TP_90-60_A.pdf

TP: 3557

(HM&E MANUAL)

Department of Homeland Security

UNITED STATES

COAST GUARD

DISTRIBUTION STATEMENT D - Distribution authorized to Department of Homeland Security, DoD and their contractors to protect publications required for official use or for administrative or operational purposes only;

determined on 07 JAN 1997. Other requests for this document shall be referred to Commander, USCG Surface Forces Logistics Center, ESD – Tech Info Mgmt Br, 2401 Hawkins Point Road, Baltimore, MD 21226.

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979 (Title 50, U.S.C., App. 2401 et seq.), as amended. Violations of these export laws are subject to severe criminal penalties.

DESTRUCTION NOTICE - For unclassified, limited documents, destroy by any method that will prevent disclosure of contents or reconstruction of the document.

PUBLISHED UNDER AUTHORITY OF THE U.S. COAST GUARD

SWBS: 573

SECTION: A

TECHNICAL MANUAL

CRANE, BUOY - MODEL TB90-60

MARINETTE MARINE CORPORATION

Individual Manual Application Sheet

Technical Publications Number

Section Applicability

SWBS Number 573

SWBS Element Title

CARGO HANDLING SYSTEMS (CARGO,

BUOYTENDING EQUIPMENT, CRANES AND

BOOMS)

Section Identifier A

Equipment Functional Description CRANE, BUOY - MODEL TB90-60

CI Functional Description ESWBS Code Remarks SEE TECHNICAL PUBLICATION 3498

Planset Hulls

225-WLB 201, 202, 203, 204, 205

TP- 3557 Section A

LIST OF EFFECTIVE PAGES

INSERT LATEST CHANGED PAGES. DESTORY SUPERSEDED PAGES

NOTE: The portion of the text, tables, and figures affected by the changes are indicated by a vertical line in the outer margin of the page. Changes to illustrations are indicated by pointing hands.

Changes to wiring diagrams are indicated by shaded areas.

Date of issue for original and changed pages are:

Original......................0 .................. 15 JUN 1996

Change.......................6 .................. 10 SEP 2007

Change.......................1 .................. 15 MAY 1998 Change.......................7 .................. 19 JUN 2008

Change.......................2 .................. 29 JAN 2001 Change.......................8 .................. 20 JAN 2009

Change.......................3 .................. 16 JUN 2004 Change.......................9 .................. 01 APR 2009

Change.......................4 .................. 01 APR 2006 Change.......................10 ................ 07 NOV 2014

Change.......................5 .................. 01 MAR 2007 Change ...................... 11................18 JUN 2015

PAGES IN THIS PUBLICATION, CONSISTING OF THE FOLLOWING:

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

Title Page/(Blank)

LOEP-1

LOEP-2

Technical Manual Validation Certificate, (dated 5/10/01)/(Blank) Technical Manual Validation Certificate, (dated 5/15/98)/(Blank) Change Record-1 Change Record-2 Forward/List of Abbreviations/Acronyms Page i Pages ii Page iii and iv Page v Page vi Pages vii thru xii(Blank) Page 1-1 Page 1-2 Page 1-3 Page 1-4 Pages 1-5 and 1-6 Page 1-7 Page 1-8 Pages 2-1 thru 2-7 Pages 2-8/(Blank) thru 2-10 Pages 2-11 and 2-12 Pages 2-13 and 2-14 Page 3-1 Page 3-2 Page 3-3 Pages 3-4 and 3-5 Page 3-6 thru 3-8 Pages 3-9 thru 3-12 Page 3-13/3-14(Blank) Page 3-15/3-16(Blank) Page 3-17/3-18(Blank) Page 4-1 Page 4-2 Page 4-3

Page 4-4 Page 4-5 Page 4-6 thru 4-6b Page 4-7/(Blank) Pages 5-1 thru 5-8 Page 6-1 Pages 6-2 thru 6-5 Pages 6-6 thru 6-18 Page 6-19 Pages 6-20 thru 6-31 Pages 6-32 thru 6-38 Page 6-39 Page 6-40 Page 7-1 Page 7-2 Pages 7-3 thru 7-5 Pages 7-6 and 7-7 Page 7-8 Page 7-9 Page 7-10 Page 7-11 Pages 7-12 thru 7-19 Pages 7-20 and 7-21 Page 7-22 Pages 7-23 and 7-24 Page 7-25 Pages 7-26 thru 7-32 Page 7-33 Pages 7-34 and 7-35 Pages 7-36 thru 7-40 Pages 7-41 thru 7-42 Pages 7-43 thru 7-45 Page 7-46 Pages 7-47 thru 7-51 Page 7-52 Page 7-53 Page 7-54 Page 7-55 Pages 7-56 thru 7-60

LOEP-1

TP- 3557 Section A

Pages 7-61 thru 7-63 Pages 7-64 thru 7-66 Pages 7-67 thru 7-77 Pages 7-78 and 7-79 Page 7-80 Pages 7-81 thru 7-89 Pages 7-90 thru 7-90C Page 7-90D

Pages 7-91 thru 7-95 Page 7-96 Pages 7-97 and 7-98

Pages 8-1 and 8-2 Page 8-3 Page 8-4 Pages Index 1 thru Index 3/(Blank)

APPENDIX A (4 pages)

APPENDIX B (40 pages)

(*) Zero indicates an original page

LOEP-2

APPENDIX C (46 pages)

APPENDIX D (14 pages)

APPENDIX E (4 pages)

Pages 7-90E and 7-90F

Change Record-1

CHANGE RECORD

CHANGE

NO.

DATE TITLE AND / OR BRIEF

DESCRIPTION

SIGNATURE

1 05/15/98 Incorporate Swing Modification and Swivel Sheave addition.

2 01/29/01 Changed Lubrication requirement for Boom Pivot Pin & deleted O-Ring from Boom to Turret Assembly.

3 06/16/04 To provide updated parts list for the Extension Cylinder Assembly.

