SG811-BV-MMA-010

REVISION 1

TECHNICAL MANUAL
[SGML VERSION; SEE CHANGE
RECORD ]
BOAT CRANE
TYPE GN1/5
WITH ILLUSTRATED PARTS BREAKDOWN

DISTRIBUTION STATEMENT B: DISTRIBUTION AUTHORIZED TO U.S. GOVERNMENT

AGENCIES ONLY; THIS PUBLICATION IS REQUIRED FOR OFFICIAL USE OR FOR
ADMINISTRATIVE OR OPERATIONAL PURPOSES: (DATE OF PUBLICATION). OTHER
REQUESTS FOR THIS DOCUMENT MUST BE REFERRED TO THE NAVAL SEA SYS-
TEMS COMMAND (SEA-09T).

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 EXECUTIVE ORDER 12470. VIOLATIONS OF THESE EXPORT LAWS ARE
SUBJECT TO SEVERE CRIMINAL PENALTIES.

DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL PREVENT DISCLO-

SURE OF CONTENTS OR RECONSTRUCTION OF THIS DOCUMENT.

THIS MANUAL SUPERSEDES NAVSEA SG811–BV-MMA-010 DATED 1/6/1995 AND ALL

CHANGES THERETO

PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

30 JUN 2000
TITLE-1 / (TITLE-2 Blank)@@FIpgtype@@TITLE@@!FIpgtype@@
@@FIpgtype@@TITLE@@!FIpgtype@@
TITLE-2
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

CHANGE RECORD
CHANGE NO. DATE TITLE AND/OR BRIEF DESCRIPTION/PREPARING ACITIVITY
REV. 1 6/30/2000 REVISION INCORPORATES WORK PACKAGES 182, 185, 186, 174, 176,
AND OTHER CONFIGURATION AND MAINTENANCE INFORMATION.
PREPARED BY NSWCCD-SSES CODES 9441 AND 9730
NOTE
THIS TECHNICAL MANUAL (TM) HAS BEEN DEVELOPED FROM AN INTELLIGENT ELECTRONIC
SOURCE KNOWN AS STANDARD GENERALIZED MARKUP LANGUAGE (SGML). THERE IS NO LOEP.
ALL CHANGES, IF APPLICABLE, ARE INCLUDED. THE PAGINATION IN THIS TM WILL NOT MATCH
THE PAGINATION OF THE ORIGINAL PAPER TM; HOWEVER, THE CONTENT IS EXACTLY THE SAME.
ANY CHANGES RECEIVED AFTER RECEIPT OF THIS TM WILL ONLY FIT IN THIS PAGINATED VERSION.

CHANGE RECORD-1 / (CHANGE RECORD-2 Blank)

CHANGE RECORD-2
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

FOREWORD

This manual provides the information necessary to operate, service, and perform maintenance on the Boat
Crane. This manual consists of the following chapters:

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 CALIBRATION PROCEDURES
SECTION II - REPAIR PROCEDURES
CHAPTER 7 - PARTS LIST
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 reported to
the Commander, NAVSURFWARCENDIV, 4363 Missile Way, Port Hueneme, CA 93043-4307 on NAVSEA/
SPAWAR Technical Manual Deficiency/Evaluation Report (TMDER), NAVSEA Form 4160/1. To facilitate such
reporting, copies of NAVSEA Form 4160/1 are included at the end of each bound part of each technical manual.
All feedback comments shall be thoroughly investigated and originators will be advised of action resulting there-
from. Extra copies of NAVSEA Form 4160/1 may be requisitioned from the DDSP Susquehanna, PA, 05 E Street,
Mechanicsburg, PA 17055-5003.

SHIP ALTERATIONS AND OTHER UPDATES. Work packages 128 and 129 have been incorporated into
this Ship Information Book.

FOREWORD-1 / (FOREWORD-2 Blank)

FOREWORD-2
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

TABLE OF CONTENTS

Chapter/Paragraph Page

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

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

1-1.1 Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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

1-2.1 Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2.2 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2.3 Applicability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2.4 Interface Relationships. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2.5 Design Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2.6 Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-3 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-3.1 Equipment Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-3.2 Physical Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-3.2.1 Main Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-3.2.2 Jib Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-3.2.3 Control Panel Assembly. . . . . . . . . . . . . . . . . . . . . . . 1-5
1-3.2.4 Control Joysticks. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-3.2.5 Electric Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-3.2.6 Hydraulic Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-3.2.7 Cylinder Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-3.2.8 Slew Drive Assembly (Hydraulic Motors, Pinion, Reduction
Gear, and Brake Assemblies). . . . . . . . . . . . . . . . . . . 1-6
1-3.2.9 Winch Assembly (Hydraulic Motors, Reduction Gear, and Brake
Assemblies). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-3.2.10 Boom Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . 1-7
1-3.2.11 Slew Ring Locking Assembly. . . . . . . . . . . . . . . . . . . . 1-7
1-3.2.12 Revolving Turret Assembly. . . . . . . . . . . . . . . . . . . . . . 1-7
1-3.2.13 Electronic Control Unit. . . . . . . . . . . . . . . . . . . . . . . . 1-7
1-3.2.14 Electric Motor Starter. . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1-3.2.15 Slew Hydraulic Circuit. . . . . . . . . . . . . . . . . . . . . . . . 1-7
1-3.2.16 Main Cylinder Hydraulic Circuit. . . . . . . . . . . . . . . . . . 1-7
1-3.2.17 Jib Cylinder Hydraulic Circuit. . . . . . . . . . . . . . . . . . . . 1-8
1-3.2.18 Winch Hydraulic Circuit. . . . . . . . . . . . . . . . . . . . . . . 1-8
1-3.2.19 Hydraulic Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1-3.2.20 Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1-3.2.21 Hydraulic Hand Pump. . . . . . . . . . . . . . . . . . . . . . . . 1-8
1-3.2.22 Hydraulic Cross-Connect Equipment. . . . . . . . . . . . . . . . 1-8
1-3.3 Reference Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1-3.4 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1-3.5 Publications Required But Not Supplied. . . . . . . . . . . . . . . . . . . . . 1-10

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

i
SG811-BV-MMA-010

TABLE OF CONTENTS - Continued

Chapter/Paragraph Page

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

2-2 CONTROLS AND INDICATORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-2.1 Control Panel Controls And Indicators. . . . . . . . . . . . . . . . . . . . . . 2-1
2-2.2 Control Joyticks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-2.3 Servovalves Manual Control Functions. . . . . . . . . . . . . . . . . . . . . . 2-1
2-2.4 Battle Short Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-2.5 Slew Ring Locking Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-2.6 Hand Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-2.7 Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-3 PROTECTIVE DEVICES AND JACKS. . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-4 OPERATING PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2-4.1 Operator Turn-On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2-4.2 Modes of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2-4.2.1 Boat Hook Operation. . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2-4.3 Operator Turn-Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2-4.4 Battle Short Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2-4.5 Battle Short Turn-Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

2-5 MANUAL OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

2-6 OPERATORS MAINTENANCE INSTRUCTIONS. . . . . . . . . . . . . . . . . . . 2-30

2-7 STANDARD LOG FORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

2-8 HYDRAULIC CROSS-CONNECT SYSTEM. . . . . . . . . . . . . . . . . . . . . . 2-32

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

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

3-2 PRINCIPLES OF OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-2.1 Hoisting Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-2.2 Topping Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-2.3 Slewing Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3-2.4 Emergency Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-3 OVERALL HYDRAULIC SYSTEM DESCRIPTION. . . . . . . . . . . . . . . . . . 3-5

3-3.1 Overall Hydraulic Cross-Connect System Description. . . . . . . . . . . . . . 3-5

3-4 FUNCTIONAL HYDRAULIC SYSTEM DESCRIPTION. . . . . . . . . . . . . . . . 3-5

3-4.1 Functional Hydraulic Cross-Connect System Description. . . . . . . . . . . . 3-6

3-5 HYDRAULIC SYSTEM DETAILED FUNCTIONAL DESCRIPTION. . . . . . . . 3-6

3-5.1 Hydraulic Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

ii
 SG811-BV-MMA-010

TABLE OF CONTENTS - Continued

Chapter/Paragraph Page

3-5.2 Valve Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3-5.2.1 Servo Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3-5.2.1.1 Mechanical Override. . . . . . . . . . . . . . . . . . 3-8
3-5.2.2 Pilot Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-5.2.3 Drain Cock Valves. . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-5.3 Control Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-5.3.1 Antishock Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-5.3.2 Overcenter Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-5.3.2.1 Cylinder Overcenter Valves. . . . . . . . . . . . . . . 3-9
3-5.3.2.2 Hydraulic Motor Overcenter Valves. . . . . . . . . . 3-9
3-5.3.3 Double Control Valves. . . . . . . . . . . . . . . . . . . . . . . . 3-10
3-5.3.4 One Way Restrictor Valves. . . . . . . . . . . . . . . . . . . . . . 3-11
3-5.4 Cylinder Assembly (Main and Jib). . . . . . . . . . . . . . . . . . . . . . . . 3-11
3-5.5 Reduction Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3-5.6 Turret Hydraulic Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3-5.7 Turret Hydraulic Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3-5.8 Winch Hydraulic Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3-5.9 Winch Hydraulic Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3-5.10 Hydraulic Power Cross-Connect System. . . . . . . . . . . . . . . . . . . . . 3-27
3-5.10.1 Functional Hydraulic Cross-Connect System Description. . . . . 3-27

3-6 ELECTRICAL SYSTEM DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . 3-28

3-7 ELECTRICAL SYSTEM DETAILED FUNCTIONAL DESCRIPTION. . . . . . . . 3-28

3-7.1 Electric Motor Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3-7.2 Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3-7.3 Control Joytick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3-7.4 Electric Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3-7.5 Electronic Control Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3-7.5.1 Dirty Box (EMI Filters). . . . . . . . . . . . . . . . . . . . . . . 3-36
3-7.5.2 Control Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3-7.5.3 Supply Board CST 102. . . . . . . . . . . . . . . . . . . . . . . . 3-37
3-7.6 Slew Limit Relay Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

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

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

4-1.1 Planned Maintenance System. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-2 MAINTENANCE ACTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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

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

5-2 TEST EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

iii
SG811-BV-MMA-010

TABLE OF CONTENTS - Continued

Chapter/Paragraph Page

5-3 FAULT LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-4 SYSTEMS FAULT ISOLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

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

SECTION I ADJUSTMENTS AND CALIBRATION PROCEDURES . . . . . . . . . . . . . . 6-1

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

6-2 ADJUSTMENTS/CALIBRATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-2.1 Servo Valve Null (Mechanical) Adjustment. . . . . . . . . . . . . . . . . . . 6-1
6-2.2 Pump Compensator Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-2.3 Relief Valve (Solenoid-Controlled) Adjustment. . . . . . . . . . . . . . . . . 6-2
6-2.4 Geared Limit Switch Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-2.5 Hydraulic Valve Adjustment (Post-Repair, Prior to Installation in System). . 6-4
6-2.6 Gauge Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

SECTION REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-3 BOAT CRANE REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . 6-4

