NEW_S9583-B5-MMA-010_Rev_7.pdf

TECHNICAL MANUAL

OPERATION, MAINTENANCE, AND REPAIR

BOAT DAVIT SYSTEM WITH

CONSTANT TENSION WINCH

SUPERSEDURE NOTICE: THIS MANUAL SUPERSEDES S9583-B5-MMA-010,

REVISION 6, DATED 15 JAN 2015, AND ALL CHANGES THERETO.

DISTRIBUTION STATEMENT C: DISTRIBUTION AUTHORIZED TO U.S. GOVERNMENT AGENCIES AND THEIR CONTRACTORS; ADMINISTRATIVE/OPERATIONAL USE; 10 FEB 2004. OTHER U.S. REQUESTS

FOR THIS DOCUMENT SHALL BE REFERRED TO NSWC PHILADELPHIA, CODE 314.

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. DISSEMINATE IN ACCORDANCE WITH THE

PROVISIONS OF DOD DIRECTIVE 5230.25.

DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL PREVENT DISCLOSURE OF CONTENTS

OR RECONSTRUCTION OF THIS DOCUMENT.

S9583-B5-MMA-010

REVISION 7

TITLE-1 / (TITLE-2 Blank)@@FIpgtype@@TITLE@@!FIpgtype@@ @@FIpgtype@@TITLE@@!FIpgtype@@

PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

*0910LP1156837* 15 NOV 2015

TITLE-2

@@FIpgtype@@BLANK@@!FIpgtype@@

RECORD OF REVISIONS

REVISION

NO. TITLE AND/OR BRIEF DESCRIPTION/PREPARING ACTIVITY DATE

0 ORIGINAL DATE OF PUBLICATION. 10 FEBRUARY 2004

1 REVISION 1 INCORPORATES CHANGES RESULTING FROM ECPS 583-

04A-C006, 583-04A-C008, 583-04A-C009, 583-04A-C011, 583-04A-C012

AND 583-04AC013. THE POC IS SUPSHIP BATH MAINE, N62786, CODE

240.

03 AUGUST 2005

2 REVISION 2 INCORPORATES CHANGES RESULTING FROM ECPS 583-

04A-C014 AND -C015. THE POC IS SUPSHIP BATH MAINE, N62786,

CODE 240.

01 OCTOBER 2007

3 REVISION 3 INCORPORATES CHANGES RESULTING FROM ADMINIS-

TRATIVE CORRECTIONS FOR ECP 583-04A-C014. THE POC IS

SUPSHIP BATH MAINE, N62786, CODE 240.

21 JULY 2008

4 REVISION 4 INCORPORATES TMDERS N65540-07-SA17, NA1099-09-

AH01 AND N55236-11-JB01 TO CORRECT POSITIONS OF THE SLACK

AND TAUT ROPE, REPLACE FIGURES FOR CLARITY, CHANGE

REQUIREMENTS FOR MANDATORY WIRE ROPE REPLACEMENT AND

CORRECT FIGURES DEPICTING PLUG ON PRESSURE FILTER MANI-

FOLD. CHANGE AUTHORIZED BY NSWCCD-SSES CODES 944 AND

9731.

25 APRIL 2011

5 REVISION 5 INCORPORATES CHANGES RESULTING FROM ECP-583-

04A-C017, RHIB LOWERING OPERATIONS IN MANUAL MODE. THE

POC IS SUPSHIP BATH MAINE, N62786, CODE 240.

13 FEBRUARY 2012

6 REVISION 6 INCORPORATES CHANGES RESULTING FROM OMITTED

MARK-UPS FOR ECP-583-04A-C017, ECP-583-04A-C018 REMOTE CON-

TROL DELETION, ECP-583-04A-C019 REPLACE OBSOLETE HYDRAU-

LIC HOIST MOTOR, AND ECP-583-04A-C020 RHIB FINGER SAFE FUSE

BASE AND TERMINAL BLOCK CHANGE, RHIB EISA LAW CHANGE,

SLEW BEARING LUBRICATION AND ENVIRONMENTAL PROTEC-

TION. ALL SHEETS OF FIGURE 8-9 REPLACED WITH LATEST VEN-

DOR DRAWING. THE POC IS SUPSHIP BATH MAINE, N62786, CODE

240. INCORPORATED TMDERS N65540-13-RK22, N50054-13-AAJA AND

N65540-15-AA02 TO UPDATE OPERATING PROCEDURE. CHANGE

AUTHORIZED BY NSWCCD-SSES CODES 944 AND 973. THE FOL-

LOWING WAS CHANGED:

PARAGRAPH(S) , 1-3.1, 2-2.1.1, 2-4, 2-7.1, 2-7.8, 2-7.16, 2-7.17, 3-3, 3-4,

3-5, 3-6, 4-7, 6-6.1.5, 6-10.1, 6-10.2, 6-11.1, 6-11.2, 6-11.4.1, 6-11.4.2, 6-11.5, 6-11.5.1, 6-11.5.2, 6-11.9.1, 6-11.9.10, 6-15.5.2, 6-15.5.3, 6-15.5.4, 6-18, 6-18.2, 6-19, 6-20 AND 7-1.2.10