4 04/01/06 Added procedure for testing the Rotek bearing located in the Crane Swivel.

5 03/01/07 Incorporated changes to document the change from a 5 sheave regular steel dynamometer to a 3 sheave stainless steel unit, as well as included information for the Anti-2-Block system.

6 09/10/07 The purpose of this change is to submit updated information resulting from the modification of the crane control.

7 06/19/08 Added National Stock Numbers to Table 7-11 Boom Lift Cylinder, LH and Table 7- 12 Boom Lift Cylinder, RH.

8 01/20/09 The purpose of this change is to incorporate an Engineering Change which removes the Constant Tension feature from the Main Winch.

9 01/01/09 The purpose of this change is to incorporate an Engineering Change which replaces the obsolete CH185 auxiliary winch with a current CH210 winch.

10 11/07/14 Crane constant tension winches (GH50CT) were replaced by non-constant tension winches (GH50). Winch installation tightening decreased from 800 lb-ft to 775 lb-ft. in approximately 40 lb-ft increments.

DKR/USCG

CHANGE RECORD

CHANGE

NO. DATE TITLE AND / OR

BRIEF DESCRIPTION SIGNATURE

11 6/18/15 Replaced Paragraph 4-7, Crane Swivel Bearing Inspection Procedure with the new Turntable (slewing, swivel) Bearing Clearance Inspection Procedure, TP 3557 Crane, Buoy Model TB90-60.

SLF/USCG

Change Record - 2

12 12/15/15 Added Appendices C-E. Replaced outdated information related to the Anti Two-Block

(AMD-123).

ARC/USCG

FOREWORD

This technical manual includes installation, operation, maintenance, and repair instructions, with a parts list, for the CRANE, BUOY, model TB 90-60 equipment aboard WLB JUNIPER class ships. This manual covers the following:

Chapter No. . . . . . . . . . . . . . . . . . . . Title

1. . General Information and Safety Precautions

2. . . . . . . . . Operation

3. . Functional Description

4. Scheduled Maintenance

5. . . . . . Troubleshooting

6. . Corrective Maintenance

7. . . Parts List

8. . . Installation

Ships, training activities, supply points, depots, and Supervisors of Shipbuilding are requested to arrange for the maximum practical use and evaluation of U.S. Coast Guard technical publications.

All errors, omissions, discrepancies, and suggestions for improvement to U.S. Coast Guard technical publications shall be reported to the Commander, U.S. Coast Guard.

LIST OF ABBREVIATIONS/ACRONYMS

ABS. American Bureau of Shipping F Fahrenheit Adj Adjust/ Adjustable c Celsius ADV. Advance fpm feet per minute API American Petroleum Institute FSCM. Federal Supply Code for APL . Allowance Parts List Manufacturers AIR As Required G/GR Grade ASC. Allied Systems Company Gal Gallon Asm/Assy Assembly Galv. Galvanized ATB Anti-Two-Block Gnd. Ground Aux Auxiliary GPM Gallon Per Minute bar x 14.5 = psi GRN Green BLK Black GRY. Gray BLU Blue Hd Head Brg Bearing Hel Helical BRN. Brown HP Horse Power Cad . Cadmium HPU. Hydraulic Power Unit CAGE Commercial And Government Hvy Heavy

Entity Hyd Hydraulic C'Bal Counter Balance Hz. Hertz (cycles per second) CIC Channel Index Change ID. Inside Diameter cid .. cubic inch displacement IEEE Institute of Electrical and COMALACK. Common Alarm Acknowledgment Electronics Engineers Cpscr Capscrew Inst I Installation CT .. Constant Tension ISO International Standards cw Clockwise Organization ccw Counter-Clockwise IWRC lndependant Wire Rope Core DIN Deutsche International Norm J-Block Junction Block EIPS . Extra Improved Plough Steel J-Box Junction Box Elec . Electric/Electrical kPa kilo pascal ESNA Elastic Stop Nut Association KW Killowatt Ext Extension/External lb pound

TABLE OF CONTENTS

CHAPTER / PARAGRAPH PAGE CHAPTER / PARAGRAPH PAGE

1 GENERAL INFORMATION AND

SAFETY PRECAUTIONS............................ 1-1 2-6 DETERMINING CRANE CAPACITY .......... 2-9

1-1 SAFETY PRECAUTIONS ............................ 1-1 2-7 OVERCOMING OVERLOAD

1-1.1 Warnings and Cautions................................ 1-1 CONDITIONS ...................................... 2-10 1-1.2 General Safety Precautions ......................... 1-1 2-8 (DELETED) ................................................. 2-11 1-1.3 General Rules................................................ 1-1 2-9 (DELETED) ................................................. 2-11 1-2 INTRODUCTION ........................................... 1-2 2-10 EMERGENCY OPERATION ..................... 2-12 1-2.1 Purpose ....................................................... 1-2 2-10.1 Load Line, Winch Lowering ....................... 2-12 1-2.2 Scope........................................................... 1-2 2-10.2 Fast Line, Winch Lowering ........................ 2-12 1-2.3 Applicability.................................................. 1-2 2-10.3 Swing Brake Release ................................ 2-12 1-3 SHIPBOARD MAINTENANCE..................... 1-2 2-11 HAND SIGNALS ....................................... 2-13 1-3.1 Scope ........................................................... 1-2 1-4 INTERMEDIATE AND DEPOT ......................... 3 FUNCTIONAL DESCRIPTION ................... 3-1