6-3.1 Boat Crane Removal From Pedestal. . . . . . . . . . . . . . . . . . . . . . . 6-5
6-3.2 Boat Crane Installation on Pedestal. . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-4 REPAIR OF THE BOAT CRANE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6-4.1 Jib Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6-4.1.1 Jib Boom Cylinder Removal. . . . . . . . . . . . . . . . . . . . . 6-9
6-4.1.1.1 Jib Boom Cylinder Disassembly. . . . . . . . . . . . 6-11
6-4.1.1.2 Jib Boom Cylinder Assembly. . . . . . . . . . . . . . 6-14
6-4.1.2 Jib Boom Cylinder Installation. . . . . . . . . . . . . . . . . . . . 6-14
6-4.1.3 Winch Assembly Removal. . . . . . . . . . . . . . . . . . . . . . 6-14
6-4.1.3.1 Removal and Disassembly of the Hydraulic Motor
Assembly. . . . . . . . . . . . . . . . . . . . . . . 6-18
6-4.1.3.2 Assembly and Installation of Hydraulic Motor
Assembly. . . . . . . . . . . . . . . . . . . . . . . 6-19
6-4.1.3.3 Removal and Disassembly of the Gear Limit Switch
Assembly. . . . . . . . . . . . . . . . . . . . . . . 6-19
6-4.1.3.4 Assembly and Installation of Gear Limit Switch. . . 6-21
6-4.1.3.5 Disassembly of the Cable Drum Assembly. . . . . . 6-21
6-4.1.3.6 Assembly of Cable Drum. . . . . . . . . . . . . . . . 6-22
6-4.1.4 Installation of Winch Assembly. . . . . . . . . . . . . . . . . . . 6-22
6-4.1.5 Boom Head Assembly Removal. . . . . . . . . . . . . . . . . . . 6-22
6-4.1.5.1 Boom Head Assembly Disassembly. . . . . . . . . . 6-24
6-4.1.5.2 Assembly of Boom Head Assembly. . . . . . . . . . 6-26
6-4.1.6 Installation of Boom Head Assembly. . . . . . . . . . . . . . . . 6-26
6-4.2 Remove/Replace Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
6-4.3 Jib Boom Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

iv
 SG811-BV-MMA-010

TABLE OF CONTENTS - Continued

Chapter/Paragraph Page

6-4.4 Main Boom Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

6-4.4.1 Main Boom Cylinder Removal. . . . . . . . . . . . . . . . . . . 6-31
6-4.4.1.1 Main Boom Cylinder Disassembly. . . . . . . . . . . 6-32
6-4.4.1.2 Main Boom Cylinder Assembly. . . . . . . . . . . . 6-32
6-4.4.2 Installation of Main Boom Cylinder. . . . . . . . . . . . . . . . . 6-32
6-4.4.3 Main Boom Removal. . . . . . . . . . . . . . . . . . . . . . . . . 6-33
6-4.4.4 Main Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . 6-34
6-4.5 Operator Seat Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
6-4.5.1 Operator Seat Assembly Removal. . . . . . . . . . . . . . . . . . 6-34
6-4.5.2 Operator Seat Assembly Installation. . . . . . . . . . . . . . . . . 6-37
6-4.5.3 Removal of Control Panel. . . . . . . . . . . . . . . . . . . . . . 6-39
6-4.5.4 Control Panel Disassembly. . . . . . . . . . . . . . . . . . . . . . 6-41
6-4.5.5 Control Panel Assembly. . . . . . . . . . . . . . . . . . . . . . . 6-41
6-4.5.6 Replace Control Panel. . . . . . . . . . . . . . . . . . . . . . . . 6-41
6-4.5.7 Remove and Replace Terminal Board TB1. . . . . . . . . . . . . 6-41
6-4.5.8 Remove, Disassemble, Assemble, and Replace the Control Panel
Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
6-4.5.9 Removal/Installation of Pressure Gauge. . . . . . . . . . . . . . . 6-43
6-4.5.10 Remove and Replace the Control Joysticks. . . . . . . . . . . . . 6-44
6-4.5.11 Remove Electronic Control Unit. . . . . . . . . . . . . . . . . . . 6-46
6-4.5.12 Electronic Control Unit Disassembly/Reassembly. . . . . . . . . 6-47
6-4.5.12.1 Remove Control Board. . . . . . . . . . . . . . . . . 6-47
6-4.5.12.2 Replace Control Board. . . . . . . . . . . . . . . . . 6-48
6-4.5.12.3 Remove Supply Board. . . . . . . . . . . . . . . . . 6-48
6-4.5.12.4 Remove and Replace Dirty Box. . . . . . . . . . . . 6-51
6-4.5.12.5 Disassemble/Replace Dirty Box. . . . . . . . . . . . 6-51
6-4.5.12.6 Remove and Replace Transformers TO47 and TO48.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
6-4.5.12.7 Remove and Replace Resistors R1 through R4. . . . 6-52
6-4.5.12.8 Remove and Replace Capacitor C1. . . . . . . . . . 6-52
6-4.5.12.9 Remove and Replace Fuseholders F1 and F2. . . . . 6-53
6-4.5.12.10 Remove and Replace Heat Sink. . . . . . . . . . . . 6-53
6-4.5.12.11 Remove and Replace ECU Door. . . . . . . . . . . . 6-54
6-4.5.13 Electric Motor Starter Removal. . . . . . . . . . . . . . . . . . . 6-54
6-4.5.14 Electric Motor Starter Disassembly. . . . . . . . . . . . . . . . . 6-58
6-4.5.14.1 Remove and Replace Overload Relay OL1. . . . . . 6-58
6-4.5.14.2 Remove and Replace Contactor CO1. . . . . . . . . 6-58
6-4.5.14.3 Remove and Replace Relays R1 and R2. . . . . . . 6-58
6-4.5.14.4 Remove and Replace Transformer TR1. . . . . . . . 6-59
6-4.5.14.5 Remove and Replace Fuseholder F1 through F6. . . 6-59
6-4.5.14.6 Remove and Replace Terminal Board TB1. . . . . . 6-59
6-4.5.14.7 Remove and Replace RESET Switch. . . . . . . . . 6-59
6-4.5.14.8 Remove and Replace BATTLE SHORT Switch. . . . 6-60
6-4.5.14.9 Remove and Replace Elecric Motor Starter Door. . . 6-60
6-4.5.15 Electric Motor Starter Installation. . . . . . . . . . . . . . . . . . 6-60
6-4.5.16 Remove and Replace Connection Box No. 4. . . . . . . . . . . . 6-62

v
SG811-BV-MMA-010

TABLE OF CONTENTS - Continued

Chapter/Paragraph Page

6-4.6 Disassemble/Assemble the Turret Enclosure. . . . . . . . . . . . . . . . . . . 6-62

6-4.7 Remove Electric Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
6-4.7.1 Disassemble Electric Motor. . . . . . . . . . . . . . . . . . . . . 6-63
6-4.7.2 Clean and Inspect Electric Motor. . . . . . . . . . . . . . . . . . 6-66
6-4.8 Replace Electric Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
6-4.9 Slew Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
6-4.9.1 Slew Ring Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
6-4.9.2 Slew Ring Disassembly. . . . . . . . . . . . . . . . . . . . . . . . 6-68
6-4.9.3 Assembly of Slew Ring. . . . . . . . . . . . . . . . . . . . . . . 6-70
6-4.9.4 Installation of Slew Ring. . . . . . . . . . . . . . . . . . . . . . . 6-70
6-4.9.5 Removal of Slew Ring Locking Device. . . . . . . . . . . . . . . 6-70
6-4.9.6 Disassembly of the Slew Ring Locking Device. . . . . . . . . . 6-71
6-4.9.7 Assembly of Slew Ring Locking Device. . . . . . . . . . . . . . 6-73
6-4.10 Hydraulic Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76
6-4.10.1 Removal of Hydraulic Motor. . . . . . . . . . . . . . . . . . . . . 6-76
6-4.10.2 Assembly and Installation of Hydraulic Motor. . . . . . . . . . . 6-78
6-4.11 Hydraulic Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78
6-4.11.1 Hydraulic Brake Removal. . . . . . . . . . . . . . . . . . . . . . 6-78
6-4.11.2 Disassembly of Hydraulic Brake. . . . . . . . . . . . . . . . . . . 6-80
6-4.11.3 Assembly of Hydraulic Brake. . . . . . . . . . . . . . . . . . . . 6-81
6-4.11.4 Installation of Hydraulic Brake. . . . . . . . . . . . . . . . . . . 6-82
6-4.12 Reduction Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-83
6-4.12.1 Removal of Reduction Gear. . . . . . . . . . . . . . . . . . . . . 6-83
6-4.12.2 Disassembly of Reduction Gear. . . . . . . . . . . . . . . . . . . 6-84
6-4.12.3 Assembly of Reduction Gear. . . . . . . . . . . . . . . . . . . . . 6-85
6-4.12.4 Installation of Reduction Gear. . . . . . . . . . . . . . . . . . . . 6-87
6-4.13 Hydraulic Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-88
6-4.13.1 Removal of Hydraulic Pump. . . . . . . . . . . . . . . . . . . . . 6-88
6-4.13.2 Installation of Hydraulic Pump. . . . . . . . . . . . . . . . . . . 6-89
6-4.14 Access Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
6-4.14.1 Removal of Access Panel. . . . . . . . . . . . . . . . . . . . . . . 6-90
6-4.14.2 Installation of Access Panel. . . . . . . . . . . . . . . . . . . . . 6-90
6-4.15 Filters, Valves, Gauges, and Hand Pump. . . . . . . . . . . . . . . . . . . . . 6-90
6-4.15.1 Removal/Installation of High Pressure Filter Assembly. . . . . . 6-90
6-4.15.2 Removal, Replacement and Installation of High Pressure Filter
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-92
6-4.15.3 Removal/Installation of Low Pressure (LP) Filter Assembly. . . 6-94
6-4.15.4 Removal/Installation of Differential Pressure Gauge. . . . . . . . 6-96
6-4.15.5 Removal/Installation of Low Pressure Filter Element. . . . . . . 6-96
6-4.15.6 Repair of Low Pressure Filter Assembly. . . . . . . . . . . . . . 6-97
6-4.15.7 Removal/Installation of Submersible Suction Filter. . . . . . . . 6-98
6-4.15.8 Repair of Submersible Suction Filter Element. . . . . . . . . . . 6-101
6-4.15.9 Removal/Installation of Valve Block. . . . . . . . . . . . . . . . 6-101
6-4.15.10 Removal/Installation of Servo Valve. . . . . . . . . . . . . . . . . 6-105
6-4.15.11 Removal/Installation of Ball Valves. . . . . . . . . . . . . . . . . 6-105
6-4.15.12 Removal/Installation of Pilot Operated Relief Valve. . . . . . . . 6-107

vi
 SG811-BV-MMA-010

TABLE OF CONTENTS - Continued

Chapter/Paragraph Page

6-4.15.13 Removal/Installation of the Antishock Valve. . . . . . . . . . . . 6-108

6-4.15.14 Removal/Installation of the Hand Pump. . . . . . . . . . . . . . 6-108
6-4.15.15 Removal/Installation of Temperature Gauge. . . . . . . . . . . . 6-110
6-4.15.16 Removal/Installation of Sight Liquid Level Indicator. . . . . . . 6-110
6-4.16 Remove and Replace Control Joystick ID Plate. . . . . . . . . . . . . . . . . 6-113
6-4.17 Remove and Replace the Oil Sump Cover. . . . . . . . . . . . . . . . . . . . 6-113
6-4.18.1 Slew Limit Relay Box Removal. . . . . . . . . . . . . . . . . . . 6-115
6-4.18.2 Slew Limit Relay Box Disassembly/Reassembly. . . . . . . . . . . . . . . . . 6-115
6-4.18.3 Slew Limit Relay Box Installation. . . . . . . . . . . . . . . . . . 6-116

