is located below deck.

n WARNING n The equipment is not designed or intended for lifting or moving people.

1-4 REFERENCEDATA

Table 1-1 contains the reference data on the crane as well as the hydraulic power unit (HPU).

TABLE 1-1 REFERENCE DATA

CRANE

RATING

EXTENDED BOOM

RETRACTED BOOM

LINE PULL

CABLE

1-1

See chart on Figure 8-2

50feet

30feet

8, 330 lbs. at 80 feet per minute (fpm)

250 ft. of 5/8 inch diameter wire rope

TG811-AT-MM0-0IO

TABLE 1-1 REFERENCE DATA (CONT'D)

HYDRAULIC POWER UNIT

RESERVOIR

MOTOR

PUMP

PUMP DELIVERY

PRESSURE

1-5 TOOLS AND TEST EQUIPMENT

100 gallon steel tank

40 HP/460V /3PH/60Hz/1800RPM

Variable displacement, horsepower limited, axial piston pump

30 Gallons Per Minute (GPM)

3,250 P.S.l MAX

There are no special tools or test equipment required to maintain the crane. Table 1-2 is a list of common tools which can be found aboard ship.

·1-6 ENVIRONMENTAL AND STORAGE REQUIREMENTS

C) The environmental requirements to be considered during pre-installation storage are limited

- to covering the unit and placing it in a clean, dry environmentally controlled atmosphere.

Extended storage procedures should include periodic inspection to ensure packing integrity.

For efficient shipboard operation the unit should be properly preserved and lubricated to prevent deterioration due to ambient conditions, i.e., sea spray and verdigris. The crane is virtually unaffected by temperature and humidity.

1-2

(J

FIGURE 1-1 BOOM CRANE

1-3 n

I/ i!!!!

C)

I

TG811-AT-MM0-010

FILTER

[} I-€ tr

MOTOR

RESERVOIR

GATE

VALVE

ADAPTER

i - .__I ~ I ~ r

SUCTIIJC

STRAINER

SIGHT

61lU6£

I~= u _, ~ ..

-« meta

COUPLING

FIGURE 1-2 HYDRAULIC POWER UNIT

1-4

FILL

CAP

EL

L r c)

PIii' en

I

<J

TABLE 1-2 LIST OF TOOLS AND TEST EQUIPMENT

QTY DESCRIPTION STOCK NO. FSCM

1 2 lb machinist hammer 9Q-5120-00-061-8546 58536

1 Hand hacksaw 9Q-5120-00-289-9657 58536

1 Thickness gage 9Q-5210-00-221-1986 81349

1 Dial indicator with accessories 9Q-5210-00-377-6525 81349

1 Micrometer depth gage 9Q-5210-00-826-5368 81349

1 0-12" Vernier calipers 9Q-5210-00-293-2913 81348

1 6" Side cutting pliers 9Q-5210-00-239-8254 81348

1 Mechanical puller kit 9Q-5120-00-033-5606 81348

1 18" Machinist steel rule 9Q-5210-00-243-3367 81348

1 Flat tip screwdriver 9Q-5210-00-288-9708 81348

1 6" Machinist Try-Square 9Q-5210-00-190-3339 81349

1 1 1/2 lb Soft head hammer 9Q-5120-00-194-1647 81349

0 1 Socket head screw key set 9Q-5120-00-935-4641 55119

1 Multimeter, Simpson 260 series or equal 55026

1 6" Long nose pliers 9Q-5120-00-529-0841 81348

1 Retaining ring pliers 90° 9Q-5120-00-602-4845 03950

1 Drive pin punch set 9Q-5120-00-883-3003 03950

1 Screwdriver and wrench set 5/16" - 1" · 9Q-5120-00-165-4098 03950

1 Combination box & open end wrench set 9Q-5120-00-148-7917 58536

1 Socket wrench set, 1/4" Dr 9Q-5120~00-081-2305 06542

1 Socket wrench set, 1/2" Dr 9Q-5120-00-081-2307 06542

1-5

CHAPTER2

OPERATION

2-1 INTRODUCTION

TGSl!-AT-MM0-010

This chapter provides information on the operation of the crane and hydraulic power unit

(HPU).

2-2 INITIAL ST ART-UP

Upon initial start-up use the following procedure:

1. Lubricate the entire unit and check all fluid levels. Top off fluid as required.

2. Make sure the pump inlet valve is open.

3. Make sure the control valves are in their center, neutral positions.

4. Make sure all guards and covers are in place.

5. Inspect the entire unit for structural, mechanical, electrical, and hydraulic system damage or disassembly. Verify the unit is completely assembled.

0 6. Make sure the boom is not lashed down.