TABLE(S) 1-1, 1-2, 1-4, 2-1.1, 2-3, 2-5, 2-5.1, 2-6, 4-6, 5-2.1, 6-24, 7-1, 7-2,

7-4.1, 7-8, 7-9, 7-10, 7-16, 7-20, 7-23, 7-23.1, 7-27, 7-28, 7-29, 7-29.1 AND

7-29.2

FIGURE(S) 1-1, 1-2, 1-3, 2-1.1, 2-2, 6-6.1, 6-6.1, 6-6.1, 6-15, 6-32, 6-32,

6-37, 6-38, 6-39, 8-9, 8-9, 8-9, 8-9, 8-9, 8-9, 8-9, 8-9, 8-9, 8-9 AND 8-9

15 JANUARY 2015

S9583-B5-MMA-010

RECORD OF REVISIONS-1

RECORD OF REVISIONS - CONTINUED

REVISION

NO. TITLE AND/OR BRIEF DESCRIPTION/PREPARING ACTIVITY DATE

7 REVISION 7 INCORPORATES TMDER N65540-15-EM09 WHICH COR-

RECTS NEW P/N REFERENCE FOR OBSOLETE PART 1PF2G2-40B/

016RR19MR TO 9510290056. INCORPORATES NON-TECHNICAL

TMDER N55262-15-JB15 WHICH CORRECTS GRAMMAR MISTAKE.

FINALLAY, INCORPORATES TMDER N64498-15-WN01 WHICH COR-

RECTED ERROR TO THE DAVIT OPERATING PROCEDURES. CHANGE

AUTHORIZED BY NSWCCD-SSES CODES 314 AND 433. THE FOL-

LOWING WAS CHANGED:

PARAGRAPH(S) AND 4-7

TABLE(S) 2-6, 2-6 AND 7-12

15 NOV 2015

FOR OPTIMAL VIEWING OF THIS TECHNICAL MANUAL THE PAGE LAYOUT IN ADOBE ACROBAT

READER SHOULD BE SINGLE PAGE. CONTINUOUS PAGE DISPLAY CAN CAUSE PROBLEMS WITH

LINK REFERENCES AND THE BOOKMARKS.

RECORD OF REVISIONS-2

FOREWORD

This manual contains the information needed to operate, maintain, and repair the Boat Davit System with Constant Tension Winch. This manual consists of eight chapters as follows:

Chapter 1 - General Information And Safety Precautions

Chapter 2 - Operation

Chapter 3 - Functional Description

Chapter 4 - Scheduled Maintenance

Chapter 5 - Troubleshooting

Chapter 6 - Corrective Maintenance

Section I - Adjustments and Alignments

Section II - Repair

Chapter 7 - Parts List

Section I - Introduction

Section II - Group Assembly Parts Lists (GAPL)

Chapter 8 - Installation

Ships, training activities, supply points, depots, Naval Shipyards, and Supervisors of Shipbuilding are requested to arrange for the maximum practical use and evaluation of NAVSEA technical manuals. All errors, omissions, discrepancies, and suggestions for improvement to NAVSEA technical manuals shall be forwarded to:

COMMANDER, CODE 310 TMDER, BLDG. 1389 NAVSURFWARCENDIV NSDSA, 4363 MISSILE WAY,

PORT HUENEME, CA 93043-4307 on NAVSEA/SPAWAR Technical Manual Deficiency/Evaluation Report (TMDER), NAVSEA form 4160/1. All feedback comments shall be thoroughly investigated, and originators will be advised of action resulting therefrom. One copy of NAVSEA form 4160/1 is at the end of each separately bound technical manual 8-1/2 x 11 inches or larger. Copies of NAVSEA form 4160/1 may be requisitioned from the Naval Systems Data Support Activity Code 310 at the above address. Users are encouraged to transmit defi-ciency submittals via the web site located at:

https://mercury.tdmis.navy.mil/def_external/pubsearch.cfm

All feedback comments shall be thoroughly investigated and originators will be advised of action result-ing therefrom.

List of Abbreviations

Abbreviation/ Acronym Definition

Abbreviation/ Acronym Definition

AR As Required CAGE Commercial and Government Entity CCW Counterclockwise CRES Corrosion Resistant Steel CW Clockwise EMI Electromagnetic Interference EP Extreme Pressure FPM Feet per Minute GAPL Group Assembly Parts List GPM Gallons per Minute HP Horsepower HPU Hydraulic Power Unit Hz Hertz ID Inside Diameter IPB Illustrated Parts Breakdown ISO International Standards Organization