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

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

7-1.1 Subassemblies and Components. . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-1.2 Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-2 LIST OF MAJOR COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-3 LIST OF MANUFACTURERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-4 PARTS LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-4.1 Format. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-4.2 Figure and Item Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-4.3 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-4.4 Quantity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-4.5 Commercial and Government Entity. . . . . . . . . . . . . . . . . . . . . . . 7-1
7-4.6 Manufacturer’s Part Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-4.7 Parts List Figures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

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

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

8-2 TOOLS AND MATERIALS REQUIRED FOR INSTALLATION. . . . . . . . . . . 8-1

8-3 SPECIAL FOUNDATION PREPARATION. . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-4 INSTALLATION PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-5 ELECTRICAL CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8-6 INSTALLATION CHECKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8-6.1 Preoperational Checks on Installation. . . . . . . . . . . . . . . . . . . . . . . 8-2
8-6.2 Operational Checks on Installation. . . . . . . . . . . . . . . . . . . . . . . . 8-6

8-7. STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

8-7.1 Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

vii
SG811-BV-MMA-010

TABLE OF CONTENTS - Continued

Chapter/Paragraph Page

8-7.2 Defective Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gloss-1

viii
 SG811-BV-MMA-010

LIST OF TABLES

Table Title Page

1-1. Boat Crane Component Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-2. Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

1-3. Publications Required But Not Supplied . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

2-1. Control Panel Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2-2. Operator Control Joystick Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2-3. Servovalves Control Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2-4. Battle Short Lever Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2-5. Gauge Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2-6. Protective Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2-7. Crane Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2-8. Pre-Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2-9. Turn-On Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

2-10. Boat Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

2-11. Operator Turn-Off Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

2-12. Battle Short Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

2-13. Battle Short Turn-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

2-14. Manually Operating the Winch, Main Boom, and Jib Boom with the Hand Pump . . 2-26

2-15. Manual Procedure for Rotating the Crane . . . . . . . . . . . . . . . . . . . . . . . . 2-28

2-16. Operation of the Crane from the Servovalves . . . . . . . . . . . . . . . . . . . . . . 2-29

2-17. Valve Positions for Boat Crane for Cross-Connect and Normal Operation . . . . . . 2-32

2-18. Boat Crane Supplying Hydraulic Power to the MPC . . . . . . . . . . . . . . . . . . 2-32

2-19. Multi-purpose Crane Supplying Hydraulic Power to the Boat Crane . . . . . . . . . 2-34

5-1. List of Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-2. Boat Crane Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-3. Hydraulic Pump Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5-4. Winch Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

ix
SG811-BV-MMA-010

LIST OF TABLES - Continued

Table Title Page

5-5. Slewing Control Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-6. Control Systems Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5-7. Electronic Control Unit Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-8. Control Panel Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-9. Electric Motor Starter Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5-10. Hydraulic System Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-11. Main Boom Cylinder Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-12. Jib Boom Cylinder Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

6-1. Hydraulic Valve Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-2. Boat Crane Assembly Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-3. Winch Assembly Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

7-1. List of Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-2. List of Manufacturers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-3. Boat Crane Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7-4. Winch Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7-5. Main Boom Cylinder Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7-6. Jib Boom Cylinder Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

7-7. Boom Head Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

7-8. Control Panel Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

7-9. Electronic Control Unit Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

7-10. Control Board Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

7-11. Power Supply (Part of ECU) Parts List . . . . . . . . . . . . . . . . . . . . . . . . . 7-29

7-12. Dirty Box Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

7-13. Electric Motor Starter Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

7-14. Electric Motor Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

7-15. Slew Ring Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40

x
 SG811-BV-MMA-010

LIST OF TABLES - Continued

Table Title Page

7-16. Hydraulic Motor Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41

7-17. Hydraulic Brake Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44

7-18. Reduction Gear Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46

7-19. Hydraulic Pump Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49

7-20. Operator Seat Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55

7-21. Slew Ring Locking Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . 7-62

7-22. Connection Box Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65

7-23. High Pressure Hydraulic Filter Parts List . . . . . . . . . . . . . . . . . . . . . . . . 7-65

7-24. Low Pressure Hydraulic Filter Parts List . . . . . . . . . . . . . . . . . . . . . . . . . 7-68

7-25. Submersible Suction Filter Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70

7-26. Hydraulic System Diagram Assembly Parts List . . . . . . . . . . . . . . . . . . . . . 7-72

7-27. Slew Limit Relay Box Assembly Parts List (MHC 52, 55, 58 & 59) . . . . . . . . . 7-76

7-28. Release Hook Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-78

7-29. Hydraulic System Piping Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80

8-1. Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

xi
SG811-BV-MMA-010

LIST OF ILLUSTRATIONS

Figure Title Page

1-1. Deployment, Retrieval and Storage of the RIB . . . . . . . . . . . . . . . . . . . . . 1-3

1-2. Boat Crane Rotation Envelope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1-3. Hydraulic Cross-Connect System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

FO-1. Boat Crane (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

FO-1. Boat Crane (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

FO-1. Boat Crane (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

FO-2. Boat Crane With Hydraulic Cross-Connect (Sheet 1 of 3) . . . . . . . . . . . . . . . 1-19

FO-2. Boat Crane With Hydraulic Cross-Connect (Sheet 2 of 3) . . . . . . . . . . . . . . . 1-21

FO-2. Boat Crane With Hydraulic Cross-Connect (Sheet 3 of 3) . . . . . . . . . . . . . . . 1-23

2-1. Control Panel Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2. Operator Control Joyticks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2-3. Servo Valve Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-4. Battle Short Lever/Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2-5. Slew Ring Locking Device Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-6. Hand Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2-7. Gauges Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2-8. ECU Fuse Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2-9. Electric Motor Starter Fuse Locations . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2-10. Control Panel Jack Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2-11. Electronic Control Unit Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2-12. Hook and Locking Pin Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2-13. Valve Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2-14. Hook Assembly and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

2-15. Standard Crane Log Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

2-16. Hydraulic Cross-Connect Valve Locations . . . . . . . . . . . . . . . . . . . . . . . . 2-37

3-1. Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

xii
 SG811-BV-MMA-010

LIST OF ILLUSTRATIONS - Continued

Figure Title Page

3-2. Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

3-3. Servo Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3-4. Control Joysticks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

3-5. Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3-6. Overcenter Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

3-7. Overcenter Valve Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3-8. Overcenter Valve Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

3-9. Overcenter Valve Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

3-10. Dual Overcenter Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3-11. Double Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3-12. Double Control Valve Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3-13. Cylinder Assembly (Main-Jib) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3-14. Reduction Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

3-15. Turret Hydraulic Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3-16. Turret Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

3-17. Winch Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

3-18. Winch Hydraulic Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

3-19. Hydraulic Power Cross-Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

3-20. EMI Filter Board (Dirty Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

3-21. EMI Protective Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

3-22. Slew Limit Stop Schematic (MHC 52, 55, 58 & 59 ONLY) . . . . . . . . . . . . . . 3-41

FO-3. Hydraulic System Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

FO-4. Hydraulic System (With Cross-Connects) Schematic Diagram . . . . . . . . . . . . . 3-45

FO-5. Electrical System Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

FO-6. Electrical System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

FO-7. Electric Motor Starter Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

xiii
SG811-BV-MMA-010

LIST OF ILLUSTRATIONS - Continued

Figure Title Page

FO-8. Control Panel Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

FO-9. Electronic Control Unit Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

FO-10. Control Board Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

FO-11. Supply Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

5-1. Boat Crane Fault Logic Diagram (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . 5-16

5-1. Boat Crane Fault Logic Diagram (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . 5-17

5-2. Winch Fault Logic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5-3. Crane Slewing Fault Logic Diagram (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . 5-19

5-3. Crane Slewing Fault Logic Diagram (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . 5-20

5-4. Control System Fault Logic Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

5-4. Control System Fault Logic Diagram (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . 5-22

5-5. Electronic Control Unit Fault Logic Diagram . . . . . . . . . . . . . . . . . . . . . . 5-23

5-6. Control Panel Fault Logic Diagram (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . 5-24

5-6. Control Panel Fault Logic Diagram (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . 5-25

5-7. Motor Starter Fault Logic Diagram (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . 5-26

5-7. Motor Starter Fault Logic Diagram (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . 5-27

5-8. Hydraulic System Fault Logic Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

5-9. Crane Slewing Limit Fault Logic Diagram. (MHC 52, 55, 58, & 59) . . . . . . . . . 5-29

6-1. Jib Boom Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6-2. Jib Boom Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

6-3. Wire Rope Removal (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

6-3. Wire Rope Removal (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6-4. Gear Limit Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

6-5. Boom Head Assembly Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

6-6. Operator Seat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

6-7. Control Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40

xiv
 SG811-BV-MMA-010

LIST OF ILLUSTRATIONS - Continued

Figure Title Page

6-8. Control Panel Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42

6-9. Control Joystick Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-45

6-10. Electronic Control Unit Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49

6-11. Supply Board/Transformer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50

6-12. Heat Sink Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55

6-13. ECU Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56

6-14. Electric Motor Starter Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57

6-15. Electric Motor Starter Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61

6-16. Electric Motor (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64

6-16. Electric Motor (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65

6-17. Slew Ring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69

6-18. Slew Ring Locking Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72

6-19. Use of Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74

6-20. Hydraulic Motor, Brake, and Reduction Gear . . . . . . . . . . . . . . . . . . . . . . 6-77

6-21. Hydraulic Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81

6-22. Reduction Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86

6-23. High Pressure Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-91

6-24. High Pressure Hydraulic Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . 6-93

6-25. Low Pressure Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-95

6-26. Submersible Suction Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-99

6-27. Submersible Suction Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-103

6-28. Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-104

6-29. Ball Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-106

6-30. Hand Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-109

6-31. Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-111

6-32. Liquid Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-112

xv
SG811-BV-MMA-010

LIST OF ILLUSTRATIONS - Continued

Figure Title Page

6-33. Control Stick ID Plate Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-114

6-34. Slew Limit Relay Box (Sheet 1 of 2) (MHC 52, 55, 58, & 59) . . . . . . . . . . . . 6-117

6-34. Slew Limit Relay Box (Sheet 2 of 2) (MHC 52, 55, 58 & 59) . . . . . . . . . . . . 6-118

FO-12. Boat Crane Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-119

FO-13. Boat Crane Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-121

FO-14. Winch Assembly Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-123

7-1. Main Boom Cylinder Parts Location . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

7-2. Jib Boom Cylinder Parts Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

7-3. Boom Head Assembly Parts Location . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

7-4. Control Panel Assembly Parts Location (Sheet 1 of 3) . . . . . . . . . . . . . . . . . 7-20

7-4. Control Panel Assembly Parts Location (Sheet 2 of 3) . . . . . . . . . . . . . . . . . 7-21

7-4. Control Panel Assembly Parts Location (Sheet 3 of 3) . . . . . . . . . . . . . . . . . 7-22

7-5. Electronic Control Unit Parts Location (Sheet 1 of 3) . . . . . . . . . . . . . . . . . 7-24

7-5. Electronic Control Unit Parts Location (Sheet 2 of 3) . . . . . . . . . . . . . . . . . 7-25

7-5. Electronic Control Unit Parts Location (Sheet 3 of 3) . . . . . . . . . . . . . . . . . 7-26

7-6. Control Board (Part of ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

7-7. Power Supply (Part of ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

7-8. Dirty Box (Part of ECU) (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

7-8. Dirty Box (Part of ECU) (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . 7-33

7-9. Electric Motor Starter Parts Location (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . 7-35

7-9. Electric Motor Starter Parts Location (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . 7-36

7-9. Electric Motor Starter Parts Location (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . 7-37

7-10. Electric Motor Parts Location (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . 7-39

7-10. Electric Motor Parts Location (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . 7-40

7-11. Hydraulic Motor Parts (Turret) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43