J

7. Clear the crane work area of personnel and equipment.

8. Energize the 460 V AC power supply to the crane.

9. Turn on the HPU control panel main disconnect switch.

10. Jog the pump motor and check for proper rotation. The motor should rotate clockwise when viewed from the shaft end. If rotation is incorrect, shut off all incoming power and interchange any two of the three 460V incoming leads. Again jog the motor to verify proper pump rotation. Replace the access cover.

11. Start the motor and allow the power unit to run for a few minutes. Slowly actuate each crane function. Operate each function for several minutes to purge all air from the system. Make sure each control lever operates the correct function in the proper direction as shown on the control stand legend plate.

12. Check for hydraulic leaks. Repair as necessary. Check hydraulic reservoir level with boom fully retracted and lowered. Fill as necessary. Shell Tellus 46 or equivalent hydraulic oil is reco=ended.

13. The unit is now ready to be put in service.

2-1

WARNING 11 _

This equipment is not designed or intended for lifting or moving people.

2-3 ROUTINE PRE-START CHECKS

Before starting or operating the unit, check the following:

1. Make sure that the unit has been properly lubricated and serviced.

2. Make sure the pump inlet valve is open. The valve is open when the handle is parallel to the valve body.

3. Make sure the control valves are in their center, neutral positions.

4. Make sure all guards and covers are in place.

5. Make sure the boom is not lashed down.

6. Make sure the winch wire rope is not frayed or damaged.

7. Clear the crane walkway and work area of personnel and equipment.

CJ 8. DO NOT attempt to lift loads which exceed load chart ratings.

2-4 SWING OPERATION

The swing control lever is located at the front of the operators station in the cab. To swing the crane to the left, push the control lever forward. To swing the crane to the right, pull the control lever back. The control should be moved smoothly and deliberately, not with a jerking motion. The aft crane is capable of 360° continuous rotation in either direction. The fwd. crane is restricted in rotation by stop blocks due to its location.

The swing control is a spring centered, proportional control. When the lever is released, the control will automatically return to the neutral position. Moving the lever progressively farther from the neutral position in either direction will increase the rate at which the crane swings.

When the swing control lever is in the neutral position, automatic spring actuated brakes will prevent any rotation of the crane. The degree of application of the automatic brake is controlled by the flow of oil through the adjustable needle valve in the 1/4 inch brake tank return line. ·

2-5 BOOMOPERATION

The boom lifting control lever is located at the front of the operators station in the cab. To lower the boom, push the control lever forward. To raise the boom, pull the control lever back. The control should be moved smoothly and deliberately, not with a jerking motion.

The boom lifting control is spring centered, proportional control. When the lever is released, the control is automatically returned to the neutral position. Moving the lever progressively farther from the neutral position in either direction will increase the rate at which the boom

2-2

CJ

raises or lowers.

The boom extension control lever is located at the front of the station in the cab. To extend· the boom, push the control lever forward. To retract the boom, pull the control lever back.

The control should be moved smoothly and deliberately, not with a jerking motion.

The telescoping control is a spring centered, proportional control. When the lever is released, the control will automatically return to the neutral position. Moving the lever progressively farther from the neutral position in either direction will increase the rate at which the boom telescopes retracts.

2-6 WINCH OPERATION

U WARNING n Maintain at least five dead wraps of wire rope on the drum at all times.

The winch control lever is located at the front of the operators station in the cab. To lower the load/hook, push the control lever forward. To raise the load/hook, pull the control lever back. The control should be moved smoothly and deliberately, not with a jerking motion.

The winch control is a spring centered, proportional control. When the lever is released, the control will automatically return to the neutral position. Moving the lever progressively farther from the neutral position in either direction will increase the rate at which the hook is raised or lowered.

2-7 HYDRAULIC POWER UNIT

The following paragraphs describe the operation procedures for the power unit

U WARNING n The start-up of this power unit should only be done by qualified technicians who are experienced in the operation of this equipment.

2-7.1 Pre-Start-Up Precautions

1. Safety glasses should be worn by all persons involved in the start-up or in the area of the power unit during start-up.

2. Stand clear of all machinery during the start-up.

3. Make sure all electrical enclosures are closed before operation of any equipment.

4. All machinery protective guards should be replaced before start-up.

5. Each pipe hose fitting should be checked to make sure it is tight before start-up.

2-3

CJ.·

2-7.2 Filling the Reservoir

After all connections are completed, the power unit may _be filled with oil. Use a premium grade hydraulic fluid with anti-wear additives and a viscosity of approximately 150 SSU at 100 degrees F. Use only new oil from unopened drums, and check drums for any signs of particle or water contamination. Fill the unit by pumping the oil through a 10 micron or better filter into the filler/breather cap strainer basket. The strainer basket is intended only to keep large items from falling into the tank and is not a suitable filter itself. Fill to the full line. Ignoring this procedure could cause premature pump failure.