MAINTENANCE ....................................... 1-2 3-1 INTRODUCTION ........................................ 3-1 1-5 CRANE DESCRIPTION............................... 1-2 3-2 PEDESTAL ................................................. 3-1 1-5.1 Overall Capabilities ...................................... 1-2 3-3 TURRET ..................................................... 3-1 1-5.2 Physical Data............................................... 1-2 3-4 BOOM ......................................................... 3-2 1-6 MECHANICAL EQUIPMENT ....................... 1-3 3-5 HYDRAULIC CYLINDERS.......................... 3-2 1-6.1 Boom ........................................................... 1-3 3-6 MAIN WINCH.............................................. 3-3 1-6.2 Main Winch .................................................. 1-4 3-7 FASTLINE WINCH ...................................... 3-3 1-6.3 Fastline Winch ............................................... 1-4 3-8 SWING DRIVE ASSEMBLY ........................ 3-6 1-6.4 Turret ............................................................. 1-4 3-9 OPERATOR’S CONTROLS ........................ 3-4 1-6.5 Swing Drive Assembly ....................................1-4 3-9.1 (DELETED) ................................................... 3-4 1-6.6 Pedestal......................................................... 1-4 3-10 HYDRAULIC SYSTEM ................................ 3-5 1-6.5 Swing Drive Assembly ....................................1-4 3-10.1 Main Control Valve ........................................ 3-6 1-6.6 Pedestal...........................................................1-4 3-10.2 Swing System ............................................... 3-6 1-6.7 Operator’s Cab............................................. 1-5 3-10.3 Boom System ............................................. 3-6 1-6.8 Remote Operator’s Station ............................ 1-5 3-10.4 Hydraulic Cylinder Load Lock Valve ............ 3-6 1-6.9 Hydraulic System........................................... 1-5 3-10.5 Fastline Winch System ................................. 3-7 1-7 ELECTRICAL EQUIPMENT......................... 1-6 3-10.6 Fastline Winch ............................................ 3-7 1-7.1 Operator’s Cab............................................. 1-6 3-10.7 Main Winch System .................................. 3-10 1-7.2 Load Moment/Remote........................................ 3-10.8 Main Winch Operations ............................. 3-10

Control System......................................... 1-6 3-10.9 (DELETED) ................................................. 3-11 1-8 SPECIFICATIONS......................................... 1-6 3-10.10 Emergency Operation System ................... 3-11 1-8.1 General.......................................................... 1-7 3-10.10.1 Emergency Lowering .................................. 3-11 1-8.2 Dimensions .................................................... 1-7 3-10.10.2 Swing Brake Release ................................ 3-12

2 OPERATIONS ............................................. 2-1 4 SCHEDULED MAINTENANCE .................. 4-1 2-1 INTRODUCTION ........................................... 2-1 4-1 GENERAL ................................................... 4-1 2-2 OPERATING CREW ..................................... 2-1 4-2 PREVENTIVE MAINTENANCE ................... 4-1

2-3 INSTRUMENTS AND CONTROLS............... 2-1 4-3 SCHEDULED MAINTENANCE

2-3.1 General .......................................................... 2-1 RECOMMENDATIONS ......................... 4-1 2-3.2 (DELETED) ................................................... 2-1 4-3.1 Walk Around Inspection............................... 4-1 2-3.3 (DELETED) ................................................... 2-1 4-3.2 Lubricant Specifications .............................. 4-1 2-3.4 (DELETED) ................................................... 2-1 4-3.2 Lubricant Specifications .............................. 4-1 2-4 (DELETED) ................................................... 2-1 4-3.3 Scheduled Maintenance Instructions ........... 4-1 2-4.1 (DELETED) ................................................... 2-1 4-3.4 Other Checks .............................................. 4-4 2-4.2 (DELETED) ................................................... 2-1 4-4 HYDRAULIC OIL MAINTENANCE .............. 4-5 2-4.3 (DELETED) ................................................... 2-1 4-4.1 Storage and Handling ................................. 4-5 2-4.4 (DELETED) ................................................... 2-1 4-4.2 In-Operation Care........................................ 4-5 2-4.5 (DELETED) ................................................... 2-1 4-4.3 Determining Oil Condition ........................... 4-5 2-4.6 (DELETED) ................................................... 2-1 4-5 LOAD MOMENT SYSTEM 2-4.7 (DELETED) ................................................... 2-1 MAINTENANCE .................................... 4-5 2-4.8 (DELETED) ................................................... 2-1 4-6 EXTENDED STORAGE 2-4.9 (DELETED) ................................................... 2-1 PROCEDURES ............................................ 4-5 2-4.10 (DELETED) ................................................... 2-1 4-7 TURNTABLE (SLEWING, SWIVEL) BEARING

2-4.11 (DELETED) ................................................... 2-1

2-5 HOW TO FIGURE LINE PARTS .................. 2-9

CLEARANCE INSPECTION

PROCEDURE, MODEL TB90-60.........4-6a

4-8 ANTI-2-BLOCK (A-2-B) SYSTEM ............... 4-7

i Change 11

TABLE OF CONTENTS (continued)

CHAPTER / PARAGRAPH PAGE CHAPTER / PARAGRAPH PAGE

5 INTRODUCTION ........................................... 5-1 6-3.11.1 Carrier Sub-Assembly ............................... 6-17 5-1.1 Purpose ......................................................... 5-1 6-3.11.2 Hub-Shaft Sub-Assembly .......................... 6-17 5-1.2 Scope ............................................................ 5-1 6-3-11.3 Main Assembly .......................................... 6-19 5-1.3 Safety ............................................................ 5-1 6-3.12 Swing Drive Installation ............................. 6-21 5-1.4 Problem Area Isolation .................................. 5-1 6-3.13 Main Winch Removal ................................. 6-21 5-2 PRELIMINARY TROUBLESHOOTING ......... 5-1 6-3.14 Fastline Winch Removal ............................ 6-21 5-2.1 Preliminary Checks ........................................ 5-1 6-3.15 Main Winch Disassembly .......................... 6-23 5-2.2 Probably Mechanical Causes ........................ 5-1 6-3.15.1 Final Drive Disassembly ............................ 6-23 5-2.3 Probably Hydraulic Causes ........................... 5-1 6-3.15.2 Final Planet Carrier Disassembly .............. 6-23 5-2.4 Common Electrical Wiring Problems ............. 5-2 6-3.15.3 Primary Drive Disassembly ....................... 6-23 5-3 TROUBLESHOOTING PROCEDURES ........ 5-2 6-3.15.4 Primary Planet Disassembly ...................... 6-25 5-3.1 Mechanical Troubleshooting Procedures ...... 5-2 6-3.15.5 Brake Hub Disassembly ............................ 6-25 5-3.2 Hydraulic Troubleshooting Procedures ......... 5-2 6-3.15.6 Drum and Base Disassembly .................... 6-25 5-3.3 Electrical Troubleshooting Procedures .......... 5-2 6-3.16 Inspection of Parts ..................................... 6-25