7-12. Hydraulic Brake Parts Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45

xvi
 SG811-BV-MMA-010

LIST OF ILLUSTRATIONS - Continued

Figure Title Page

7-13. Reduction Gear Parts Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48

7-14. Hydraulic Pump Parts Location (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . 7-52

7-14. Hydraulic Pump Parts Location (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . 7-53

7-14. Hydraulic Pump Parts Location (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . 7-54

7-15. Operator Seat Assembly Parts Location (Sheet 1 of 5) . . . . . . . . . . . . . . . . . 7-57

7-15. Operator Seat Assembly Parts Location (Sheet 2 of 5) . . . . . . . . . . . . . . . . . 7-58

7-15. Operator Seat Assembly Parts Location (Sheet 3 of 5) . . . . . . . . . . . . . . . . . 7-59

7-15. Operator Seat Assembly Parts Location (Sheet 4 of 5) . . . . . . . . . . . . . . . . . 7-60

7-15. Operator Seat Assembly Parts Location (Sheet 5 of 5) . . . . . . . . . . . . . . . . . 7-61

7-16. Slew Ring Locking Assembly Parts Location . . . . . . . . . . . . . . . . . . . . . . 7-64

7-17. Connection Box Assembly Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 7-65

7-18. High Pressure Hydraulic Filter Parts Location . . . . . . . . . . . . . . . . . . . . . . 7-67

7-19. Low Pressure Hydraulic Filter Parts Location . . . . . . . . . . . . . . . . . . . . . . 7-69

7-20. Submersible Suction Filter Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 7-71

7-21. Hydraulic System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74

7-22. Hydraulic System With Cross-Connect . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75

7-23. Slew Limit Relay Box (MHC 52, 55, 58 & 59) . . . . . . . . . . . . . . . . . . . . . 7-77

7-24. Release Hook Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79

FO-15. Boat Crane Piping and Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83

FO-15. Boat Crane Piping and Tubes (Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . 7-85

FO-15. Boat Crane Piping and Tubes (Sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . . . . 7-87

FO-15. Boat Crane Piping and Tubes (Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . 7-89

8-1. Boat Crane Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

8-2. Boat Crane Lifting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8-3. Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

xvii
SG811-BV-MMA-010

SAFETY SUMMARY

GENERAL SAFETY NOTICES The following general safety notices supplement specific warnings and
cautions appearing in this manual. General and specific precautions must be understood and applied during
operation and maintenance of equipment covered herein. The Commanding Officer or other authority will issue
orders necessary for any situations not covered in these general and specific safety precautions.

DO NOT REPAIR OR ADJUST ALONE Under no circumstances should repair or adjustment of ener-
gized 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, 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.

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 when taking measurements.

FIRST AID An injury, no matter how slight, should never go unattended. Always obtain first aid or
medical attention immediately.

RESUSCITATION Personnel working with or near high voltages shall be familiar with approved resus-
citation methods. If someone is injured and stops breathing, initiate resuscitation immediately. A delay could cost
the victim’s life. Refer to Naval Ships Technical Manual, Chapter 300.

GENERAL PRECAUTIONS The following general precautions are to be observed at all times:

1. All electrical components associated with equipment shall be installed and grounded in accordance
with applicable Navy regulations and approved shipboard practices.
2. All maintenance operations shall comply with Navy Safety Precautions for Forces Afloat,
OPNAVINST 5100 series.
3. Special precautionary measures are essential to prevent applying power to equipment at any time
maintenance work is in progress.
4. Do not make any unauthorized alterations to equipment.
5. Before working on electrical equipment, use voltmeter to ensure that system is not energized.
6. All circuits not known to be DEAD must be considered LIVE and dangerous at all times.
7. Do not wear loose clothing while working around rotating parts of machinery.
8. When working near electricity, do not use metal rules, flashlights, metallic pencils, or any other
objects having exposed conducting material.
9. Be sure to deenergize all equipment before connecting or disconnecting meters or test leads.
10. When connecting a meter to terminals for measurement, use range higher than expected voltage.
11. Before operating equipment or performing any tests or measurements, ensure that frames of all
motors and starter panels are securely grounded.

xviii
 SG811-BV-MMA-010

SAFETY SUMMARY - Continued

12. Ensure that area is well ventilated when using cleaning solvent. Avoid prolonged breathing of fumes
and solvent contact with skin or eyes.

WARNINGS AND CAUTIONS Specific warnings and cautions covered by this manual, with page ref-
erences, are summarized below for emphasis.

WARNING

Identifies an operating or maintenance procedure, practice, condition, state-

ment, etc., which if not strictly followed could result in death or serious
injury to personnel. (Page 1-1)

WARNING

When the boat crane is being powered by the hydraulic pump and operated
with the servovalves, only slow speeds shall be used as injury to personnel
could occur. (Page 2-7)

WARNING

The equipment shall be returned to its normal operating condition once the
emergency is secured, as injury to personnel and damage to the equipment
could occur. (Page 2-8)

WARNING

Operation of the servo valves using the local valve controls is inherently
dangerous to operating personnel especially for slewing the boat crane.
(Page 2-17)

WARNING

The hook should only be set for automatic release when ordered by the
Officer-in-Charge and under the direction of the boat COXSWAIN just
prior to launching the boat. Premature release could cause damage to per-
sonnel injury.

xix
SG811-BV-MMA-010

1. Closing and Locking. The hook is closed and locked by either inserting the ring
of the boat sling into the open ejector, or by rotating the ejector cam down, by hand,
into the closed and locked position.

2. Tripping and Opening. With the hook in the closed and locked position, the ejec-
tor cam is tripped and pivoted to the open position by pulling down on the release
hook lanyard. The cam pivots with sufficient force to eject the lifting ring, but only
if the load has been removed.

3. Automatic Release. After the release hook is closed and locked, it can be set for
automatic release by loading the hook with a 50–pound minimum load and briefly
exerting a 25-pound pull on the release lanyard. The hook will automatically permit
the ejector cam to rotate to the open position without having to pull the release lan-
yard a second time. (Page 2-18)

WARNING

Boat Crane operations have inherent hazards that cannot be mechanically

safeguarded. Hard hats, safety glasses, and safety shoes must be worn to
prevent personal injury or death. (Page 2-18)

WARNING

Care should be taken when sitting in the operator seat, as the seat is not
protected. Failure to comply may result in injury to the operator. (Page 2-22)

WARNING

The seat belt shall be worn at all times while operating the boat crane. Fail-
ure to comply may result in personnel injury. (Page 2-22)

WARNING

Visually observe the lift area for personnel or obstructions before operating
the control joysticks. Failure to comply may result in personnel injury or
damage to the equipment. (Page 2-23)

xx
 SG811-BV-MMA-010

WARNING

Ball valve (45), must be in its normally closed position before proceeding
with manually rotating the crane, to prevent the crane from rotating freely,
as injury to personnel or damage to the equipment may occur. (Page 2-28)

WARNING

Ball valve (45) must not be opened at any time unless restraining tag lines
are attached to the crane to prevent the crane from rotating freely, as injury
to personnel or damage to the equipment may occur. (Page 2-28)

WARNING

When moving the boat crane while using the servovalves, care must be
taken to use only slow speeds for the crane movement and main boom
movement as personnel injury could occur. (Page 2-29)

WARNING

When slewing the crane while standing next to the servovalves, care must be
taken to watch the crane movement as personnel injury could occur. (Page
2-30)

WARNING

Before performing any operation on hydraulic valves, verify that the crane’s
power is turned off to prevent injury to personnel or damage to the equip-
ment. (Page 2-33, page 2-34)

WARNING

Before performing any operation on hydraulic disconnect, verify that the

MPC hydraulic pump switch is in the off position and tagged out of service
to prevent injury to personnel or damage to the equipment. (Page 2-33)

xxi
SG811-BV-MMA-010

WARNING

Before performing any operation on hydraulic valves, verify that the crane’s
power is turned off to prevent injury to personnel or damage to equipment.
(Page 2-33)

WARNING

Wear safety goggles and rubber gloves while removing hydraulic hose to
prevent personnel injury. (Page 2-34, page 2-36)

WARNING

Before performing any operation on hydraulic disconnect verify that the

crane electric MOTOR ON switch is in the off position and tagged ″OUT-OF
SERVICE″ to prevent injury to personnel or damage to the equipment.
(Page 2-35)

WARNING

Before performing any operation on hydraulic valves verify that the crane
power is turned off. To prevent injury to personnel or damage to the equip-
ment. (Page 2-35)

WARNING

Troubleshooting procedures frequently require that checks be made while

power is on. Extreme care should be used to prevent contact with live cir-
cuit parts. Touching these parts could result in electrical shock. The voltage
used in the boat crane can cause injury or death. (Page 5-1)

WARNING

Shipboard tagout procedures must be followed when tagging equipment

″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel. (Page 6-1)

xxii
 SG811-BV-MMA-010

WARNING

Before performing any maintenance action notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel. (Page 6-5,
page6-9,page6-17,page6-23,page6-26,page6-28,page6-30,page6-31,page6-33,
page 6-35, page 6-37, page 6-39, page 6-44, page 6-48, page 6-67, page 6-70)

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply may result in injury or
death to maintenance personnel. (Page 6-5, page 6-10, page 6-17, page 6-43,
page6-46,page6-47,page6-48,page6-48,page6-54,page6-67,page6-71,page6-79,
page 6-88)

WARNING

Ensure the slew ring locking device is engaged to prevent injury and dam-
age to equipment from boat crane movement. (Page 6-5)

WARNING

Ensure the mobile crane being used to move the Boat Crane is adequate for
the weight of the boat crane as injury or death to maintenance personnel
could occur. (Page 6-6)

WARNING

The lifting points for the crane reflect the center of gravity with the pedes-
tal attached. Care should be used when lifting the crane with pedestal
removed as the balance will be off. Injury to personnel could occur. (Page
6-6, page 6-6)

WARNING

Boat crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn off electrical power. This will

xxiii
SG811-BV-MMA-010

reduce hydraulic pressure to zero. Failure to comply may result in injury or

death to maintenance personnel. (Page 6-10, page 6-17, page 6-29, page 6-30,
page6-32,page6-33,page6-43,page6-76,page6-79,page6-83,page6-88,page6-92,
page 6-110)

WARNING

When performing the following procedures, ensure adequate hoisting equip-

ment is used as the jib boom weighs 356 pounds and jib boom cylinder
weighs 265 pounds. Injury or death to maintenance personnel could occur if
these equipments are mishandled. (Page 6-10, page 6-29)

WARNING

Proper equipment must be used to support the jib boom during installation
of the jib boom cylinder. Failure to comply may result in injury or death to
maintenance personnel. (Page 6-14)

WARNING

Boat Crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn-off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply may result in injury or
death to maintenance personnel. (Page 6-14)

WARNING

Leather gloves should be worn anytime personnel are handling the wire rope
as personnel injury could occur. (Page 6-17, page 6-21, page 6-24, page 6-27)

WARNING

The winch assembly weighs 381 pounds. Failure to support it properly dur-
ing handling may result in injury to maintenance personnel or damage to
equipment. (Page 6-18)

xxiv
 SG811-BV-MMA-010

WARNING

Crane operations have inherent hazards that cannot be mechanically safe-

guarded. Hard hats and safety shoes are required when performing mainte-
nance as injury or death to personnel could occur. (Page 6-18, page 6-23, page
6-26, page 6-84)

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE″. Failure to comply may result in injury or
death to maintenance personnel. (Page 6-22)