2-7.3 Motor Rotation

CAUTION

Failure to open suction gate valve can cause premature pump failure.

Before bumping motor starter to check motor rotation, open suction gate valve. Failure to open valve can cause premature pump failure. The shoes can be sucked off the pump pistons.

Have someone look at the rear of the motor and observe the rotation while the start and stop buttons are rapidly jogged (one second max.) The motor should turn clockwise when viewed from the rear. If it does not, have an electrician modify the wiring and check again.

2-7.4 Running the System

After all of the previous instructions have been met the system may be run. Start the pump by pressing the start button. The pump should have a sort of loud hammer noise, then quiet down a little. Follow the fluid lines to the crane and be sure there are no oil leaks. If leaks are found, turn the unit off and repair them. While the unit is running, check the motor amps on all 3 lines for overload or imbalance. Also check tank and pump for heat If you can not hold your hand any place for more than 2-3 seconds the system is too hot and should be shut off and checked out for malfunctions. On initial start-up allow unit to run about 15 minutes before operating crane. Check fluid level after filling lines, the level should be at the full line when the boom is down.

2-7.5 Shutdown

Providing that the crane is not being operated, the power unit may be shut down at any time.

Just press the stop button on the motor starter. There is no need to close the suction valve, unless the pump is to be repaired.

2-4

TGSI I-AT-MM0-010

CHAPTER3

FUNCTIONAL DESCRIPTION

3-1 INTRODUCTION

This chapter provides information on the description of the crane, hydraulic power unit and components of the system.

3-2 CRANE

The crane is a pedestal mounted, extendable boom unit designed for weather deck mounting in a marine environment. The unit has an open operators cab. The unit is powered by an electro-hydraulic, open loop system. The crane is rated to handle 16,700 pounds at a 25 foot radius. The unit is capable of operation with rated loads at list angles of up to 5°. The crane is designed to ABS and USCG requirements.

3-2.1 Pedestal

The pedestal is a fabricated steel cylinder with a 44 inch diameter. It is designed to be welded onto the deck foundation. The pedestal is bolted to the turret structure with 30 each 1 inch bolts.

3-2.2 Turret

The turret is a steel weldment. It is connected to the pedestal through the turntable bearing · and provides anchor points for the boom and boom cylinders as well as suppon for the crane upper structure. The operators platform and access ladder are mounted to the turret.

3-2.3 Boom

The boom is a box section weldment of 50 ksi structural steel. The heel of the boom is outfitted with two bronze bushings which pivot on a heat treated stainless steel pin. The retracted boom length is 30 feet. Maximum extended length is 50 feet. The telescoping boom sections slide on self lubricated nylon pads. The boom is equipped with one winch.

3-2.4 Operators Platform

The operators cab is an open steel cage providing an operation station fixed to the crane turret.

3-2.S Proportional Control Valve

A hydraulic proponional/directional control valve is located in the operators cab. A multiple section hydraulic control valve is used to control the crane swing, boom telescoping, winch and boom luffing functions. All spool sections feature manual spring centered to neutral.

The fanher the spool is moved off its neutral position the greater the delivered flow of hydraulic fluid. The control valve is an "open center" type where all hydraulic lines are connected to the tank when the spools are in the neutral position. Through the parallel circuitry of the multisection control valve, multiple functioning of the crane is possible.

3-2.6 Swing System

0 The crane swing system consists of a hydraulic motor, planetary gear reducer and enclosed

3-1 hydraulic brake assembly with output pinion that drives on the swing bearing gear. Crane rotational speed is variable from O to LO rpm. The crane will function with rated load at up to a 5° lisL The brakes provide positive static locking of the swing system. The brakes are released by hydraulic pressure from a shuttle valve located in the swing counterbalance valve_ Application of the brakes is adjusted by a needle valve in the brake tank line. The cartridge type dual load counterbalance valve controls flow to prevent cavitation and keeps the crane from swinging ahead of the pump in a list condition. The crane is capable of 360 degree rotation.

3-2.7 Luffing System

Raising and lowering of the main boom is accomplished by an 11 inch bore hydraulic cylinder- The cylinder is equipped with heat treated, stainless steel rods and integral cartridge type counterbalance valves. The counterbalance valve will hold the boom in the event of a loss of hydraulic pressure to the lift side of the cylinder. The boom system is capable of topping to a maximum boom angle of 80 degrees.