............................................................................ 6-3.16.1 Inspection of Final Drive ............................ 6-25 6 CORRECTIVE MAINTENANCE ................... 6-1 6-3.16.2 Inspection of Planet Assembly, 6-1 INTRODUCTIONS ........................................ 6-1 Final Drive .............................................. 6-27 6-1.1 Purpose ......................................................... 6-1 6-3.16.3 Inspection of Parts, Primary Drive ............. 6-27 6-1.2 Scope ............................................................ 6-1 6-3.16.4 Inspection of Primary Drive 6-1.3 Arrangement .................................................. 6-1 Planet Assembly .................................... 6-27 6-1.4 Tools And Equipment .................................... 6-1 6-3.16.5 Inspection of Primary Brake Hub ............... 6-29 6-1.5 Corrective Maintenance Notes ...................... 6-2 6-3.16.6 Drum and Base Inspection ........................ 6-29 6-2 HYDRAULIC & ELECTRICAL ............................ 6-3.17 Main Winch Assembly ............................... 6-29

SYSTEM ADJUSTMENTS ....................... 6-2 6-3.17.1 Final Drive Assembly ................................. 6-29 6-2.1 (DELETED) ................................................... 6-3 6-3.17.2 Final Drive Planet Assembly ...................... 6-31 6-2.2 (DELETED) ................................................... 6-3 6-3.17.3 Primary Drive Assembly ............................ 6-31 6-2.3 (DELETED) ................................................... 6-3 6-3.18 Fastline Winch ........................................... 6-33 6-2.4 (DELETED) ................................................... 6-3 6-3.18.1 Fastline Winch Disassembly ...................... 6-33 6-3 REPAIRS ....................................................... 6-6 6-3.18.2 Brake Cylinder Service .............................. 6-34 6-3.1 Piston Packing Test ....................................... 6-6 6-3.18.3 Brake Cylinder Assembly .......................... 6-34 6-3.2 Load Lock Valve Test .................................... 6-6 6-3.18.4 Planet Carrier Service................................ 6-35 6-3.3 Boom Cylinder Removal ................................ 6-6 6-3.18.5 Planet Carrier Assembly ............................ 6-35 6-3.4 Extension Cylinder Removal ......................... 6-7 6-3.18.6 Cleaning and Inspection ............................ 6-35 6-3.5 Boom Cylinder Repair ................................... 6-8 6-3.18.7 Brake Clutch Disassembly and 6-3.6 Extension Cylinder Repair ............................. 6-9 Inspection ............................................... 6-37 6-3.7 Hydraulic Swivel Service ............................. 6-10 6-3.18.8 Brake Clutch Assembly ............................. 6-38 6-3.7.1 Hydraulic Swivel Removal ........................... 6-10 6-3.18.9 Fastline Winch Assembly .......................... 6-38 6-3.7.2 Hydraulic Swivel Disassembly ..................... 6-10 6-3.18.10 Winch Installation ....................................... 6-39 6-3.7.3 Hydraulic Swivel Assembly .......................... 6-10 6-3.19 Winch Cable Installation ............................ 6-39 6-3.7.4 Hydraulic Swivel Installation ........................ 6-10 6-3.8 Swing Drive Service .................................... 6-11 7 PARTS LIST ................................................ 7-1 6-3.8.1 Swing Drive Removal .................................. 6-11 7-1 GENERAL ................................................... 7-1 6-3.8.2 Swing Drive Disassembly ............................ 6-11 7-1.1 Introduction .................................................. 7-1 6-3.8.3 Swing Drive Assembly ................................. 6-11 7-1.2 Subassemblies and Components ................ 7-1 6-3.8.4 Swing Hydraulic Motor Disassembly ........... 6-11 7-2 LIST OF MAJOR COMPONENTS .............. 7-1 6-3.8.5 Inspection of Parts, Swing .................................. 7-3 LIST OF MANUFACTURERS ..................... 7-3

Hydraulic Motor ........................................ 6-11 7-4 PARTS LIST ................................................ 7-6 6-3.8.6 Swing Hydraulic Motor Assembly ................ 6-12 7-4.1 Format ......................................................... 7-6 6-3.9 Swing Brake Service ................................... 6-13 7-4.2 Item .............................................................. 7-6 6-3.9.1 Swing Brake Disassembly ........................... 6-13 7-4.3 Notes ........................................................... 7-6 6-3.9.2 Swing Brake Assembly ................................ 6-14 7-4.4 ASC P/N ...................................................... 7-6 6-3.9.3 Swing Brake Bleeding ................................. 6-15 7-4.5 Qty ............................................................... 7-6 6-3.10 Swing Gear Reducer Disassembly .............. 6-15 7-4.6 Description ................................................... 7-6 6-3.10.1 Main Disassembly ....................................... 6-15 7-4.7 CAGE ........................................................... 7-6 6-3.10.2 Hub-Shaft Disassembly ............................... 6-15 7-4.8 Manufacturer’s P/N ..................................... 7-6 6-3.10.3 Internal Gear Disassembly .......................... 6-15 7-4.9 Compliance with Provisioning 6-3.10.4 Carrier Disassembly .................................... 6-17 Technical Documentation......................... 7-6 6-3.11 Swing Gear Reducer Assembly .................. 6-17 7-4.10 Illustration .................................................... 7-6