WARNING

The winch assembly weighs 381 pounds. Failure to support properly during
handling may result in injury to maintenance personnel or damage to equip-
ment. (Page 6-22)

WARNING

When performing the following procedures, ensure adequate hoisting equip-

ment is used as the boom head assembly weighs 246 pounds. Injury or death
to maintenance personnel could occur if these equipments are mishandled.
(Page 6-23)

WARNING

Use care when removing wire rope fixing plate (106, figure FO-14) to pre-
vent injury to personnel. (Page 6-27)

WARNING

Cleaning solvent is highly toxic to eyes, skin and respiratory tract. Avoid all
contact. Skin and eye protection is required. Use only with adequate venti-
lation. (Page 6-27)

xxv
SG811-BV-MMA-010

WARNING

Hazardous voltages are present. Ensure power is removed and tagged

″OUT-OF-SERVICE″. Failure to comply may result in injury or death to
maintenance personnel. (Page 6-29)

WARNING

Crane operations have inherent hazards that cannot be mechanically safe-

guarded. Hard hats and safety shoes are required when performing mainte-
nance as injury to personnel could occur. (Page 6-29, page 6-33)

WARNING

Proper equipment must be used to support the main boom cylinder during
removal. The main boom cylinder weighs 287 pounds. Failure to comply
may result in injury or death to maintenance personnel. (Page 6-30, page 6-31)

WARNING

Proper equipment must be used to support the main boom during installa-
tion of the main boom cylinder. Failure to comply may result in injury or
death to maintenance personnel. (Page 6-32)

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply may result in injury or
death to maintenance personnel. (Page 6-33, page 6-35, page 6-116)

WARNING

When performing the following procedures, ensure adequate hoisting equip-

ment is used as the jib boom weighs 356 pounds, the jib boom cylinder
weighs 265 pounds and the main boom cylinder weighs 287 pounds. Injury
or death to maintenance personnel could occur if these equipments are mis-
handled. (Page 6-34)

xxvi
 SG811-BV-MMA-010

WARNING

The main boom pin (37) weighs 61 pounds. Before attempting the next step,
the two man lift applies to prevent personnel injury. (Page 6-34)

WARNING

When removing hydraulic lines, ensure that all excess oil is cleaned up as it
is slippery and injury to personnel could occur. (Page 6-35)

WARNING

The operator seat assembly weighs 527 pounds. Proper equipment must be
used to support the operator seat assembly during removal and installation.
Failure to comply may result in injury or death to maintenance personnel.
(Page 6-37, page 6-38)

WARNING

For any hydraulic maintenance action, turn off electric power. This will
reduce hydraulic pressure to zero. Failure to comply may result in injury or
death to maintenance personnel. (Page 6-38, page 6-39)

WARNING

Hazardous voltages are present. Ensure electric power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply may result in injury or
death to maintenance personnel. (Page 6-39)

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE″. Failure to comply may result in injury or
death to maintenance personnel. (Page 6-44, page 6-62, page 6-63, page 6-83)

xxvii
SG811-BV-MMA-010

WARNING

Before performing any maintenance action, notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel. (Page 6-46,
page 6-54, page 6-62, page 6-76, page 6-79, page 6-83, page 6-88, page 6-90, page 6-101,
page 6-115)

WARNING

The ECU weighs over 20 pounds. Care should be used to properly support
the ECU as personnel injury could occur. (Page 6-47)

WARNING

Before performing any maintenance action, notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury on death to maintenance personnel. (Page 6-47)

WARNING

Capacitors are storage devices for electricity. Care should be used in han-
dling capacitors as electric shock or injury could occur. (Page 6-52)

WARNING

The starter weighs in excess of 50 lbs. Ensure the unit is well supported to
prevent injury to personnel. (Page 6-58)

WARNING

Hazardous voltages exist inside electric motor starter. If the electric motor
starter is disassembled on the crane, ensure all power is removed as in
paragraph 6-4.7.1 prior to starting work as death or injury to personnel
could occur. (Page 6-58)

xxviii
 SG811-BV-MMA-010

WARNING

The turret enclosure and ladder weighs approximately 194 pounds. Failure
to support properly during handling may result in injury to maintenance
personnel or damage to equipment. (Page 6-62)

WARNING

Failure to support electric motor properly during handling may result in

personnel injury or damage to equipment. (Page 6-63)

WARNING

Cleaning solvents are hazardous to personal health. When use of solvent

P-D-680 is necessary, only Type III, which has a high flash point shall be
used. Use only in a well ventilated area. Use care as personnel injury or
death can result. (Page 6-66)

WARNING

Personnel must be clear of the total lifting chain swing radius. Failure to
comply may result in personnel injury or death. (Page 6-68)

WARNING

The spring (4) inside the mobile bushing (5) is under high tension. Do not
remove screw driver from the slot in mobile bushing as the fixed bushing (2)
will be free to come out and injury to personnel will occur. (Page 6-71)

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply may result in injury or
death to maintenance personnel. (Page 6-76)

xxix
SG811-BV-MMA-010

WARNING

Failure to support hydraulic motor properly during handling may result in

personnel injury or damage to equipment. (Page 6-78, page 6-78)

WARNING

Failure to support hydraulic brake properly during handling may result in

personnel injury or damage to equipment. (Page 6-80, page 6-82)

WARNING

The hydraulic brake and reduction gear weight is 440 lbs (200 kg). Failure
to support properly during handling may result in personnel injury or dam-
age to equipment. (Page 6-84)

WARNING

The turret enclosure and ladder weighs approximately 194 pounds. Failure
to support turret enclosure properly during handling may result in person-
nel injury or damage to equipment. (Page 6-89)

WARNING

Hydraulic pump weight is 33 pounds. Failure to support hydraulic pump

properly during handling may result in personnel injury or damage to
equipment. (Page 6-89, page 6-89)

WARNING

Boat crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply may result in injury or
death to maintenance personnel. (Page 6-91)

xxx
 SG811-BV-MMA-010

WARNING

Avoid prolonged contact with, or inhalation of, cleaning solvents. Avoid use
near heat or open flame and provide adequate ventilation. Wear safety
goggles and rubber gloves while cleaning parts to prevent personnel injury
or death. (Page 6-92)

WARNING

Boat crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply may result in person-
nel injury or death. (Page 6-94, page 6-96)

WARNING

Avoid prolonged contact with, or inhalation of, cleaning solvents. Avoid use
near heat or open flame and provide adequate ventilation. Wear safety
goggles and rubber gloves while cleaning parts to prevent personnel injury.
(Page 6-97)

WARNING

Boat crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply will result in personnel
injury or death. (Page 6-97, page 6-100, page 6-102, page 6-105, page 6-107, page 6-107,
page 6-108)

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply will result in personnel
death or injury. (Page 6-98)

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply may result in personnel
death or injury. (Page 6-100)

xxxi
SG811-BV-MMA-010

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply will result in personnel
injury or death. (Page 6-102, page 6-105, page 6-107, page 6-108)

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply may result in personnel
injury or death. (Page 6-109)

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to tag equipment may result in injury
or death to maintenance personnel. (Page 6-115)

WARNING

Ensure the mobile crane being used to move the boat crane is adequate for
the weight of the boat crane as injury or death to personnel could occur.
(Page 8-1)

WARNING

Verify area around crane is clear of personnel and equipment before rota-
tion. Failure to comply may result in injury to personnel or damage to
equipment. (Page 8-6)

CAUTION

Identifies an operating or maintenance procedure, practice, condition, state-

ment, etc., which if not strictly followed could result in destruction of or
damage to equipment, or serious impairment of system operation. (Page 1-1)

xxxii
 SG811-BV-MMA-010

CAUTION

If the hydraulic fluid level in the boat crane sump is below the safe operat-
ing level (below minimum range) or any physical defects are noted, tag the
boat crane ″OUT-OF-SERVICE.″ Failure to comply may cause damage to
the boat crane. (Page 2-19, page 2-26)

CAUTION

Ball valve 45 must be closed prior to normal operation of crane. Failure to

close this valve prior to operation may damage the hydraulic motor due to
the hydraulic brake not being released when trying to slew the crane. (Page
2-19)

CAUTION

Before performing the turn-on procedure, perform the preoperational

checkout procedures in table 2-8. Failure to comply may result in damage to
the equipment. (Page 2-22)

CAUTION

Partially clogged filters may have an adverse affect on the crane operation.
The high pressure filter indicator, low pressure filter indicator, and the sub-
mersible suction filter indicator should be checked for status as soon as pos-
sible after the MOTOR ON pushbutton is pressed, as damage to the equip-
ment may occur. (Page 2-23)

CAUTION

If the hydraulic fluid level in the boat crane sump is below the operating
level (below minimum range) or any physical defects are noted, tag the boat
crane ″OUT-OF-SERVICE.″ Failure to comply may cause damage to the
boat crane. (Page 2-28)

CAUTION

Before operating the cross-connect make sure the oil level on both cranes is
within the normal range. Sump of boat crane may over flow if slewing and
hoisting operations exceed 10 minutes total. See *NOTE below. (Page 2-32)

xxxiii
SG811-BV-MMA-010

CAUTION

Replace the oil in the flexible hoses every twelve months to prevent damage
to flexible hoses. (Page 2-34, page 2-36)

CAUTION

Store the flexible hoses where they are not exposed to strong sunlight or
severe cooling. Failure to comply may cause damage to flexible hoses. (Page
2-34, page 2-36)

CAUTION

Before operating the cross-connect make sure the oil level on both cranes is
within the normal range. Sump of multi-purpose crane may over flow if
slewing and hoisting operations exceed 10 minutes total. See *NOTE below.
(Page 2-34)

CAUTION

Adjust the servo valves in small increments. Verify direction of adjustment

provides speed balance or increase in speed in one direction at release point.
(Page 6-2)

CAUTION

Do not allow the system to run for more then 15 seconds before adjusting
the pressure compensator back temporarily to 3,000 psi. Operation of the
system over the relief setting for extended periods of time causes excessive
heat and can damage equipment. (Page 6-3)

CAUTION

Care must be taken when removing the reduction gear (27) as damage to the
slew ring (10) can occur. (Page 6-6)

CAUTION

The slew ring is made of aluminum. Care should be taken when performing
the following steps to ensure the weight of the crane is not dropped on or
does not bump the slew ring as damage to the equipment will occur. (Page
6-7)

xxxiv
 SG811-BV-MMA-010

CAUTION

Take care when inserting pinion gear (86) attached to the reduction gear
(27). The slew ring (10) is made of aluminum and can be damaged very eas-
ily. (Page 6-7)

CAUTION

Care must be taken to ensure no contamination to the system occurs. When

hydraulic lines are disconnected they must be capped immediately to pre-
vent contamination and damage to the equipment. (Page 6-10, page 6-18, page
6-31, page 6-34)

CAUTION

Use care when removing wire rope as kinking or damage to the wire rope
can occur. (Page 6-17, page 6-21, page 6-24)

CAUTION

To prevent damage to equipment, do not use soldering iron over 25 watts.

(Page 6-51, page 6-51, page 6-51, page 6-52, page 6-53, page 6-53)

CAUTION

Identify and tag electrical leads as they are disconnected to prevent incor-
rect wiring connection during installation procedures. (Page 6-63)

CAUTION

Removing the rotor assembly from the motor shaft is not recommended, as
damage to the motor shaft could occur. (Page 6-66)

CAUTION

Cap all hose connections to ensure that the hydraulic system is not contami-
nated by the introduction of foreign material. (Page 6-78, page 6-79, page 6-83,
page 6-89)

xxxv
SG811-BV-MMA-010

CAUTION

Be prepared to quickly press MOTOR OFF pushbutton (3, figure 2-1) if

u-bolt contacts boom head. (Page 8-6)

xxxvi
 SG811-BV-MMA-010

CHAPTER 1

GENERAL INFORMATION AND SAFETY PRECAUTIONS

1-1. SAFETY PRECAUTIONS.