3-2.8 Boom Extension System

Extending and retracting the boom is accomplished by a single 7 inch bore hydraulic cylinder. The cylinder is equipped with a heat treated stainless steel rod and integral cartridge type counterbalance valve. The counterbalance valve prevents boom retraction in the event of a loss of hydraulic pressure. The telescoping system is capable of extending and retracting the boom from the minimum retracted boom length of 30 feet to the maximum extended length of 50 feet_

3-2.9 Winch

The hoisting system consists of a boom mounted hydraulic winch located near the heel of the boom. An automatic, failsafe, wet, multidisc, spring applied hydraulically released brake is designed for both static and dynamic braking applications. The winch is capable of an 8,330 pound line pull at 80 feet per minute (FPM) on the mean drum layer. The winch is spooled with 250 feet of 5/8 inch diameter wire rope. The crane is supplied with a 15 ton hook block with swivel hook.

3-3 HYDRAULIC POWER UNIT

The electro-hydraulic power unit is located below deck. The hydraulic pump and electric motor are located beneath the hydraulic reservoir on a common base. Power is supplied to the hydraulic power unit by the shipboard electrical system. The HPU electric motor is an A.C.

motor, 40 HP, severe duty, 1.15 service factor, 1EFC, horizontal foot mount, C face, 1800 RPM, 3 Phase, 460V, 60 Hz. The hydraulic pump consists of a variable displacement, horsepower limited, axial piston pump. The pump is supported by a pump mount on the electric motor and is driven by the electric motor through a gear type coupling. Maximum pump delivery is 30 gallons per minute (GPM) with pressure capabilities to 3250 pounds per square inch (PSI). The reservoir is a 100 gallon steel tank equipped with a pump inlet shutoff valve, return line filter and indicator, oil level gauge, oil temperature gauge, tank drain valve, access cover and tank breather.

3-2

CHAPTER4

SCHEDULED MAINTENANCE

4-1 . INTRODUCTION

This chapter provides information on the scheduled maintenance for the crane and hydraulic power unit. Scheduled maintenance can be described as those tasks performed at periodic intervals to keep the equipment operating at its peak condition and minimize unnecessary down time.

"The scheduled maintenance instructions in this manual are not intended to duplicate those furnished in the Planned Maintenance System (PMS). In case of conflicts, the PMS documentation takes precedence. Such conflicts should be reported immediately on the user comment in accordance with the maintenance procedures for this manual."

4-2 MAINTENANCE PLAN

The maintenance plan, Table 4-1, contains tasks to be performed on the hydraulic power unit, time intervals for performing the tasks and action to be taken.

4-3

CAUTION

The oil bypass setting in the return filter is 25 psi. The filter element must be replaced before the pressure drop across the filter reaches 25 psi or contamination may enter the hydraulic pump and other critical components.

HYDRAULIC OIL CHANGE

Use the following procedure to change the hydraulic oil in the reservoir annually or whenever the oil fails an analysis test.

u WARNING H Before attempting to change oil make sure the system is de-energized and tagged 11 Out-of-Service. 11

1. Before draining, close the valve which feeds the pump inlet.

2. Place a suitable (100 gallon) waste oil container under the drain valve.

3. Remove the plug from the drain valve and open the valve to drain the oil.

4. Remove the access cover on the top of the reservoir.

/~) 5. Clean out the inside of the reservoir with mineral spirits and clean lint free rags.

4-1

TG811-AT-MM0-010

6. Remove the suction strainer and clean it in sol vent.

7. Dry the strainer with dry filtered air and replace.

8. Replace the return line filter element. (para. 4-4)

9. Replace the access cover and gasket on the top of the reservoir.

10. Close the drain valve and install the drain plug.

11. Refill the tank, through the filler/breather, with TELUS 46 or similar hydraulic oil to the full mark (approx. 85 gallons).

12. Open the pump inlet valve.

4.4 RETURN FILTER REPLACEMENT

Use the following procedure to replace the return filter element when so indicated by the visual dirt alarm (back pressure over 25 psi) which is located in the filter head or when changing the hydraulic oil.

NOTE

In cold weather, the din alarm may indicate that the filter is plugged until the oil warms up.

1. Shut down the systems power unit supply and relieve pressure in the filter line.

2. Loosen the hex head cap screws on the cover.

3. Turn cover until cover slots clear the cap screws and remove cover.

4. Remove the element from the housing or cover. Discard all disposable (not cleanable) elements. These include paper, water removal and fiberglass composite types. Woven wire elements are cleanable and may be reused. Ultrasonic cleaning is the best method of dislodging trapped dirt.