FOREWORD-1

FOREWORD - Continued

List of Abbreviations

Abbreviation/ Acronym Definition

Abbreviation/ Acronym Definition

IWRC Independent Wire Rope Core JIC Joint Industrial Council LCD Liquid Crystal Display MIP Maintenance Index Page NHA Next Higher Assembly NPT National Pipe Thread NSDSA Naval Systems Data Support Activity NSTM Naval Ship Technical Manual OD Outside Diameter OEM Original Equipment Manufacturer ORB O-ring Boss PMS Planned Maintenance System PSI Pounds per Square Inch PWM Pulse Width Modulating RCS Radar Cross-section RHIB Rigid Hull Inflatable Boat RPM Revolutions per Minute SAE Society of Automotive Engineers TMDER Technical Manual Deficiency/Evaluation

Report VAC Volts Alternating Current

FOREWORD-2

TABLE OF CONTENTS

Chapter/Paragraph Page

1 GENERAL INFORMATION AND SAFETY PRECAUTIONS . . . . . . . . . . . 1-1

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

1-2 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-2.1 Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-2.2 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-2.3 Applicability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-2.4 Reporting Errors, Omissions and Discrepancies. . . . . . . . . . . . . . . . . 1-2

1-3 GENERAL DESCRIPTION OF THE BOAT DAVIT SYSTEM WITH CONSTANT

TENSION WINCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-3.1 Lower Pedestal Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-3.2 Constant Tension Winch Assembly. . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-3.2.1 Constant Tension Function. . . . . . . . . . . . . . . . . . . . . . 1-3 1-3.2.2 Limit Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-3.3 Davit Arm Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1-3.4 Slack Line Limit Switch Assembly. . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-4 REFERENCE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-5 EQUIPMENT, ACCESSORIES AND DOCUMENTS SUPPLIED. . . . . . . . . . . 1-13

1-6 SUPPORTING COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

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

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

2-2 CONTROLS AND INDICATORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-2.1 Control Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-2.1.1 Operator Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-2.2 Hydraulic Power Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 2-2.3 Constant Tension Winch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 2-2.4 Emergency Stop Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 2-2.5 Quick Release Hook. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2-3 START UP OPERATING PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . 2-15

2-4 NORMAL OPERATING PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2-5 MANUAL OPERATING PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . 2-23

2-6 EMERGENCY SHUT DOWN PROCEDURES. . . . . . . . . . . . . . . . . . . . . 2-28

2-7 OPERATOR MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 i

TABLE OF CONTENTS - Continued

2-7.1 General Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 2-7.2 General Visual Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 2-7.3 Davit Arm Sheave. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 2-7.4 Constant Tension Winch Drum Bearings. . . . . . . . . . . . . . . . . . . . . 2-33 2-7.5 Slack Line Limit Switch Assembly. . . . . . . . . . . . . . . . . . . . . . . . 2-33 2-7.6 Quick Release Hook. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 2-7.7 Ratchet Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 2-7.8 Slew Bearing and Pinion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 2-7.9 Heat Dissipation Vents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

2-7.10 Hydraulic Fluid Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 2-7.11 Hoist Rope and Winch Drum. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 2-7.12 Main Hoist Gearbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 2-7.13 Main Hoist/Constant Tension Planetary. . . . . . . . . . . . . . . . . . . . . . 2-40 2-7.14 Slew Drive Gearbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 2-7.15 Hydraulic Power Unit Electric Motor. . . . . . . . . . . . . . . . . . . . . . . 2-41 2-7.16 General Inspection of Electrical Enclosures. . . . . . . . . . . . . . . . . . . 2-41 2-7.17 Touch Up Painting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

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

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

3-2 HYDRAULIC POWER UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-3 HOIST FUNCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3-3.1 Hoist Up/Down Limit Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3-3.2 Constant Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3-3.3 Manual Hoisting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-4 LUFF FUNCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3-4.1 Manual Luffing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3-5 SLEW FUNCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3-5.1 Slew Limit Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3-5.2 Manual Slewing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3-6 REMOTE OPERATOR PACK (NOT APPLICABLE TO EQUIPMENT MODIFIED

BY ECP 583-04A-C018). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

4 SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-1.1 Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-1.2 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-1.3 Applicability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-1.4 Arrangement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-1.5 Safety Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ii

4-1.6 Tools and Test Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-2 MAINTENANCE PLAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-3 SYSTEM FUNCTIONAL TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-4 HYDRAULIC POWER UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4-4.1 Hydraulic Power Unit Fluid and Pressure and Return Filter Replacement. . . 4-4 4-4.2 Hydraulic Power Unit Overhaul. . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4-5 DAVIT ARM ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4-6 LOWER PEDESTAL ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4-7 SLEW DRIVE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4-8 CONSTANT TENSION WINCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

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

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

5-2 PRELIMINARY CHECKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-3 OPERATIONAL TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . 5-1

6 CORRECTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-1.1 Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-1.2 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-1.3 Arrangement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-1.4 Safety Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-1.5 Tools and Test Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

SECTION I ADJUSTMENTS AND ALIGNMENTS . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-2 ADJUSTMENT AND ALIGNMENT COVERAGE. . . . . . . . . . . . . . . . . . . 6-3

6-3 LUFF ANGLE INDICATOR AND TRANSDUCER ADJUSTMENT. . . . . . . . . . 6-3

6-4 SLACK LINE LIMIT SWITCH ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . 6-5