1-1.1 Warnings and Cautions Warnings and cautions appearing throughout this technical manual are of para-
mount importance to personnel and equipment safety. Prior to any attempt to operate, maintain, troubleshoot, or
repair any part of the sliding block drive, all warning and cautions should thoroughly reviewed and understood.
Refer to the Safety Summary, which appears in the front matter of this manual, for a complete listing of warn-
ings and cautions used throughout the manual. The following paragraphs define warnings, cautions, and notes as
they are used in this manual.

WARNING

Identifies an operating or maintenance procedure, practice, condition, state-

ment, etc., which if not strictly followed could result in death or serious
injury to personnel.

CAUTION

Identifies an operating or maintenance procedure, practice, condition, state-

ment, etc., which if not strictly followed could result in destruction of or
damage to equipment, or serious impairment of system operation.

NOTE

Notes are used to highlight certain operating or maintenance conditions or state-

ments which are essential but not of known hazardous nature as indicated by
warnings or cautions.

The Boat Crane, Type GN1/5, is operated using electrical and hydraulic systems. Serious injury or death may
result if personnel improperly use electrically or hydraulically operated equipment or fail to adhere to posted
warnings and cautions. The warnings and cautions appearing throughout this technical manual are essential to
personnel and equipment safety. Prior to any attempt to operate, maintain, troubleshoot, or repair any part of the
Boat Crane, Type GN1/5, all warnings and cautions shall be thoroughly reviewed and understood. General safety
notices and specific warning and caution statements used in this manual appear in the safety summary immedi-
ately preceding this chapter.

1-2. INTRODUCTION.

This manual contains equipment description, operating instructions, preventive maintenance overview, cor-
rective maintenance procedures, fault isolation procedures, parts list, and installation instructions for the Boat
Crane, Type GN1/5, manufactured by Marine Equipment Pellegrini (MEP).

1-1
SG811-BV-MMA-010

1-2.1 Purpose. The purpose of this manual is to provide sufficient information for shipboard personnel to oper-
ate and conduct maintenance-related activity on the boat crane, Type GN1/5, hereinafter referred to as the boat
crane.

1-2.2 Scope. The information provided in this manual will enable ship’s personnel to operate, troubleshoot,
maintain, and replace components of the boat crane at the organizational, intermediate, and depot levels.

1-2.3 Applicability. This manual is applicable to all MHC-51 class ship’s with the Boat Crane, Type GN1/5,
installed including MHC-51, 52, 55, 58, 59, 60, 61, 62.

1-2.4 Interface Relationships. The boat crane is an electro-hydraulic machine controlled by electrical/electronic
controls. The electric motor is electrically controlled via the motor controller. Once started, the electric motor
rotates at a near constant speed driving the hydraulic pump which along with its hydraulic controls, provides the
flow when needed to drive the hydraulic actuators such as the hydraulic motors and cylinders which drive the
mechanical assemblies (booms, winch and turret). Actuator speed and positioning is electronically controlled via
the electronic control unit, servo valves and control joysticks. Hydraulic motors are used to drive the winch drum
and drive the slew drive gearing to rotate the turret. Hydraulic cylinders drive the main and jib booms.

One emergency mode of operation is accomplished manually/hydraulically. The hand pump is used to manu-
ally/hydraulically slew the crane, top the booms out, and payout the winch. The hydraulic actuators are controlled
via manual operation of the servo valves. Operational procedures are provided in chapter 2. A detailed descrip-
tion of manual operation is provided in chapter 3.

A second emergency mode requires cross connection of hydraulic piping with the multi-purpose crane. When
the boat crane is cross connected with the multi-purpose crane, the boat crane can be powered hydraulically with
actuator movement accomplished using the control joysticks powered by the electronic control unit. During this
mode of operation, the boat crane electric motor is not powered and the pump is not driven. All hydraulic fluid
flow is delivered from the multi-purpose crane pump when cross connected.

The boat crane can also be cross connected to provide hydraulic fluid power to the multi-purpose crane.

1-2.5 Design Features. The primary function of the boat crane is to deploy and retrieve the rigid inflatable boat
(RIB); refer to Ship’s Information Book (SIB) Volume 1 and figure 1-1 for information on the deployment,
retrieval, and storage of the RIB. Connection to the RIB is accomplished using a wire rope with a hook on the
end that attaches to the RIB lifting sling. The winch hoist drum is designed to hold 100 feet of 1/2 inch diam-
eter wire rope. The boat crane is rated at maximum of 2,000 lbs lifting capacity. It is capable of lifting the RIB
from its stowage on the ship’s deck, deploying it into the water, retrieving it from the water, and returning it to
its stowage on the ship’s deck. The boat crane is also capable of handling other equipment on or about the ship’s
deck, weighing less than 2,000 lbs. The rotation of the Boat Crane is limited to a rotation envelope (figure 1-2)
of 178 degrees 55 minutes by electrical and mechanical stops.

The boat crane is designed for grade A shock in the stowed position. It is capable of operating with one inch
of ice and with the ship heeled at 15 degrees. The boat crane is capable of performing any two operations simul-
taneously.

1-2
 SG811-BV-MMA-010

Figure 1-1. Deployment, Retrieval and Storage of the RIB

1-3
SG811-BV-MMA-010

1-2.6 Warranty. The boat crane is guaranteed against faulty materials and workmanship for a period of 12
months after preliminary acceptance of the vessel by the U.S. Government.

1-3. DESCRIPTION.
The following paragraphs describe the equipment associated with the boat crane.

1-3.1 Equipment Description. The Boat Crane is pedestal mounted and has an articulated knuckle boom. The
crane is located on the aft portion of the 01 1/2 level. It consists of:

a. Main boom
b. Jib boom
c. Control panel assembly
d. Control joysticks
e. Electric motor
f. Hydraulic pump
g. Cylinder assemblies (main and jib)
h. Slew drive assembly (hydraulic motor, hydraulic brake, reduction gear, pinion)
i. Winch assembly (hydraulic motor, hydraulic brake, reduction gear)
j. Boom head assembly
k. Slew ring locking assembly
l. Revolving turret assembly
m. Electronic control unit (ECU)
n. Electric motor starter
o. Operator seat assembly
p. Pedestal
q. Slew hydraulic circuit
r. Main cylinder hydraulic circuit
s. Jib cylinder hydraulic circuit
t. Winch hydraulic circuit
u. Hydraulic fluid
v. Oil cooler
w. Hydraulic hand pump
The main boom, control joysticks, ECU, electric motor, electric motor starter, hydraulic pump, operator seat,
slew drive, slew hydraulic circuit and control panel are mounted on the revolving turret of the boat crane.

1-3.2 Physical Description. The following paragraphs describe physical configuration of the Boat Crane.

1-4
 SG811-BV-MMA-010

1-3.2.1 Main Boom. The main boom (figure FO-1 or figure FO-2) is a metal structure which extends outward
9.688 ft (3,020 millimeters (mm)) from the centerline of the crane. This structure is connected between the
revolving turret and jib boom. One end of the jib and main boom cylinders are connected to the center of the
main boom structure. The other end of the main boom cylinder is connected to a pivot on the turret mounted
directly below the main boom pivot. Rotation of the boom about the fixed main boom pivot on the turret is
accomplished by extending or retracting the main boom hydraulic cylinder, resulting in relative movement of the
jib boom, wire rope end fitting connected to the load. The main boom position is controlled by the operator rotat-
ing a joystick on the control console.

1-3.2.2 Jib Boom The jib boom (figure FO-1 or figure FO-2) is a metal structure which extends outward 5.66
ft (1,764 mm) from its pivot point at the end of the main boom. The winch assembly and boom head assembly
are mounted on opposite ends of the jib boom structure. One end of the jib boom cylinder is connected to the jib
boom structure near the jib boom pivot at the same end the winch is installed. The other end of the jib boom
cylinder is connected to a pivot near the center of the main boom. Rotation of the jib boom about the fixed pivot
near the center of the main boom is accomplished by extending or retracting the jib boom hydraulic cylinder.
Movement of the jib boom results in relative movement of the wire rope end fitting connected to the load. The
operator controls the position and topping speed and direction of the jib boom by proportional rotation of the jib
boom control joystick. The jib boom has the ability to lift in situations requiring extended or long reaches.

1-3.2.3 Control Panel Assembly. The control panel assembly (figure FO-1 or figure FO-2) is an enclosed unit
located on the top side of the revolving turret. This panel has pushbutton switches and indicating lights for con-
trolling and monitoring various functions of the boat crane. The switches and indicators are covered with drip-
proof seals to protect against all types of weather conditions. The control panel assembly allows the operator to
monitor and control the crane’s electric motor, hydraulic components, and ECU power. The control panel assem-
bly is covered by a metal cover that must be raised and secured in the raised position when the panel is in use.

1-3.2.4 Control Joysticks. There are four control joysticks on the control console (figure FO-1 or figure FO-2).
There is a control joystick for the main boom (M), the jib boom (J), the winch (W) and the turret for slewing (S).
The control joysticks are a lever type, with a spring return to neutral. The levers are rotated about a fixed pivot
by the operator either clockwise or counterclockwise from the neutral position. The neutral position corresponds
to the stopped position. Each joystick is used to provide bi-directional, variable speed control to one of the
hydraulic actuators responsible for topping the main or jib booms, slewing the turret, and hoisting or paying out
the winch. The operator uses all four joysticks as required to position the wire rope end fitting or load during
boat handling operations.

1-3.2.5 Electric Motor. The electric motor (figure FO-1 or figure FO-2) is an enclosed 15 horsepower (hp), 12
kilowatt (kW) high impact, shock resistant electric motor. Output shaft rotation is constant at approximately 1,800
revolutions per minute (rpm). It is mounted vertically and its shaft is coupled to the hydraulic pump shaft. The
electric motor is located on the rear of the revolving turret, inside the turret enclosure. The electric motor uses
radial double row, single shielded ball bearings to support the main drive shaft. The electric motor is powered via
the motor controller by depressing the electric motor ON pushbutton on the control panel. The electric motor
incorporates thermal sensors which can sense high temperature and illuminate a thermal alarm light on the con-
trol panel.

1-3.2.6 Hydraulic Pump. The hydraulic pump is an axial piston variable volume unit driven by the electric
motor at approximately 1,800 rpm. The pump controls include an adjustable pressure compensator and maximum
volume stop. The pump is coupled to and driven by the electric motor at a continuous speed of 1,800 rpm. It is
mounted underneath the electric motor at the rear of the revolving turret. The hydraulic pump inlet is connected

1-5
SG811-BV-MMA-010

to the sump via a suction strainer. The pump output flow varies from zero to 6 gpm (gallons per minute). The
pump provides flow to the various hydraulic actuators (hydraulic motors or cylinders) as needed to move and
support the wire rope end fitting and any connected load. The position and speed of the actuators is controlled
by servo valves, electrically controlled via the ECU as commanded by the operator at the control joystick. The
pressure compensator assembly ensures pressurized fluid is always available to either one or more actuator as a
servo valve is opened, to the full volume of the pump as needed.