5. Place a new or cleaned element in housing, centering it on location in the bottom of the bowl.

6. Inspect the cover o-ring seal and replace if necessary.

7. Replace cover, centering the bypass assembly in the element.

8. Tighten the hex head cap screws to 140-160 in. lbs.

4.5 SWING DRIVE LUBRICATION

The oil level in the swing drive should be checked every three months. The oil level is checked through the plug on the side of the swing drive housing. If the oil level is below the plug, add SAE 90 gear lube through the fill plug on top of the swing drive.

r:J The swing drive should be drained and refilled annually. Before draining, operate the drive

4-2 for several minutes to agitate the oil. The drain plug is located on the bottom of the swing drive at the base of the housing. Refill the swing drive with SAE 90 gear lube (capacity = 10 quarts).

4-6 TURNTABLE BEARING

The turntable bearing should be greased every 8 hours of operation, or monthly. The bearing should be greased at all four zerks, then rotated about 45 degrees and greased again. The bearing should be. greased at 45 degree intervals until a full rotation of the bearing has been made. Use a marine grease, Shell Alvania EP #2 or equivalent.

The bearing gear teeth should be brushed or swabbed with open gear compound on a monthly basis or any time bare metal is exposed. The crane should be rotated in increments until all of the gear teeth have been swabbed with Texaco Crater 2X Fluid or equivalent.

The bearing bolt torques should be checked after every 100 hours of operation. Each bolt on the rotex bearing (inside and outside bolt circle) should be torqued to 750 ft. lbs.

4-7 BOOM LIFT CYLINDER

Although the cylinder rod is stainless steel, it should periodically be wiped off and coated with a light oil for protection, especially during prolonged idle periods. The bronze bearings in the cylinder attachment lugs should be greased every 8 hours of operation or monthly with a H.P. marine grade grease.

4-8 BOOM EXTENSION CYLINDER

Althouth the cylinder is enclosed in the boom, the cylinder rod should periodically (monthly if possible) be wiped off and coated with a light oil for protection. The bearing in the cylinder attachment lug should be greased monthly with a H.P. marine grade grease.

4-3

() TABLE 4-1 MAINTENANCE PLAN

COMPONENT INTERVAL ACTION

Oil Level Daily Check the oil level in the reservoir when the boom is down. Add as necessary.

Oil Filter Daily When the pump is running and warm, check the oil filter indicator for bypass. If the gauge reads anywhere near 25 psi , the filter is bypassing and needs replaced.

Piping Daily Check piping for leaks and repair as necessary.

Electrical Daily Check wiring and electrical enclosures for signs of damage and repair as necessary.

Fasteners Monthly Check fasteners on the power unit for signs of loosening and retighten if necessary.

Coupling Monthly Remove the motor/pump shaft coupling inspection cover and inspect

C) the insert for excessive wear. Replace as necessary.

Oil Monthly Take a sample of the oil by loosening a fitting in the pressure line, with the unit turned off. Have it analyzed for particulate and water content and viscosity breakdown. The oil must be maintained clean to the equivalent of an SAE Class 4. Change as necessary.

Oil Annually Change the hydraulic oil. See paragraph 4-3.

Exterior Surfaces As Required , Check the exterior of the crane and hydraulic power unit for dirt, grease, rust or chipped paint. Clean and/or touch up paint as required.

4-4

CHAPTERS

TROUBLESHOOTING

5-1 · INTRODUCTION

TG811-AT-MM0-010

This chapter provides information on troubleshooting the crane and hydraulic power unit should a malfunction occur. This information will aid you in localizing a problem down to a component or a part of a component in the system.

n WARNING n Since troubleshooting sometimes requires the equipment to be operating, extreme care must be taken to avoid electrical circuits and moving parts.

5-2 TROUBLESHOOTING CHART

The troubleshooting chart, Table 5-1, contains symptoms for a malfunction, probable causes for the symptoms and corrective actions to be taken to correct the malfunction. This chart can neither list all malfunctions that might occur or all corrective actions that might be required to correct the malfunction. This chart is to be used as a guide only. There is no substitute for knowledge and experience.

5-1 n ___ _, TABLE 5-1 TROUBLESHOOTING CHART

SYMPTOM PROBABLE CAUSE(S) CORRECTIVE ACTION

Electric motor will not 1. No incoming power. 1. Tum on power .. Put motor start when button is · controller disconnect to "ON" depressed. position.

2. Overload heater, elements 2. Allow motor to cool about have tripped out 5 minutes and try to start again.

3. Fuse blown. 3. Check fuses in motor controller and replace.

.. 4. Failure of one or more 4. An electrician should components in motor starter make a check of the electrical circuit. circuit.

Electric motor running. 1. Motor coupling failure. 1. Disassemble motor No pump output coupling and inspect for damage.

2. Pump running backwards. 2. Check pump rotation by jogging motor. Proper pump rotation is clockwise when viewing shaft end of electric motor.