Change 10 ii

TABLE OF CONTENTS (continued)

CHAPTER / PARAGRAPH PAGE

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

8-1 GENERAL ..................................................... 8-1

8-2 TURRET TO PEDESTAL

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

8-3 BOOM INSTALLATION ................................. 8-1

8-4 HYDRAULIC SYSTEM

CONNECTIONS ......................................8-2

8-5 ELECTRICAL SYSTEM

CONNECTIONS ......................................8-2

8-6 PRELIMINARY START-UP ........................... 8-2

8-7 REEVING AND FINAL CHECKS .................. 8-3

8-8 PREPARATIONS FOR RESHIPMENT ......... 8-3

INDEX ..................................................... Index 1 APPENDIX A.............................. APPENDIX A-i

APPENDIX B

iii Change 1

LIST OF ILLUSTRATIONS

FIGURE PAGE FIGURE PAGE

iv

1-1 Component Identification .............................. 1-3 6-11 Extension Cylinder Assembly ...................... 6-9 1-2 Main Winch .................................................. 1-4 6-12 Hydraulic Swivel Installation ...................... 6-10 1-3 Fastline Winch ............................................. 1-4 6-13 Hydraulic Swivel Assembly ........................ 6-10 1-4 Swing Drive Assembly ................................. 1-5 6-14 Swing Drive Installation ............................. 6-11 1-5 Operator's Cab ............................................. 1-5 6-15 Swing Hydraulic Motor Assembly .............. 6-12 1-6 Dimensional Data ......................................... 1-7 6-16 Swing Brake Assembly ............................. 6-13 2-1 (DELETED) .................................................. 2-2 6-17 Swing Gear Reducer Assembly ................ 6-16 2-2 (DELETED) .................................................. 2-3 6-18 Safety Wire Installation .............................. 6-18 2-3 (DELETED) .................................................. 2-4 6-19 Punch Mark Orientation ............................. 6-19 2-4 (DELETED) .................................................. 2-4 6-20 Shoulder Bolt Locations ............................ 6-20 2-5 (DELETED) .................................................. 2-4 6-21 Pipe Plug Timing ....................................... 6-20 2-6 (DELETED) .................................................. 2-5 6-22 Swing Drive Installation ............................. 6-21 2-7 (DELETED) .................................................. 2-5 6-23 Main Winch Assembly ................................6-22 2-8 (DELETED) .................................................. 2-5 6-24 Final Drive Assembly ................................. 6-24 2-9 (DELETED) .................................................. 2-6 6-25 Primary Drive Assembly ............................ 6-26 2-10 (DELETED) .................................................. 2-6 6-26 Final Drive Assembly ................................. 6-28 2-11 (DELETED) .................................................. 2-7 6-27 Primary Drive Assembly ............................ 6-30 2-12 (DELETED) .................................................. 2-7 6-28 Fastline Winch Assembly .......................... 6-32 2-13 Line Part Diagram ........................................ 2-8 6-29 Fastline Winch Assembly .......................... 6-36 2-14 Crane Capacity............................................... 2-9 6-30 Winch Cable Installation .............................6-40 2-15 Overload Condition ...................................... 2-10 7-1 Boom Assembly ...........................................7-7 2-16 (DELETED) ................................................ 2-11 7-2 Flagblock Assembly .....................................7-9 2-17 (DELETED) ................................................ 2-11 7-3 Extension Cylinder Assembly .................... 7-10 2-18 Emergency Operation Controls ..................2-12 7-4 Boom to Turret Assembly .......................... 7-11 2-19 Hand Signals .............................................. 2-13 7-5 Turret Installation........................................ 7-12 3-1 Component Identification .............................. 3-1 7-6 Turret Assembly ......................................... 7-13 3-2 Boom Cylinder ................................................ 3-2 7-7 Swing Drive Assembly............................... 7-15 3-3 Extension Cylinder ......................................... 3-2 7-8 Hydraulic Motor ......................................... 7-16 3-4 Main Winch .................................................. 3-3 7-9 Brake .......................................................... 7-17 3-5 Fastline Winch ............................................. 3-3 7-10 Gear Reducer ............................................... 7-18 3-6 Swing Drive Assembly ................................. 3-4 7-11 Boom Lift Cylinder, RH ............................... 7-20 3-7 (DELETED) .................................................. 3-4 7-12 Boom Lift Cylinder, LH ............................... 7-21 3-8 Swing System ................................................ 3-5 7-13 Inlet & Return System .................................. 7-22 3-9 Boom System ................................................. 3-6 7-14 Hydraulic Control Valve ............................. 7-24 3-10 Hydraulic Cylinder Load Lock Valve .............3-6 7-15 Inlet Section, Control Valve ....................... 7-25 3-11 Fastline Winch System .................................. 3-7 7-16 Valve Section, Swing ................................... 7-27 3-12 Fastline Winch Powertrain, Hoisting ............ 3-7 7-17 Valve Section, Swing ................................... 7-28 3-13 Fastline Winch Powertrain, Lowering 1 ........ 3-8 7-18 Valve Section, Boom ................................. 7-29 3-14 Fastline Winch Powertrain, Lowering 2 ........ 3-8 7-19 Valve Section, Extension ............................. 7-30 3-15 Brake in Hoisting Direction. .......................... 3-8 7-20 Valve Section, Winch ................................. 7-31 3-16 Brake in Lowering Direction .......................... 3-9 7-21 Assembly Parts, Control Valve ...................7-32 3-17 Main Winch System ..................................... 3-9 7-22 Spool Controller Assy. Control Valve ..........7-33 3-18 Main Winch Assy ....................................... 3-10 7-23 Reducer Valve, Control Valve .................... 7-35 3-19 Hydraulic Schematic ................................... 3-13 7-24 Boom System ............................................... 7-36 3-20 Electrical System Schematic. Pg 1 ............. 3-15 7-25 Extension System ........................................ 7-38 3-21 Electrical System Schematic. Pg 2............. 3-17 7-26 Winch System, Fastline ............................. 7-40 4-1 Lubrication & Maintenance Diagram.............. 4-2 7-27 Winch System, Loadline ............................ 7-41 4-2 Interior View,Turntable Bearing....................4-6a 7-28 Swing System ........................................... 7-43 6-1 (DELETED) .................................................. 3-4 7-29 Hydraulic Swivel Installation. ..................... 7-45 6-2 (DELETED) .................................................. 6-3 7-30 Hydraulic Swivel Assembly ....................... 7-46 6-3 (DELETED) .................................................. 6-4 7-31 Pilot System .............................................. 7-47 6-4 (DELETED) .................................................. 6-4 7-32 Emergency Lowering System .................... 7-48 6-5 (DELETED) .................................................. 6-5 7-33 Hand Pump ................................................7-50 6-6 (DELETED) .................................................. 6-5 7-34 Reeving Assembly .................................... 7-52 6-7 Piston Packing Test ...................................... 6-6 7-35 Winch, Main, Constant Tension ................ 7-55 6-8 Boom Cylinder Removal ............................... 6-7 7-36 Primary Drive Assembly ............................ 7-56 6-9 Extension Cylinder Removal ......................... 6-7 7-37 Hoist Motor Assembly ............................... 7-58 6-10 Boom Cylinder Assembly ............................. 6-8 7-38 Final Drive Assembly ................................. 7-59