1-3.2.7 Cylinder Assemblies. There are two cylinder assemblies used on the boat crane. There is one cylinder
assembly located underneath each boom (jib and main boom cylinders) which drives or rotates the boom about
the boom’s pivot (figure FO-1 or figure FO-2). Cylinders are linear hydraulic actuators. Cylinder motion and
speed is controlled by a servo valve which is electrically controlled by one of the control joysticks. The cylin-
ders incorporate crossover valves at each port which control the starting and stopping of the cylinders. The main
boom cylinder is connected between a pivot on the turret and a pivot near the center of the main boom. The jib
boom cylinder is connected between a pivot near the center of the boom and a pivot near the jib boom pivot.
Extension of the main boom cylinder causes the main boom to rotate up towards the vertical position. Retraction
of the main boom cylinder causes the main boom to rotate down towards the horizontal position. Extension of
the jib boom cylinder causes the jib boom to rotate out, toward the position in line with the main boom axis.
Retraction of the jib boom cylinder causes the jib boom to rotate in, under the main boom. The cylinder speed
is proportional to the control joystick position command as determined by the operator. The cylinder position is
stopped and held by the overcenter valves when the operator moves the control joystick to the neutral position.

1-3.2.8 Slew Drive Assembly (Hydraulic Motors, Pinion, Reduction Gear, and Brake Assemblies). The slew
drive, which includes the slew hydraulic motor, reduction gear, and brake assembly, drives the turret relative to
the pedestal. The slew hydraulic motor is a fixed diplacement bi-directional axial piston type which rotates or
slews the turret clockwise or counterclockwise via a reduction gear and output pinion gear. The hydraulic motor
is located on the turret near the hydraulic fluid (oil level) sight gauge. The slew drive components are mounted
on top of the slew hydraulic brake and reduction gear assembly. The hydraulic motor is driven by hydraulic fluid
supplied by the pump via the servo valve. The reduction gear consists of tapered roller bearings, an output shaft,
planetary gears, a central pinion, and planetary rings partially contained in a nonmagnetic casing. The reduction
gear output shaft meshes with the slew ring assembly and drives the revolving turret in either a clockwise (cw)
or counterclockwise (ccw) direction. The slew hydraulic brake is a hydraulically released, spring set disc type.
The slew hydraulic brake when released allows rotation of the turret and when set, will stop and hold the turret
position. The brake action is controlled by a hydraulically actuated valve in the slew hydraulic circuit. The slew
hydraulic circuit valves provide for speed control, braking, and overload protection.

1-3.2.9 Winch Assembly (Hydraulic Motors, Reduction Gear, and Brake Assemblies). The nonmagnetic winch
assembly (figure FO-1 or figure FO-2) is mounted on top of the jib boom near the jib boom pivot. This assem-
bly consists of a hoist drum mounted horizontally on a shaft, a reduction gear, hydraulic motor, brake, and a one
way clutch. The hoist drum is connected to the wire rope which is used to connect to the boat or other load. The
hydraulic motor drives a reducer which drives common planetary gear set. The hydraulic motor rotates the
reducer shaft in both the haul-in and payout direction. The brake is mounted on the hydraulic motor, however is
only released when paying out. When hauling in, the winch drum will rotate due to one way clutch operation.
The hydraulic pump drives the motors via servo valves and associated hydraulic circuitry. The hydraulic motor
can be controlled by the winch (W) control joystick. The winch also incorporates a limit switch assembly which
includes an empty drum limit switch and a full drum limit switch. The geared limit switch assembly is chain
driven via a sprocket on a hub on the winch drum and a small sprocket on the shaft of the geared limit switch
assembly.

1-6
 SG811-BV-MMA-010

1-3.2.10 Boom Head Assembly. The boom head assembly (figure FO-1 or figure FO-2) consists of a boom head
support, taper roller bearings, rings, split pins, and semi-ring and sheave mounted on the end of the jib boom.
The boom head assembly provides support, direction, and alignment of the wire rope. The boom head is able to
pass a 5/8-inch screw pin anchor shackle if additional hoist wire is added.

1-3.2.11 Slew Ring Locking Assembly. The slew ring locking assembly (figure FO-1 or figure FO-2) consists
of spherical roller bearings, an engage lever, eccentric, and tooth interlock mechanism. The slew ring locking
assembly is mounted on the rear of the revolving turret. This assembly locks the revolving turret in position and
prevents turret rotation when the engage lever is placed in the lock in position.

1-3.2.12 Revolving Turret Assembly. The revolving turret (figure FO-1 or figure FO-2) is a metal revolving
structure mounted on the pedestal. A bearing assembly mounted between the pedestal and turret allows the rela-
tive rotation of the turret. Rotation of the turret results in slewing of the main and jib booms which extend from
the pivot on the turret. Other components mounted on the turret include the control console, control joysticks,
operator’s seat, hydraulic pump, hand pump, electric motor, motor controller, ECU, and several other hydraulic
components. The slew drive components including, the hydraulic motors (2), reduction gear assemblies, and
brakes, are installed on the turret. The slew gear ring is installed on the pedestal and engages the drive gear on
the output shafts of the slew reduction gears. Rotation of the output shaft gear against the stationary slew gear
ring results in rotation of the turret. Additionally, the turret can be locked in position by engaging the rack of the
slew locking mechanism mounted on the turret into the slew gear ring.

1-3.2.13 Electronic Control Unit. The ECU includes components and circuit boards mounted in a nonmagnetic,
dripproof enclosure which provide electronic power to drive the servo valves, solenoid valve and associated con-
trols/indicators. It contains all the electronics and consists of power resistors, transformers, circuit cards and a
filter circuit. Access to the ECU is through a door, on the right side of the turret, adjacent to the operator seat.

1-3.2.14 Electric Motor Starter. The electric motor starter (Figure FO-1 or Figure FO-2) consists of transform-
ers, relays, and shock proof contactor mounted in a nonmagnetic drip proof enclosure. The electric motor starter
is located behind the turret’s side door. When energized, the electric motor starter provides 440 volts alternating
current (vac) to the electric motor and 115 vac to the control panel and ECU.

1-3.2.15 Slew Hydraulic Circuit. The slew hydraulic motor is driven by the pump via the slew hydraulic cir-
cuit as commanded by the operator on the (S) joystick. The circuit consists of the slew hydraulic motor, (S) servo
valve, dual overcenter valve, double control valve (brake valve), and antishock valves. Rotation of the joystick
to left or right causes the servo valve to port fluid to the appropriate side of the slew hydraulic motor, causing
the turret to rotate left or right slewing the booms. The primary function of the overcenter valves is to control the
starting and stopping of the hydraulic motor, acting much like a brake. The double control valve sets or releases
the slew hydraulic motor. The antishock valve will cause the motor to stall should pressure spikes occur in the
hydraulic circuit or the turret strikes any structure or inadvertent overload occurs.

1-3.2.16 Main Cylinder Hydraulic Circuit. The main cylinder is driven by the pump via the main cylinder
hydraulic circuit as commanded by the operator on the (M) joystick. The circuit consists of the main cylinder,
(M) servo valve, overcenter valves, flow restrictor valves, and antishock valves. Rotation of the joystick up or
down causes the servo valve to port fluid to the appropriate end of the main cylinder, causing the cylinder to
extend or retract, forcing the main boom to top up or down. The servo valve controls the amount of flow and
direction of flow (which end of cylinder) to the cylinder based on the joystick position selected by the operator.
The primary function of the overcenter valves is to control the starting and stopping of the cylinder, acting much
like a brake. The antishock valve will cause the cylinder to stall should the boom reach its end travel, interfere

1-7
SG811-BV-MMA-010

with any structure, or excessive loading. The flow restrictor valves are used to ensure the pilot stage of the loaded
overcenter valve is dampened resulting in no boom oscillation.

1-3.2.17 Jib Cylinder Hydraulic Circuit. The jib cylinder is driven by pump via the jib cylinder hydraulic cir-
cuit as commanded by the operator on the (J) joystick. The circuit consists of the jib cylinder, (J) servo valve,
overcenter valves, and antishock valves. Rotation of the joystick in or out causes the servo valve to port fluid to
the appropriate end of the jib cylinder, causing the cylinder to extend or retract, forcing the jib boom to top in
or out. The primary function of the overcenter valves is to control the starting and stopping of the cylinder, act-
ing much like a brake. The antishock valve will cause the cylinder to stall should the jib boom reach its end
travel, interfere with any structure, or excessive loading.

1-3.2.18 Winch Hydraulic Circuit. The winch hydraulic motor is driven by the pump via the winch hydraulic
circuit as commanded by the operator on the (W) joystick. The circuit consists of the winch hydraulic motor, (W)
servo valve, overcenter valve, double control valve (brake valve), and antishock valves. Rotation of the joystick
to hoist or lower causes the servo valve to port fluid to the appropriate side of the winch hydraulic motor, caus-
ing the winch drum to hoist or lower the boat hook. The primary function of the overcenter valves is to control
the starting and stopping of the hydraulic motor, acting much like a brake. The double control valve sets or
releases the hydraulic brake mounted on the hydraulic motor. The antishock valve will cause the motor to stall
should the winch end fitting two block, or the wire rope is overloaded for any reason during movement.

1-3.2.19 Hydraulic Fluid. The hydraulic fluid used in all hydraulic components is petroleum based product per
Mil-H-17672, Symbol 2075, Grade 32. The oil is continually filtered to ensure reduced particulate contamina-
tion. The system includes a suction filter mounted in the pump suction line, a high pressure filter mounted at the
pump discharge and return line filter mounted in the line which returns fluid to the sump. The fluid level in the
sump os visible at the oil level sight glass which is marked for normal range.

1-3.2.20 Oil Cooler. The oil cooler consists of a heat exchanger and a fan driven by a thermostatically con-
trolled electric motor. Oil passes continually through the heat exchanger in the return hydraulic circuit. The fan
pushes air through the cooling fins when the electric motor is running. The electric motor will start to rotate when
the thermostat contacts close when the oil temperature reaches approximately 110 degrees F.

1-3.2.21 Hydraulic Hand Pump. The hydraulic hand pump (figure FO-1 or figure FO-2) is mounted on the left
side of the revolving turret. The hydraulic hand pump is used to manually operate the boat crane if the power
fails while the boat crane is in use. Only one hand pump operation (slewing, topping, lowering) can be performed
at a time due to reduced hydraulic flow.

1-3.2.22 Hydraulic Cross-Connect Equipment. The hydraulic cross-connect equipment, (figure FO-2 and figure
1-3) mounted on the revolving turret consists of three quick disconnect couplings and four ball valves.

1-3.3 Reference Data. Table 1-1 presents a summary of operational characteristics of the boat crane.

1-8
 Figure 1-2. Boat Crane Rotation Envelope

SG811-BV-MMA-010
1-9
SG811-BV-MMA-010

1-3.4 Dimensions. Table 1-2 lists the overall dimensions of the boat crane.

1-3.5 Publications Required But Not Supplied. Table 1-3 lists all the publications required but not supplied
with the Boat Crane.