3. Oil level in hydraulic 3. Check fluid level. Add to reservoir low. full mark on gauge.

4. Pump failure. 4. Replace pump.

Swing function does not 1. Brake does not release. 1. Check brake line pressure.

work. Need 180 psi to release brake. ·

2. Relief valve setting too low. 2. Adjust relief valve.

3. Counterbalance valve leaking.

3. Consult factory.

4. Failure of swing drive. 4. Disassemble swing drive and inspect for damage or excessive wear.

S. Failure of swing drive 5. Disassemble hydraulic hydraulic motor. motor and inspect for damage or excessive wear.

5-2

TABLE 5-1 TROUBLESHOOTING CHART (CONT'D)

SYMPTOM PROBABLE CAUSE(S) CORRECTIVE ACTION

Cylinders will not lift 1. Load exceeds rating. 1. Reduce load.

load

2. Pump compensator setting too 2. Adjust pump low. compensator.

3. Relief valve setting too low. 3. Adjust relief valve.

Cylinders will not hold a 1. Load exceeds rating. 1. Reduce load.

load. Cylinders leak down. 2. Counter balance valve leaking. 2. Consult factory.

3. Cylinder seal failure. 3. Disassemble cylinder and replace seals.

Winch will not lift load. l. Load exceeds rating. 1. Reduce load.

2. Relief valve setting too low. 2. Adjust relief valve.

3. Winch failure. 3. Disassemble winch and inspect for damage or excessive wear.

CJ 4. Winch hydraulic motor failure. 4. Disassemble hydraulic motor and inspect for damage or excessive wear.

5. Brake does not release. 5. Check brake line pressure. Need 180 psi to release brake.

Leaks at fittings. 1. Loose fitting. 1. Tighten fitting.

2. Damaged or missing a-ring. 2. Replace a-ring.

3. Cracked fitting. 3. Replace fitting.

Excessive noise or 1. Mounting hardware loose or 1. Tighten or replace vibrations. missing. mounting hardware.

2. Motor/pump misalignment 2. Align motor/pump.

3. Air in hydraulic system. 3. Bleed air from system.

5-3

TG811-AT-MMO-OI0

CHAPTER6

CORRECTIVE MAINTENANCE

6-1 INTRODUCTION

This chapter contains information on the corrective maintenance procedures for the crane and hydraulic power unit (HPU). Corrective maintenance can be described as those procedures performed to restore equipment to operational status after a malfunction has occurred.

n WARNING n Before attempting any maintenance on this equipment, disconnect all incoming power, relieve all pressure on the hydraulic lines and tag the equipment "Out of Service."

6-2 MAINTENANCE

This equipment has been manufactured to provide years of maintenance free service. Should a malfunction occur, maintenance at this level will normally be limited to the removal and replacement of the electric motor/hydraulic pump on the hydraulic power unit or replacement of the winch on the crane. These procedures are explained in the following paragraphs.

6-3 HYDRAULIC POWER UNIT

Use the following procedures to replace the motor/pump assembly.

6-3.1 Removal

Use the following procedure to remove the motor/pump assembly.

1. Remove incoming power to the electric motor and tag "Out-of-Service."

2. Close the gate valve from the reservoir to the pump input.

3. Bleed any hydraulic pressure from the system.

4. Remove the two screws and open conduit box on the electric motor.

5. Remove and tag the electrical wires from the motor.

6. Remove the input and output hydraulic hoses from the pump.

7. Connect a suitable lifting system to the motor/pump assembly.

8. Remove the four bolts, washers and nuts that hold the motor to the foundation.

9. Using the lifting system remove the motor/pump assembly and place it on a suitable work area.

6-1

'C)

10. Open the access in the motor/pump adapter and loosen the coupling.

11. Remove the bolts and washers on the motor or pump end of the adapter, whichever is defective.

12. Remove the defective motor or pump.

6-3.2 Installation

Use the following procedure to install the motor/pump assembly.

1. Set the new motor or pump in position against the adapter.

2. Align and tighten the coupling.

3. Install bolts and washers into the motor or pump end of the adapter.

4. Connect a suitable lifting system to the motor/pump assembly.

5. Lift the assembly and move it into position in the hydraulic power unit.

6. Align the motor mount to the mounting holes in the foundation.

7. Install the four mounting bolts, washers and nuts, but do not tighten.

8. Connect the input and output hydraulic hoses to the pump.

9. Check and align coupling if necessary.

10. Tighten mounting bolts on motor.

11. Connect electrical wiring to the motor and remove tags.

12. Place the cover on the conduit box and install the two screws.

13. Open the gate valve between the reservoir and the input to the pump.

14. Restore electrical service to the unit.

6-4 WINCH REPLACEMENT

Use the following procedures for the replacement of the winch on the crane.