6-5 HOIST UP/DOWN LIMIT SWITCH ADJUSTMENT. . . . . . . . . . . . . . . . . . 6-5

6-5.1 Slew Limit Switch Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-6 HYDRAULIC/ELECTRICAL SYSTEM ADJUSTMENT AND SETUP

PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 iii

6-6.1 Hydraulic System Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 6-6.1.1 Compensator Relief Valve Adjustment (RV4). . . . . . . . . . . . 6-9 6-6.1.2 Main System Relief Valve Adjustment (RV1). . . . . . . . . . . 6-9 6-6.1.3 Constant Tension Boost Pump Relief Valve Adjustment (RV2). . 6-10 6-6.1.4 Load Sense Valve Adjustment (RV5). . . . . . . . . . . . . . . . 6-11 6-6.1.5 Gravity Lowering Circuit Adjustment (RV8 and NV1) for equipment not modified by ECP 583-04A-C017. . . . . . . . 6-12 6-6.2 Amplifier Circuit Card Adjustment. . . . . . . . . . . . . . . . . . . . . . . . 6-12

6-6.2.1 Hoist Amplifier Circuit Card (MDSD1) Adjustment (Hoist Heave). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

6-6.2.2 Hoist Amplifier Circuit Card (MDSD1) Adjustment (Payout). . . 6-14 6-6.2.3 Slew Amplifier Circuit Card (MDSD2) Adjustment (Clockwise or Right). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 6-6.2.4 Slew Amplifier Circuit Card (MDSD2) Adjustment

(Counterclockwise or Left). . . . . . . . . . . . . . . . . . . . 6-17 6-6.2.5 Slew Amplifier Circuit Card (MDSD2) Adjustment (Frequency).

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 6-6.2.6 Luff Amplifier Circuit Card (MDSD3) Adjustment (IN). . . . . . 6-20 6-6.2.7 Luff Amplifier Circuit Card (MDSD3) Adjustment (OUT). . . . 6-21

SECTION II REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

6-7 REPAIR COVERAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

6-8 GENERAL CLEANING AND INSPECTION PROCEDURES. . . . . . . . . . . . . 6-24

6-8.1 Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 6-8.2 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

6-9 GENERAL REPAIR AND REPLACEMENT PROCEDURES. . . . . . . . . . . . . 6-25

6-9.1 Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 6-9.2 Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

6-10 BOAT DAVIT SYSTEM WITH CONSTANT TENSION WINCH REPAIR. . . . . . 6-28

6-10.1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 6-10.2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33

6-11 LOWER PEDESTAL ASSEMBLY REPAIR. . . . . . . . . . . . . . . . . . . . . . . 6-39 6-11.1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 6-11.2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47 6-11.3 Slew Drive Gearbox Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59

6-11.3.1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59 6-11.3.2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62

6-11.4 Hydraulic Junction Box Repair. . . . . . . . . . . . . . . . . . . . . . . . . . 6-67 6-11.4.1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67 6-11.4.2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76

6-11.5 Remote Operator Interface Junction Box Repair (not applicable to equipment modified by ECP 583-04A-C018). . . . . . . . . . . . . . . . . 6-93 iv

6-11.5.1 Disassembly (not applicable to equipment modified by ECP 583-04A-C018). . . . . . . . . . . . . . . . . . . . . . . . . . . 6-93

6-11.5.2 Assembly (not applicable to equipment modified by ECP 583-04A-C018). . . . . . . . . . . . . . . . . . . . . . . . . . . 6-98

6-11.6 Slew Drive Hydraulic Motor Repair. . . . . . . . . . . . . . . . . . . . . . . 6-104 6-11.6.1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-104 6-11.6.2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-105

6-11.7 Slew Drive Hydraulic Brake Repair. . . . . . . . . . . . . . . . . . . . . . . . 6-107 6-11.7.1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-107 6-11.7.2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-108

6-11.8 Control Console Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-112 6-11.8.1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-112 6-11.8.2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-121

6-11.9 Hydraulic Power Unit Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-126 6-11.9.1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-126 6-11.9.2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-132 6-11.9.3 Electric Motor Repair. . . . . . . . . . . . . . . . . . . . . . . . . 6-144

6-11.9.3.1 Disassembly. . . . . . . . . . . . . . . . . . . . 6-144 6-11.9.3.2 Assembly. . . . . . . . . . . . . . . . . . . . . . 6-147

6-11.9.4 Motor Starter Repair. . . . . . . . . . . . . . . . . . . . . . . . . 6-152 6-11.9.5 Hand Pump Repair. . . . . . . . . . . . . . . . . . . . . . . . . . 6-157

6-11.9.5.1 Disassembly. . . . . . . . . . . . . . . . . . . . 6-157 6-11.9.5.2 Assembly. . . . . . . . . . . . . . . . . . . . . . 6-158

6-11.9.6 Pump Assembly Repair. . . . . . . . . . . . . . . . . . . . . . . . 6-159 6-11.9.6.1 Disassembly. . . . . . . . . . . . . . . . . . . . 6-159 6-11.9.6.2 Assembly. . . . . . . . . . . . . . . . . . . . . . 6-160