Change 12

LIST OF ILLUSTRATIONS (continued)

FIGURE PAGE FIGURE PAGE

7-39 (DELETED) ............................................... 7-61 7-59 (DELETED) ............................................... 7-87 7-40 (DELETED) ............................................... 7-62 7-60 (DELETED) ............................................... 7-88 7-41 (DELETED) ............................................... 7-63 7-61 (DELETED) ............................................... 7-89 7-42 Winch Assembly, Fastline ........................ 7-64 7-62 Dynamometer ............................................ 7-90 7-43 Hook Block ................................................ 7-67 7-62A Dynamometer Adapter Kit ..................... 7-90A 7-44 Haul Ball .................................................... 7-68 7-62B Anti-2-Block Control Assembly ............... 7-90B 7-45 Turret Platform Assembly ......................... 7-69 7-62C Switch Assembly ................................... 7-90D 7-46 Counterweight Installation ....................... 7-71

7-63 (DELETED) ...............................................7-917-47 Operator’s Platform Installation ................7-72 7-64 (DELETED) ...............................................7-927-48 Operator’s Platform Assembly ................. 7-73 7-65 (DELETED) ...............................................7-937-49 Ladder Installation ..................................... 7-74 7-66 (DELETED) ............................................... 7-947-50 Operator’s Cab Assembly. ........................ 7-75 7-67 (DELETED) ...............................................7-957-51 Operator’s Cab ......................................... 7-76 7-68 Light Mount Installation .............................7-967-52 Wiper Assembly ....................................... 7-77 7-69 Cable Reel, Floodlight .............................. 7-977-53 (DELETED) ............................................... 7-78 8-1 Turret to Pedestal Installation .....................8-17-54 Seat Assembly ......................................... 7-80 8-2 B Inoom stallation.........................................8-17-55 (DELETED) ............................................... 7-81 8-3 Cylinder Pin Installation ............................... 8-27-56 (DELETED) ............................................... 7-83 8-4 Reeving Arrangement, Main Winch ............8-37-57 (DELETED) ............................................... 7-84 8-5 Reeving Arrangement, Fastline Winch ........ 8-3 7-58 (DELETED) ............................................... 7-86 v Change 1

LIST OF TABLES

TABLE PAGE TABLE PAGE

Change 12 vi

1-1 Reference Data...................................... 1-8

7-29 Hydraulic Swivel Installation ...................7-45

3-1 Hydraulic Motor Performance Curves .... 3-12

7-30 Hydraulic Swivel Assembly.....................7-46

4-1 Maintenance and Lubrication Chart......... 4-2

7-31 Pilot System................................................ 7-47

4-2 Wire Rope Tolerances ............................. 4-3

7-32 Emergency Lowering System .................... 7-49

4-3 Turntable Bearing Wear Inspection

7-33 Hand Pump ..............................................7-51

Table.................................................. 4-6b

7-34

5-1 Troubleshooting Table, General .............. 5-2 7-35 Winch, Main................................................ 7-55

5-2 Troubleshooting Table, 7-36 Primary Drive Assembly.............................7-57

Load Moment System .......................... 5-6 7-37 Hoist Motor Assembly...............................7-58

5-3 Troubleshooting Table, Control Valve...... 5-7 7-38 Final Drive Assembly.................................. 7-60

6-1 Tools and Equipment ............................... 6-1

7-39 (DELETED)................................................. 7-61

6-2 (DELETED) .............................................. 6-2

7-40 (DELETED)................................................. 7-62

6-3 Shim Chart............................................. 6-17

7-41 (DELETED)................................................. 7-63

6-4 Recommended Torque Values................ 6-40 7-42 Winch Assembly, Fastline.........................7-65