6-4.1 R.emoval

Use the following procedure to remove the winch.

1. Remove all incoming power to the system and tag the system "Out-of-Service."

2. Close the hydraulic valves to the winch motor.

3. Bleed any hydraulic pressure from the system.

6-2

TG811-AT-l\1M0-0IO

4. Remove the wire rope from the winch.

5. Remove all hydraulic lines to the winch.

6. Connect a suitable sling and lifting device to the winch.

7. Remove the eight mounting bolts, washers and nuts from the winch and crane.

8. Remove the winch from the crane and place on a suitable surface.

6-4.2 Installation

Use the following procedure to install the winch on the crane.

1. Connect a sling and a suitable lifting device to the replacement winch.

2. Lift the winch and place it in position on the crane.

3. Line-up the mounting holes in the winch and crane.

4. Install the eight mounting bolts, washers and nuts.

5. Remove the sling and lifting device from the winch.

6. Connect the hydraulic lines to the winch.

,C) 7. Install the wire rope on the winch.

8. Open the hydraulic valves to the winch.

9. Restore power to the system and remove tags.

6-3

CHAPTER7

PARTS LIST

7-1 INTRODUCTION

This chapter provides information on parts for the crane and hydraulic power unit. The parts are listed in the parts tables and are referenced to a drawing for their location.

7-2 PARTS LIST

The parts lists or tables in this chapter contain the following columns and information.

7 -2.1 Figure and Item Number

This column contains the Figure and Item number where the part is located.

7-2.2 Description

This column lists the noun name of the referenced with a description as necessary.

7-2.3 Qty/Unit

This column lists the quantity of the part needed for one complete unit.

7-2.4 FSCM

This column list the Federal Supply Code for the Manufacturer (FSCM) for the company that makes the part.

7-2.5 Part Number

This column lists the manufactures part number that is assigned to the part.

7-1

C) TABLE7-1 ELECTRICMOTORPARTS

FIG& DESCRIPTION QTY/ FSCM PARTNUMBER

ITEMNO. UNIT

7-1

1 Body Assembly 1 38151 A-B22583-116 2 Stator Winding 1 38151 H-324480-6 3 Front Bracket 1 38151 A-26781D-Y 4 Rear Bracket 1 38151 A-22465AD-Y

5 Rotor Assembly 1 38151 A-KC144E50NJ-15 6 Bearing Cap 1 38151 A-503367F-A

7 Screw, Bearing Cap 2 38151 A-9680-125 8 Not Used

9 Bearing 1 38151 A-7812R-55 10 Ext. Slinger 1 38151 A-511008-14 11 Bracket Screw 4 38151 A-9626-175CC 12 Key 1 38151 A-20187-32

0 13 Shaft 1 38151 B-26960-1150 14 Conduit Box

Mtg. Half 1 38151 A-510181A-Y

Screw Mtg. 2 38151 A-9680-125

Gasket 1 38151 A-26926

Cover 1 38151 A-503471A-Y

Screw-Cover 2 38151 A-9646-25CC

Gasket 1 38151 A-506413

15 Grease Drain

Plug-Both Ends 2 38151 A-7497-lCC

Coupling 1 38151 A-7496-lCC

Nipple 1 38151 A-7495-525C

16 Cover Screw 4 38151 A-9680-lOOCC

17 Ldg. Spring 1 38151 A-7661-558

18 Fan 1 38151 D-511521

7-2

TABLE 7-1 ELECTRIC MOTOR PARTS (CONT'D)

FIG&

DESCRIPTION QTY/ FSCM PARTNUMBER

ITEMNO. UNIT

19 Grease Fill

Plug-Both Ends 2 38151 E-4850-ICC

Coupling I 38151 A-11276-lCC

Nipple I 38151 A-7625-575CC

20 Eyebolt I 38151 A-9935-4A90

21 Fan Cover 1 38151 A-22467A-Y

22 Bearing 1 38151 A-2812R-55

23 Bearing Cap I 38151 A-23399C-Y

24 Screw, Bearing Cap 2 38151 A-9680-125CC

C)

7-3

TG8I l-AT-MM0-010

0 "------------~

FIGURE 7-1 ELEC1RIC MOTOR

7-4

C) TABLE 7-2 HYDRAULIC PUMP PARTS

FIG& DESCRIPTION QTY/ FSCM PARTNUMBER

ITEMNO. UNIT

7-2 1 Bearing 1 57760 735551 2 Seal 1 57760 786303 3 Piston Assembly 7 57760 786263 4 Barrel 1 57760 786293 5 Swash Plate 1 57760 786295 6 Housing-Trunnion 1 57760 786273 7 Pin-Trunnion 1 57760 786305 8 Ring-Seal 1 57760 786271 9 Retainer-Slipper 1 57760 786222 10 Ball Seat 1 57760 786223 11 Spring-Barrel 1 57760 786224 12 Piston-Servo 1 57760 786301