6-11.9.7 Directional Controls Manifold Assembly Repair. . . . . . . . . . 6-169 6-11.9.7.1 Disassembly. . . . . . . . . . . . . . . . . . . . 6-169 6-11.9.7.2 Assembly. . . . . . . . . . . . . . . . . . . . . . 6-170

6-11.9.8 Pressure Filter Manifold Assembly Repair. . . . . . . . . . . . . 6-171 6-11.9.8.1 Disassembly. . . . . . . . . . . . . . . . . . . . 6-171 6-11.9.8.2 Assembly. . . . . . . . . . . . . . . . . . . . . . 6-172 6-11.9.8.3 Pressure Filter Element Replacement. . . . . . 6-175

6-11.9.9 Return Filter Element Replacement. . . . . . . . . . . . . . . . . 6-178 6-11.9.10 Guage Panel Assembly Repair (equipment modified by ECP

583-04A-C017). . . . . . . . . . . . . . . . . . . . . . . . . . . 6-180

6-12 BOAT DAVIT ARM ASSEMBLY REPAIR. . . . . . . . . . . . . . . . . . . . . . . . 6-182 6-12.1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-182 6-12.2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-183

6-12.2.1 Luff Cylinder Repair. . . . . . . . . . . . . . . . . . . . . . . . . 6-186 6-12.2.2 Manifold Assembly Repair. . . . . . . . . . . . . . . . . . . . . . 6-189

6-13 SLACK LINE LIMIT SWITCH ASSEMBLY REPAIR. . . . . . . . . . . . . . . . . 6-191 6-13.1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-191 6-13.2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-191 v

6-14 PORTABLE LADDER REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-193 6-14.1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-193 6-14.2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-193

6-15 CONSTANT TENSION WINCH ASSEMBLY REPAIR. . . . . . . . . . . . . . . . . 6-195 6-15.1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-195 6-15.2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-198 6-15.3 Main Hoist/Constant Tension Planetary Assembly Repair. . . . . . . . . . . . 6-202

6-15.3.1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-202 6-15.3.2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-203

6-15.4 Constant Tension Hydraulic Brake Repair. . . . . . . . . . . . . . . . . . . . 6-204 6-15.4.1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-205 6-15.4.2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-206

6-15.5 Main Hoist Hydraulic Motor Repair. . . . . . . . . . . . . . . . . . . . . . . 6-210 6-15.5.1 Disassembly (equipment not modified by ECP 583-04A-C019). . 6-210 6-15.5.2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-211 6-15.5.3 Disassembly (for equipment modified by ECP 583-04A-C019). . 6-212 6-15.5.4 Assembly (for equipment modified by ECP 583-04A-C019). . . 6-217

6-15.6 Main Hoist Hydraulic Brake Repair. . . . . . . . . . . . . . . . . . . . . . . . 6-217 6-15.6.1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-218 6-15.6.2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-219

6-15.7 Main Hoist Gearbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-222 6-15.7.1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-222 6-15.7.2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-223

6-15.8 Constant Tension Hydraulic Motor Repair. . . . . . . . . . . . . . . . . . . . 6-227 6-15.8.1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-227 6-15.8.2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-228

6-15.9 Ratchet Assembly Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-231 6-15.9.1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-231 6-15.9.2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-231

6-16 HYDRAULIC ROUTING REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-234

6-17 ELECTRICAL ASSEMBLY REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-235

6-18 REMOTE OPERATOR PACK (ROP) REPAIR (Not applicable to equipment modified by ECP 583-04A-C018). . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-235

6-18.1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-235 6-18.2 Assembly (Not applicable to equipment modified by ECP 583-04A-C018). . 6-239

6-19 REMOTE OPERATOR PACK MOUNTING BRACKET REPAIR (Not applicable to equipment modified by ECP 583-04A-C018). . . . . . . . . . . . . . . . . . . . . 6-242

6-19.1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-242 6-19.2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-242

6-20 FIBER OPTIC RECEIVER (FOR) TROUBLESHOOTING INTRODUCTION (Not applicable to equipment modified by ECP 583-04A-C018). . . . . . . . . . . . . . 6-245 vi

7 PARTS BREAKDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

SECTION I INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-1.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-1.2 Group Assembly Parts List (GAPL). . . . . . . . . . . . . . . . . . . . . . . 7-1

7-1.2.1 Figure and Index No. . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-1.2.2 Part Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-1.2.3 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-1.2.4 Commercial and Government Entity (CAGE) Codes. . . . . . . 7-1 7-1.2.5 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-1.2.6 Reference Designators. . . . . . . . . . . . . . . . . . . . . . . . 7-2 7-1.2.7 Unit per Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7-1.2.8 Used On Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7-1.2.9 Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-1.2.10 GAPL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

SECTION II GROUP ASSEMBLY PARTS LIST (GAPL) . . . . . . . . . . . . . . . . . . . . . 7-2

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

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

8-2 SITE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-3 UNPACKING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-4 INSTALLATION PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 vii