7-A List of Major Components ...................... 7-1 7-43 Hook Block.................................................. 7-67 7-B List of Manufacturers ............................... 7-3 7-44 Haul Ball ...................................................7-68 7-1 Boom Assembly....................................... 7-8 7-45 Turret Platform Assembly........................... 7-70 7-2 Flagblock Assembly ............................... 7-9 7-46 Counterweight Installation.........................7-71 7-3 Extension Cylinder Assembly ................. 7-10 7-47 Operator’s Platform Installation .................7-72 7-4 Boom to Turret Assembly ........................ 7-11 7-48 Operator’s Platform Assembly ..................7-73 7-5 Turret Installation ..................................... 7-12 7-49 Ladder Installation ......................................7-74 7-6 Turret Assembly....................................... 7-14 7-50 Operator’s Cab Assembly .......................... 7-75 7-7 Swing Drive Assembly ........................... 7-15 7-51 Operator’s Cab ......................................... 7-76 7-8 Hydraulic Motor ...................................... 7-16 7-52 Wiper Assembly ......................................... 7-77 7-9 Brake........................................................ 7-17 7-53 (DELETED)................................................. 7-79 7-10 Gear Reducer .......................................... 7-19 7-54 Seat Assembly ........................................... 7-80 7-11 Boom Lift Cylinder, RH........................... 7-20 7-55 (DELETED)................................................. 7-82 7-12 Boom Lift Cylinder, LH ........................... 7-21 7-56 (DELETED).................................................7-83 7-13 Inlet & Return System.............................. 7-23 7-57 (DELETED).................................................7-85 7-14 Hydraulic Control Valve .......................... 7-24 7-58 (DELETED)................................................. 7-86 7-15 Inlet Section, Control Valve.................... 7-26 7-59 (DELETED)................................................. 7-87 7-16 Valve Section, Swing ............................... 7-27 7-60 (DELETED)................................................. 7-88 7-17 Valve Section, Swing ............................... 7-28 7-61 (DELETED)................................................. 7-89 7-18 Valve Section, Boom................................ 7-29 7-62 Dynamometer ............................................. 7-90 7-19 Valve Section, Extension ......................... 7-30 7-62A Dynamometer Adapter Kit.........................7-90A 7-20 Valve Section, Winch ............................. 7-31 7-62B Anti-2-Block Control Assembly................7-90C 7-21 Assembly Parts, Control Valve ................ 7-32 7-62C Switch Assembly........................................7-90D 7-22 Spool Controller Assy, Control Valve...... 7-34

7-63 (DELETED) ................................................... 7-917-23 Reducer Valve, Control Valve ................ 7-35 7-64 (DELETED) ................................................... 7-927-24 Boom System........................................... 7-37 7-65 (DELETED) ................................................... 7-937-25 Extension System .................................... 7-39 7-66 (DELETED) ................................................... 7-947-26 Winch System, Fastline............................ 7-40

7-67 (DELETED) ................................................... 7-957-27 Winch System, Loadline .......................... 7-42

7-68 Light Mount Installation .............................. 7-96 7-28 Swing System........................................... 7-44

7-69 Cable Reel, Floodlight...............................7-98

Reeving Assembly .................................. 7-52

7-62D Anti-2-Block NSN Listing..........................7-90F

SAFETY SUMMARY

GENERAL SAFETY NOTICES

The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual. They are recommended precautions that must be understood and applied during operation and maintenance of the equipment covered herein. Should situations arise that are not covered in the general or specific safety precautions, the commanding officer or other authority will issue orders as deemed necessary to cover the situation.

This equipment can be dangerous if operated or maintained incorrectly. The equipment, as all hydraulically operated mechanical equipment, must be operated by experienced and trained personnel. Any equipment is only as safe as its operator.

All possible safety hazards cannot be foreseen, therefore, the operator must always be alert to possible hazards that could endanger personnel or damage the equipment.

SAFETY TERMS

The following terms define the various precautions and notices in this manual:

A WARNING

WHENEVER POTENTIAL PERSONAL INJURY

OR DEATH SITUATIONS EXIST REQUIRING

CORRECT PROCEDURES OR PRACTICES

FOR PREVENTION , THIS "WARNING"

SYMBOL IS USED. THIS SAFETY ALERT

SYMBOL INDICATES IMPORTANT SAFETY

MESSAGES IN THIS MANUAL. WHEN YOU

SEE THIS SYMBOL, CAREFULLY READ THE

MESSAGE THAT FOLLOWS AND BE ALERT

TO THE POSSIBILITY OF PERSONAL INJURY

OR DEATH.

CAUTION: Whenever potent ial damage to .equipment exis ts req uiring correct procedures for p revention, the t erm "CAUTION" is used.

IMPORTANT: Whenever information exists that requires special attention to procedures or to ensure proper operation of the equipment, or to prevent its possible failure, the term " IMPORTANT" is used.

NOTE: Whenever information exists that requires additional emphasis beyond the standard text, the term "NOTE" is used.

VII

OPERATION SAFETY

OPERATOR TRAINING

You must be trained in the operation of this equipment prior to operation.

Be extremely careful if you do not normally operate this equipment. Re-orient yourself to the equipment before starting, and then proceed slowly. However, you must not operate without having received proper training.

DO NOT OPERATE ALONE

It is essential that someone be on deck to direct operations, watch clearances and give hand signals.

Ensure that the director is clear of the crane and the load before you move it. Do not move the crane or load if you cannot see the director.

GENERAL OPERATION SAFETY

Do not operate this equipment if you know of malfunctions, missing parts, and/or misadjustments.

These situations can cause or contribute to an accident or damage to the equipment. Lower the load and stop the crane immediately if problems arise after starting.

Do not start the Hydraulic Power Unit if the "start" switch has been tagged with a "DO NOT START" or "RED" tag .

Never allow anyone under the load. Wait for the area to be cleared before moving the crane or load.

Never attempt any lifting operation with fewer than five wraps of cable on the winch drum. Cable clamps are not designed to hold loads.

Never attempt to dismantle any of the safety devices built into the equipment. This may include, but is not limited to, the winch up and down limit controls, anti-2-block system, and the overload safety system.

Never swing the load over anyone.

When swinging the boom, always be sure that there is adequate clearance.. for both the boom and the load. ,, Always operate within the capacity of the equipment and its reeving components. Do not overload this equipment. Refer to the hydraulic capacity chart and the reeving capacity chart for the equipment's lifting capacity.

Inspect often any slings, chokers and other rigging devices for cuts, abrasion, rust, kinks or other damage.

Do not use any suspect equipment to lift or move a load.

Destroy any obviously damaged slings or chokers. They are not worth the risk.