0 13 Spring-Servo 1 57760 786302 14 Plug-Servo 1 57760 786314 15 Bearing 2 57760 786304 16 Cap-Trunnion 2 57760 786306 17 Thrust Washer 2 57760 786307 18 Plug-Orifice 1 57760 786060 19 Plug 1 57760 745987 20 Spring-Pressure 1 57760 785170 21 Dart 1 57760 785379 22 Adj. RN Seat 1 57760 786100

23 Plug 1 57760 755342 24 Air Bleed Assembly 1 57760 786328 25 Spool Assembly 1 57760 786079 26 Retainer - Spring 1 57760 786116

27 Spring-Mod 1 57760 786113

28 Piston 1 57760 786276

29 Cap-Differential Adjustment 1 57760 786313

7-5

TABLE 7-2 HYDRAULIC PUMP PARTS (CONT'D)

FIG& DESCRIPTION QTY/ "FSCM PART NUMBER

ITEMNO. UNIT

30 Adjustment Screw 1 57760 786275 31 Snap Ring 1 57760 56x 339 32 Snap Ring 1 57760 56 X 218 33 Snap Ring 1 57760 56x 320 34 Roll Pin 2 57760 99x 81

35 Plug 5 57760 108x4

36 Cap Screw 4 57760 10 X 301

37 Cap Screw 2 57760 lOx 293 38 Snap Ring 2 57760 56x 325

39 Ball 1 57760 98 X 16 40 Plug 1 57760 102x 1

41 Nut 1 57760 16x 23 42 Nut 1 57760 16 X 16

CJ 43 Jan Nut 1 57760 17 X 20 44 Jan Nut 1 57760 17 X 3

45 Name Plate 1 57760 786080 46 Drive Screws 2 57760 39x4 47 Back-Up Ring 1 57760 107 X 15 48 Back-Up Ring 1 57760 107 X 14

49 Back-Up Ring 1 57760 107 X 13

50 Back-Up Ring 1 57760 107 X 11

51 Back-Up Ring 2 57760 107x8

52 Back-Up Ring 1 57760 107x7

53 Washer 1 57760 786393

54 0-Ring 1 57760 2-015N-7

55 0-Ring 1 57760 2-014N-7

56 0-Ring 1 57760 2-013N-7

57 0-Ring 1 57760 2-0llN-7

58 0-Ring 2 57760 2-008N-7

59 0-Ring 1 57760. 2-007N-7

7-6

TG811-AT-.MM0-0IO

(J TABLE 7-2 HYDRAULIC PUMP PARTS (CONT'D)

FIG& DESCRIPTION QTY/ FSCM PARTNUMBER

ITEMNO. UNIT

60 0-Ring 1 57760 2-0SON-9

61 0-Ring 1 57760 2-027N-9

62 0-Ring 2 57760 2-031N-7

63 0-Ring 1 57760 3-916N-9 64 0-Ring 2 57760 3-910N-9

65 0-Ring 1 57760 3-904N-9

66 Not Used

67 Shipping Plug (Not Shown) 1 57760 120 X 12

68 Shipping Plug (Not shown) 1 57760 120 X 32

69 Shipping Plug (Not shown) 1 57760 120 X 41

70 Not Used

71 Straight Shaft 1 57760 786299

72 Key 1 57760 22x 31

73-77 Not Used

78 Housing Assembly 1 57760 786325

79 Pon Plate 1 57760 786454

80-81 Not Used

82 Plug 1 57760 786269

7-7

_70 R/lbs.

Torque mm~

• - 1

! --.. -.. NI_

,_ .. --.:a --~=:.

TG81 l-AT-MM0-010

1;.,.J,-,-" p.c1•>f ,.._ Wv~ Q,_:., f'f 'i f"-'f

FIGURE 7-2 HYDRAULIC PUMP (SHEET 1 OF 3)

7-8

3233 2 34

120ftJlbs. __ 1 4 Torque

SECTION X-X

3 35 4

12 53 11 10

SECTION 2-2

35 _ 20 ft.libs.

Torque

18 _ 9 ft.libs.

.Torque

61 9

FIGURE 7-2 HYDRAULIC PUMP (SHEET 2 OF 3)

7-9

TG811-AT-MM0-010

I 25-30 ftJlbs.

Torque

35 24 64 25

L '\_ 50 ftJlbs.