LIST OF TABLES

Table Title Page

1-1 Reference Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-2 Equipment, Accessories and Documents Supplied . . . . . . . . . . . . . . . . . . . . 1-13

1-3 Supporting Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

1-4 Boat Davit System Engineering Change Descriptions . . . . . . . . . . . . . . . . . . 1-14

2-1 Control Console Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-1.1 Remote Operator Pack Controls and Indicators (not applicable to equipment modified by ECP 583-04A-C018) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2-2 Hydraulic Power Unit Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . 2-7

2-3 Constant Tension Winch Controls and Indicators . . . . . . . . . . . . . . . . . . . . 2-11

2-4 Start Up Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2-5 Normal Operating Procedures (applicable to equipment modified by ECP 583-04A-C018) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2-5.1 Normal Operating Procedures (Using Remote Operator Pack) (not applicable to equipment modified by ECP 583-04A-C018) . . . . . . . . . . . . . . . . . . . . . 2-20

2-6 Manual Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

2-7 Operator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

2-8 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

4-1 Maintenance Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-2 Hydraulic Power Unit/Hydraulic Routing Overhaul Maintenance Items List . . . . . 4-6

4-3 Davit Arm Assembly Overhaul Maintenance Items List . . . . . . . . . . . . . . . . 4-9

4-4 Lower Pedestal Assembly Overhaul Maintenance Items List . . . . . . . . . . . . . . 4-14

4-5 Slew Drive Overhaul Maintenance Items List . . . . . . . . . . . . . . . . . . . . . . 4-15

4-6 Constant Tension Winch Maintenance Items List . . . . . . . . . . . . . . . . . . . . 4-19

5-1 Trouble Analysis Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-2 Hydraulic Junction Box Internal Wiring Table. (Not on Equipment Modified by ECP 583-04A-C006). CTAC Used On Equipment Modified by ECP-583-04A-C015 . . 5-15

5-2.1 Hydraulic Junction Box Internal Wiring Table (on equipment modified by ECP 583-04A-C006), CTAC used on equipment modified by ECP-583-04A-C015 (not applicable to equipment modified by ECP 583-04A-C018) . . . . . . . . . . . . . 5-17

5-3 Wire and Cable Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 viii

LIST OF TABLES - Continued

5-4 Termination Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

5-5 Control Console Internal Wiring Table . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

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

6-2 Standard Torque Values for Screws and Bolts . . . . . . . . . . . . . . . . . . . . . . 6-26

6-3 Standard Torque Values for Hose Fittings . . . . . . . . . . . . . . . . . . . . . . . . 6-26

6-4 Standard Torque Values for Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . 6-27

6-5 Standard Torque Values for NPT Fittings . . . . . . . . . . . . . . . . . . . . . . . . 6-27

6-6 Boat Davit System With Constant Tension Winch Repair Required Hydraulic Caps and Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

6-7 Lower Pedestal Assembly Repair Required Hydraulic Caps and Plugs . . . . . . . . 6-39

6-8 Slew Drive Gearbox Repair Required Hydraulic Caps and Plugs . . . . . . . . . . . 6-59

6-9 Slew Drive Hydraulic Motor Repair Required Hydraulic Caps and Plugs . . . . . . . 6-104

6-10 Slew Drive Hydraulic Brake Repair Required Hydraulic Caps and Plugs . . . . . . . 6-107

6-11 Hydraulic Power Unit Repair Required Hydraulic Caps and Plugs . . . . . . . . . . 6-126

6-12 Hand Pump Repair Required Hydraulic Caps and Plugs . . . . . . . . . . . . . . . . 6-157

6-13 Pump Assembly Repair Required Hydraulic Caps and Plugs . . . . . . . . . . . . . . 6-159

6-14 Directional Controls Manifold Assembly Repair Required Hydraulic Caps and Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-169

6-15 Pressure Filter Manifold Assembly Repair Required Hydraulic Caps and Plugs . . . 6-171

6-16 Boat Davit Arm Assembly Repair Required Hydraulic Caps and Plugs . . . . . . . . 6-182

6-17 Luff Cylinder Repair Required Hydraulic Caps and Plugs . . . . . . . . . . . . . . . 6-186

6-18 Constant Tension Winch Assembly Repair Required Hydraulic Caps and Plugs . . . 6-195

6-19 Constant Tension Hydraulic Brake Repair Required Hydraulic Caps and Plugs . . . 6-205

6-20 Main Hoist Hydraulic Motor Repair Required Hydraulic Caps and Plugs . . . . . . . 6-210

6-21 Main Hoist Hydraulic Brake Repair Required Hydraulic Caps and Plugs . . . . . . . 6-218

6-22 Main Hoist Gearbox Required Hydraulic Caps and Plugs . . . . . . . . . . . . . . . 6-222

6-23 Constant Tension Hydraulic Motor Repair Required Hydraulic Caps and Plugs . . . 6-227 ix

6-24 Fiber Optic Receiver Troubleshooting (Not applicable to equipment modified by ECP 583-04A-C018) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-246