Always wear appropriate safety clothes and equipment.

This includes hard hat, safety shoes, gloves, eye protection, etc.

Be accurate in load placement. It's important to know what the load will do when it's released.

Lower or remove the load before leaving the equipment or shutting down the hydraulic power unit.

Electrical energy under high voltage can discharge to ground through the equipment without direct contact with the equipment's structure. Minimum clearances from energized power lines or other power sources must be maintained. If electrical energy does discharge through the equipment, stay clear of the equipment.

Do not permit anyone to come into contact with the equipment's structure.

MAINTENANCE AND SERVICE SAFETY

DO NOT REPAIR OR ADJUST ALONE

Under no circumstances should repair or adjustment of energized equipment be attempted alone. The immediate presence of someone capable of rendering aid is required.

Before making adjustments, be sure to protect against grounding. If possible, adjustments should be made with one hand, while the other hand remains free and clear of equipment. Even when power has been removed from equipment circuits, dangerous potentials may still exist due to retention of charges by capacitors. Circuits must be grounded and all capacitors must be discharged prior to attempting repairs.

QUALIFIED PERSONNEL

Maintenance, lubrication and repair of this equipment can be dangerous unless performed properly. Each person must have the necessary skills and information, proper tools and equipment, and work safely.

Do not attempt to make adjustments, or perform maintenance or service unless you are authorized and qualified to do so.

TEST EQUIPMENT

Make certain test equipment is in good condition . If a test meter must be held, ground the case of the meter before starting measurement; do not touch live equipment or personnel working on live equipment while holding a test meter. Some types of measuring devices should not be grounded; these devices should not be held while taking measurements.

viii

HEAW EQUIPMENT

To avoid personal injury or equipment damage, use a lifting device with a lifting capacity greater than twice the weight of any item to be lifted.

PRESSURIZED EQUIPMENT

Wear safety goggles when working on or near equipment that is or may be pressurized.

Before disconnecting hydraulic lines, be sure to lower all loads and relieve all hydraulic pressure. The load could fall on you, or escaping hydraulic oil could cause severe p~rsonal injury. Never try to stop a hydraulic leak with any part of your body.

REMOVE LOADS AND SHUT-OFF POWER

Never rely on the hydraulic system to support any part of the equipment during maintenance or lubrication. If necessary, support components with appropriate safety stands. Never stand under a component that is supported only by the hydraulics. Make sure it is resting on its mechanical stops.

Never attempt maintenance or lubrication procedures while the equipment is moving or the hydraulic power unit is running.

Unless otherwise directed by this manual, never attempt maintenance or repair procedures while the main power to the equipment is ON. Tag the "start" switch and/or disconnect switch with a "DO NOT START" sign when required.

ELECTRICAL HAZARDS

Service 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 capacitors may exist when power is off. To avoid casualties, always disconnect the power and discharge the circuit before touching it.

The electrical system uses 460 volt, 3-phase, 60 Hz power. An electric shock could be fatal. Do not attempt electrical repairs unless you are qualified to do so.

Ensure that the power to the equipment is OFF before opening the electrical box( es). Never attempt electrical testing or repairs while standing in water.

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.

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

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

HOT OIL HAZARD

Use caution when working around hot oils. Always allow lubricating and hydraulic oil to cool before draining.

Burns can be severe.

FIRE PREVENTION

Hydraulic oil is flammable. Do not smoke when checking or filling the tank. Keep open flames and sparks away from the equipment.

Keep the equ ipment free of oil, grease and dirt accumulat ions. Regular steam cleaning is recommended for fire prevention and general safety.

Never overfill the hydraulic tank. Any overflow could contribute to a fire. Immediately repair any hydraulic leaks and clean up any spills.

COMPRESSED AIR SAFETY

Use extreme caution when using compressed air to dry parts. The pressure should not exceed 30 psi (208 kPa).

Never direct compressed air at anyone because air pressure penetrating your skin can be fatal.

FALLING HAZARD

Always lower the equipment as far as possible before attempting to perform repairs or service. Due to the height of the upper lube points, it is essential to personnel safety that safe ladders, personnel lifts and/or scaffolding be used while servicing this equipment.

Always use safety tread walks and handholds where provided. The equipment can be dangerously slick under conditions of rain, frost or oil smears.

WARNINGS AND CAUTIONS

Generalized warnings and cautions applying to the equipment in this manual are summarized below and repeated throughout the manual.

CAUTION: Never let the control handle snap back to neutral. (Page 2-1) ix

CAUTION : Never continue holding the control lever in the "move" position after the crane is at Its limit of travel. This can cause hydraulic system overheating. (Page 2-1)

A WARNING

TURNING. ON THE MANUAL OVERRIDE

SWITCH PREVENTS THE LMI FROM

CONTROLLING THE CRANE FUNCTIONS.

THE LMI WILL STILL FUNCTION AND WILL

TURN ON TO ALERTTHE OPERATOR OF AN

OVERLOAD. THE OPERATOR, HOWEVER, IS

IN FULL CONTROL OF THE CRANE AND

MAY CAUSE STRUCTURAL DAMAGE IF THE

LMI DATA AND ALARMS ARE IGNORED.

(Page 2-3, 2-8, 2-11)

A WARNING

DO NOT RELY ON THE WINQOW TO KEEP

THE CRANE FROM COMING INTO

CONTACT WITH ANY POWER LINES OR

OVERHEAD OBSTACLES. (Page 2-6)

A WARNING

BE SURE THAT THE SIGNAL PERSON IS

CLEAR OF THE HOOK, BOOM, OR LOAD TO

PREVENT BODILY INJURY. (Page 2-13,2-14)

A WARNING

SHUT OFF THE ELECTRICAL SUPPLY TO

THE HYDRAULIC POWER UNIT BEFORE

PERFORMING MAINTENANCE OR SERVICE

ON THE SWING GEARS. FAILURE TO DO SO

CO…