7-1 Boat Davit System with Constant Tension Winch Parts List . . . . . . . . . . . . . . 7-2

7-2 Lower Pedestal Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7-3 Slew Drive Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7-4 Hydraulic Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

7-4.1 Remote Operator Pack Interface Junction Box (On equipment modified by ECP 583-04A-C006) (Not applicable to equipment modified by ECP 583-04A-C018) . 7-16

7-5 Slew Drive Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

7-6 Slew Drive Hydraulic Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

7-7 Control Console Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

7-8 Hydraulic Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

7-9 Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

7-10 Motor Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35

7-11 Hand Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37

7-12 Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37

7-13 Axial Piston Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

7-14 Directional Controls Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 7-39

7-15 Pressure Filter Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40

7-15.1 Gauge Panel Assembly (On Equipment Modified By ECP-583-04A-C017) . . . . . . 7-40

7-16 Davit Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41

7-17 Luff Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43

7-17.1 Manifold Assembly (On equipment modified by ECP-583-04A-C017) . . . . . . . . 7-43

7-18 Slack Line Limit Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44

7-19 Portable Ladder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44

7-20 Constant Tension Winch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45

7-21 Main Hoist/Constant Tension Planetary Assembly . . . . . . . . . . . . . . . . . . . . 7-49

7-22 Constant Tension Hydraulic Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49 x

7-23 Main Hoist Hydraulic Motor (not applicable to equipment not modified by ECP 583-04A-C019) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50

7-23.1 Main Hoist Hydraulic Motor (for equipment modified by ECP 583-04A-C019) (for new motor and new Shaft Adapter F166231) . . . . . . . . . . . . . . . . . . . . . 7-51

7-24 Main Hoist Hydraulic Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52

7-25 Main Hoist Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53

7-26 Constant Tension Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54

7-27 Ratchet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56

7-28 Hydraulic Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56

7-29 Electrical Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62

7-29.1 Remote Operator Pack (On Equipment Modified By ECP 583-04A-C006) (not applicable to equipment modified by ECP 583-04A-C018) . . . . . . . . . . . . . 7-65

7-29.2 Remote Operator Pack Mounting Bracket (On Equipment Modified By ECP 583-04A-C006) (not applicable to equipment modified by ECP 583-04A-C018) . 7-67

7-30. Interface Filter Assembly (On equipment modified by ECP 583-04A-C012) . . . . . 7-67

8-1 Shipping Loose Parts Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 xi

LIST OF ILLUSTRATIONS

Figure Title Page

1-1 Boat Davit System with Constant Tension Winch . . . . . . . . . . . . . . . . . . . . 1-4

1-2 Lower Pedestal Assembly (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-3 Constant Tension Winch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1-4 Davit Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-5 Slack Line Limit Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1-6 Shaft Seal Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

1-7 Adapter Extractor Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

2-1 Control Console Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2-1.1 Remote Operator Pack Controls and Indicators (not applicable to equipment modified by ECP 583-04A-C018) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-2 Hydraulic Power Unit Controls and Indicators (Sheet 1 of 2) . . . . . . . . . . . . . 2-9

2-3 Constant Tension Winch Controls and Indicators . . . . . . . . . . . . . . . . . . . . 2-12

2-4 Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2-5 Quick Release Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2-6 Portable Ladder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

2-7 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

2-8 Measuring Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

2-9 Determining Crown Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

2-10 Main Hoist Gearbox Fluid Fill/Level Check Plug Location . . . . . . . . . . . . . . 2-40

4-1 Davit Arm Sheave Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4-2 Sheave Pin Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4-3 Cylinder Pins and Davit Pivot Pins Measurement . . . . . . . . . . . . . . . . . . . . 4-11

4-4 Sheave Pin Bore Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4-5 Davit Arm Cylinder Pin Bore Measurement . . . . . . . . . . . . . . . . . . . . . . . 4-12

4-6 Upper Pedestal Cylinder Pin Bore Measurement . . . . . . . . . . . . . . . . . . . . 4-12

4-7 Davit Arm Bore Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4-8 Slew Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 xii

LIST OF ILLUSTRATIONS - Continued

4-9 Shaft Adapter Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

4-10 Slew Pinion Support Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

4-11 Slew Pinion Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4-12 Winch Drum Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

4-13 Winch Drum Groove Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

4-14 Winch Drum Shaft Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

5-1 System Interconnect Wiring (Sheet 1 of 60) . . . . . . . . . . . . . . . . . . . . . . . 5-22

6-1 Luff Angle Indicator and Transducer Adjustment . . . . . . . . . . . . . . . . . . . . 6-4

6-2 Hoist Up/Down Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-3 Floodlight Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

6-4 Lower Pedestal Assembly (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . 6-55

6-5 Slew Drive Gearbox Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66

6-6 Hydraulic Junction Box Repair (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . 6-87

6-6.1 Remote Operator Pack Interface Junction Box (not applicable to equipment modified by ECP 583-04A-C018) (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . 6-90

6-7 Slew Drive Hydraulic Motor Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-107

6-8 Slew Drive Hydraulic Brake Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-111

6-9 Control Console Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-115

6-10 Control Console Pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-116

6-11 Control Console Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-117

6-12 Control Console Rotary Type Switches . . . . . . . . . . . . . . . . . . . . . . . . . . 6-119

6-13 Control Console Joysticks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-120

6-14 Control Console Repair (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . 6-124

6-15 Hydraulic Power Unit Repair (Sheet 1 of 6) . . . . . . . . . . . . . . . . . . . . . . . 6-138

6-16 Electric Motor Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-151

6-17 Motor Starter Repair (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-154

6-18 Hand Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-159 xiii

6-19 Pump Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-162

6-20 Axial Piston Pump Repair (Sheet 1 of 5) . . . . . . . . . . . . . . . . . . . . . . . . 6-164

6-21 Directional Controls Manifold Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 6-171

6-22 Pressure Filter Manifold Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-174

6-23 Pressure Filter Element Parts Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-177

6-24 Return Filter Element Parts Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-180

6-24.1 Gauge Panel Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-181

6-25 Boat Davit Arm Assembly Repair (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . 6-185

6-26 Luff Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-189

6-26.1 Manifold Assembly Repair (Refer to Table 7-17.1) . . . . . . . . . . . . . . . . . . . 6-190

6-27 Slack Line Limit Switch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-192

6-28 Portable Ladder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-194

6-29 Constant Tension Winch Assembly Repair (Sheet 1 of 2) . . . . . . . . . . . . . . . 6-201

6-30 Main Hoist/Constant Tension Planetary Assembly Repair . . . . . . . . . . . . . . . 6-204

6-31 Constant Tension Hydraulic Brake Repair . . . . . . . . . . . . . . . . . . . . . . . . 6-209

6-32 Main Hoist Hydraulic Motor Repair (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . 6-215

6-33 Main Hoist Hydraulic Brake Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-221

6-34 Main Hoist Gearbox Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-226

6-35 Constant Tension Hydraulic Motor Repair . . . . . . . . . . . . . . . . . . . . . . . . 6-230

6-36 Ratchet Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-233

6-37 Remote Operator Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-243

6-38 Remote Operator Pack Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . 6-244

6-39 Fiber Optic Receiver (Not applicable to equipment modified by ECP 583-04A-C018) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-245

6-40. Interface Filter Assembly Mounting (On Equipment Modified by ECP 583-04A-C012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-245

8-1 Pedestal Foundation Reaction Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-2 Sling Attachment Point, Trailer Removal . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 xiv

8-3 Sling Attachment Points, Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . 8-5

8-4 Hydraulic Power Unit Bleed Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

8-5 Slew Brake Bleed Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

8-6 Luff Cylinder and Constant Tension Winch Bleed Ports . . . . . . . . . . . . . . . . 8-10

8-7 Boat Davit System with Constant Tension Winch Operating Envelope (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

8-8 Electrical Block Diagram (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

8-9 Electrical Schematic (Sheet 1 of 11) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

8-10 Hydraulic Schematic (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41

8-11 Boat Davit System with Constant Tension Winch (Sheet 1 of 2) . . . . . . . . . . . 8-45

8-12 Hydraulic Routing (Sheet 1 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49

8-13 Electrical Assembly (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-63

8-14 Foundation Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-69 xv

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 spe-cific safety precautions, the commanding officer or other authority will issue orders as deemed necessary to cover the situation. No work shall be undertaken on energized equipment or circuits until approval of the commanding officer is obtained, and then only in accordance with Naval Ships’ Technical Manual (NSTM) S9086-KC-STM- 010/Chapter 300.

DO NOT REPAIR OR ADJUST ALONE

Under no circumstances shall repair or adjustment of energized equipment be attempted alone. The imme-diate presence of someone capable of rendering first aid is required. Before making adjustments, be sure to pro-tect against grounding. If possible, adjustments should be made with one hand, with the other hand 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 discharged prior to attempting repairs. Equipment should be deenergized and properly tagged out according to the ship’s Standard Operating Procedures.

TEST EQUIPMENT

Make certain test equipment is in good condition. If a metal-cased 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. Do not ground any measuring devices; these devices should not be held when taking measurements.

INTERLOCKS-SAFETY DEVICES

Interlocks are provided for safety of personnel and equipment and should be used only for the purpose intended. Never tamper with or render ineffective any safety device, interlock, ground strap or similar device intended to protect operators or the equipment without specific approval of the Commanding Officer. Do not depend solely upon interlocks for protection. Whenever possible, disconnect power at the distribution source.

MOVING EQUIPMENT

Personnel shall remain clear of moving equipment. If equipment requires adjustment while in motion, a safety watch shall be posted. The safety watch shall be qualified to administer CPR, have a full view of the operations being performed, and have immediate access to controls capable of stopping equipment motion.

FIRST AID

An injury, no matter how slight, shall never go unattended. Always obtain first aid or medical attention immediately, and file an injury report in accordance with OPNAVINST 5102.1 series, subj: Mishap Investigation and Reporting.

xvi

SAFETY SUMMARY - Continued

RESUSCITATION

Personnel working with or near high voltage shall be familiar with approved methods of resuscitation.

Should someone be injured and stop…