Table 1-1. Boat Crane Component Characteristics

NOMENCLATURE CHARACTERISTICS
Rated load 2,000 lbs.
Maximum outreach 16 ft. (4.9 m)
Minimum outreach 3 ft. (0.91 m)
Rotating envelope 178 degrees
Minimum crane operating radius 3 ft. (0.91 m)
Maximum crane operating radius 16 ft. max. (4.9 m)
Hoisting speed 90 feet/min. (27 m/min.)
Main boom topping rate 0 to 3.2 degrees per second
Jib boom topping rate 0 to 3.2 degrees per second
Maximum design pressure 3,132 psi (216 bar)
System design pressure 2,320 psi (160 bar)
Slewing speed 2 rpm
Electric Motor
Specification MIL-M-17060E
Frame 256 TND service A
Ambient temperature 50 degrees C. (122 degrees F)
Voltage 440 vac, 60 hertz (Hz), 3 phase
Current rated load 19 amperes
Duty Continuous
Horsepower 15 hp
Normal operating speed 1,800 rpm
Type Squirrel cage induction
Design B
Class of insulation B
Hydraulic Pump
Normal operating speed 1,800 rpm
Operating pressure range 3,000 psi (210 bar)
Type axial piston variable volume
Rotation Left hand (CCW)
Manufacturer Denison
Capacity 9.7 gpm @ 1,800 rpm
Main Boom Hydraulic Cylinder
Stroke 33.27 inches (845 mm)
Cylinder bore diameter 3.937 inches (100 mm)
Rod diameter 2.756 inches (70 mm)
Jib Boom Hydraulic Cylinder
Stroke 28.74 inches (730 mm)
Cylinder bore diameter 3.740 inches (95 mm)
Rod diameter 2.559 inches (65 mm)
Hoist Winch
Wire rope speed 90 ft./min. (27 m/min.)
Oil capacity (reducer) 0.6 gal. (3 liters)

1-10
 SG811-BV-MMA-010

Table 1-1. Boat Crane Component Characteristics - Continued

NOMENCLATURE CHARACTERISTICS
Gear ratio 20.25:1
Slew and Winch Hydraulic Motor
Normal operating speed 1,723 rpm
Type axial piston constant volume
Starting torque 0.31 in lbs./100 psi (2.3 Newton meters (Nm)/ 100 psi))
Rotation bidirectional
Weights
Boat Crane 7,057 lbs. (3,201 kg)
Main boom 695 lbs. (316 kg)
Jib boom 356 lbs. (162 kg)
Jib sheave assembly 15.18 lbs. (6.0 kg)
Turret 1,467 lbs. (667 kg)
Pedestal 418 lbs. (190 kg)
Jib cylinder 265 lbs. (120 kg)
Main cylinder 287 lbs. (130 kg)
Winch assembly 381 lbs. (173 kg)
Slew ring 138.5 lbs. (63 kg)
Operator seat 527 lbs. (240 kg)
Hydraulic motor 42 lbs. (19 kg)
Electric motor 319 lbs. (145 kg)
Hydraulic pump 35 lbs. (15 kg)
Reduction gear 163 lbs. (74 kg)
Slew ring 139 lbs. (63 kg)
Boom head assembly 246 lbs (112 kg)
Stowage stand 220 lbs. (100 kg)
Fluids and Lubricants
Hydraulic fluid 2075-T-H Grade 32 (MIL-H-17672)
Lubricant Refer to PMS MRCs
Wire Rope
Specification MIL-W-18242, (Type IV) 6X19 Warrington, 7X7 IWRC
Size (diameter) 1/2 inch 70 ft. long
Type 305 corrosion resistant steel
Minimum Breaking Strength 21,000 lbs.

Table 1-2. Dimensions

QTY NOMENCLATURE CID OVERALL DIMENSIONS WEIGHT
1 Boat Crane 1149080 H-13.98 ft (4,357 mm) 7,057 lbs. (3,201
kg)
W-5.02 ft (1,684 mm)
D-8.4 ft (2,927 mm)

Table 1-3. Publications Required But Not Supplied

DOCUMENT PUBLICATION NO.
Ship Information Book Volume 1 Hull and Hull Mechani- TM Number is Dependent on Ship Hull Number
cal System

1-11
SG811-BV-MMA-010

Table 1-3. Publications Required But Not Supplied - Continued

DOCUMENT PUBLICATION NO.

Ship Information Book Volume 3 Part 1 Power and Light- TM Number is Dependent on Ship Hull Number
ing System, Generating Plant

Figure 1-3. Hydraulic Cross-Connect System.

1-12
 SG811-BV-MMA-010

Figure FO-1. Boat Crane (Sheet 1 of 3)

1-13 / (1-14 Blank)

1-14
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

Figure FO-1. Boat Crane (Sheet 2 of 3)

1-15 / (1-16 Blank)

1-16
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

Figure FO-1. Boat Crane (Sheet 3 of 3)

1-17 / (1-18 Blank)

1-18
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

Figure FO-2. Boat Crane With Hydraulic Cross-Connect (Sheet 1 of 3)

1-19 / (1-20 Blank)

1-20
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

Figure FO-2. Boat Crane With Hydraulic Cross-Connect (Sheet 2 of 3)

1-21 / (1-22 Blank)

1-22
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

Figure FO-2. Boat Crane With Hydraulic Cross-Connect (Sheet 3 of 3)

1-23 / (1-24 Blank)

1-24
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

CHAPTER 2

OPERATION

2-1. INTRODUCTION.

This chapter provides detailed operating instructions and guidance procedures for safe, effective use of the
boat crane. These instructions and procedures are supplemented by illustrations and tables for operator identifi-
cation and understanding. Operation of the Boat Crane is performed by a single individual seated in the opera-
tor’s seat. The operator must be assisted by riggers and safety observers during movement of the Boat Crane.

2-2. CONTROLS AND INDICATORS.

The operator controls and indicators are located on the control panel and control console (control sticks),
topside, of the revolving turret. There are separate controls (manual overrides) located on the side of each servo
valve of the block of valves to allow for emergency operation. There is one indicator located on the starboard
side of the revolving turret for the high pressure filter and one indicator located on the rear of the turret for the
low pressure filter. A battle short lever is located on the turret side door, below the operator seat. This lever is
mechanically linked to the battle short switch on the ECU. A hand pump is mounted on the port side of the tur-
ret. The following paragraphs provide a description of the controls and indicators on the Boat crane.

2-2.1 Control Panel Controls And Indicators. The control panel provides the primary operator interface for
operating the crane. Figure 2-1 illustrates the location of the controls and indicators on the control panel. Table
2-1 lists the operator controls and indicators contained on the control panel.

2-2.2 Control Joyticks. The control joysticks are mounted directly in front of the operator when sitting in the
operator seat and provide the control for rotation of the crane on the pedestal, raising and lowering the main
boom, moving the jib boom in and out, and controlling the up and down movement of the winch wire rope.

Figure 2-2 identifies the location of the operator control sticks and table 2-2 describes their operation.

NOTE

The ″J,″ ″M,″ ″S,″ and ″W″ labeled above each control stick corresponds with
the revolving turret servo valves labeled ″J,″ ″M,″ ″S,″ and ″W″ located on the
revolving turret block of valves.

2-2.3 Servovalves Manual Control Functions. Movement of the jib boom, main boom, turret, and winch can be
accomplished locally at the servo valves. These controls are normally protected by a cover that must be removed
to allow operation. Operation of the servo valves using the manual overrides requires that electric power and
hydraulic pressure be available. The manual overrides are used to allow a maintenance technician to verify proper
operation of the servo valve in the event that the operator control sticks are malfunctioning. Due to the location
of the boat crane, operators should never attempt to rotate the boat crane or perform any lifting function using
the manual override for the servo valves. Refer to figure 2-3 and table 2-3 for the location and description of the
controls.

2-1
SG811-BV-MMA-010

Figure 2-1. Control Panel Layout

2-2
 SG811-BV-MMA-010

Table 2-1. Control Panel Controls and Indicators

ITEM CONTROL/INDICATOR FUNCTION
1. EMERGENCY ON pushbutton switch When the EMERGENCY ON switch is depressed, only the top por-
indicator tion of the switch (EMERGENCY) is illuminated yellow.
When the switch is depressed, the top part of the switch remains
illuminated and the bottom part of the switch is illuminated red. If
the MOTOR ON pushbutton is depressed and the motor is running,
the activation of this switch will stop the motor. The ON portion of
the MOTOR ON indicator will extinguish and the OFF portion of
the MOTOR OFF indicator will illuminate.
2. MOTOR ON pushbutton switch indicator When the MOTOR ON switch is not depressed only the MOTOR
indicator is illuminated yellow to indicate that 440 volts alternating
current (vac) is supplied to the electric motor.
When depressed, the switch top lamp (MOTOR indicator) illumi-
nates yellow and the bottom lamp (ON) illuminates green to indi-
cate the electric motor is running.
3. MOTOR OFF pushbutton switch indicator When the MOTOR OFF pushbutton is not depressed, the white
OFF lamp is extinguished and only the yellow MOTOR lamp is
illuminated.
When depressed, the switch top lamp (MOTOR) illuminates yellow
and the bottom lamp (OFF) illuminates white, indicating the electric
motor has stopped.
4. STARTER ALARM indicator (Red) When the lamp illuminates red, it indicates the relief valve has been
activated.
5. THERMAL ALARM indicator (Red) When the lamp illuminates red, it indicates an over temperature
condition being present in the electric motor.
6. NIGHT/DAY pushbutton switch indicator When placed in the DAY position (day indicator illuminates yel-
low), the indicators on the control panel illuminate brighter. When
placed in the NIGHT position, NIGHT indicator illuminates yellow,
the indicators on the control panel illuminate dimmer.
7. BATTLE SHORT indicator (Red) When the lamp illuminates red, it indicates the battle short lever on
the side of the crane has been placed in the ON (down) position.
8. ELECTRIC POWER indicator (Green) When the lamp illuminates green, it indicates that ships power is
applied to the electric motor starter.

2-3
SG811-BV-MMA-010

Figure 2-2. Operator Control Joyticks

Table 2-2. Operator Control Joystick Functions

ITEM CONTROL/INDICATOR FUNCTION
1. J IN/OUT control joystick When the locking detent on the control joystick is lifted and the
control joystick is pushed away from the operator, the jib boom will
move in the outward direction. The speed at which the jib boom
moves is dependent on how far the control joystick is pushed for-
ward. When the joystick is pushed to its maximum limit, the jib
boom will move outward at the maximum speed.
When the locking detent on the control joystick is lifted and the
control joystick is pulled towards the operator, the jib boom will
move in the inward direction. The speed at which the jib boom
moves is dependent on how far the stick is pulled back. When the
joystick is pulled back to its maximum limit, the jib boom will
move inward at the maximum speed.
When placed back to the control position, no movement of the jib
boom will occur.
2. M DOWN/UP control joystick When the locking detent on the control joystick is lifted and the
control joystick is pushed away from the operator, the main boom
will move in the downward direction. The speed at which the main
boom moves is dependent on how far the joystick is pushed for-
ward. When the joystick is pushed to its maximum limit, the main
boom will move downward at its maximum speed.

2-4
 SG811-BV-MMA-010

Table 2-2. Operator Control Joystick Functions - Continued

ITEM CONTROL/INDICATOR FUNCTION

When the locking detent on the control joystick is lifted and the
control joystick is pulled towards the operator, the main boom will
move in the upward direction. The speed at which the main boom
moves is dependent on how far the stick is pulled back. When the
joystick is pulled back to its maximum limit, the main boom will
move upward at the maximum speed.
3. S LEFT/RIGHT control joystick When the locking detent on the control joystick is lifted and the
control joystick is pushed away from the operator, the turret will
move in the counterclockwise (CCW) direction. The speed at which
the turret moves is dependent on how far the joystick is pushed for-
ward. When the joystick is pushed to its maximum limit, the turret
will move CCW at its maximum speed.
When the locking detent on the control joystick is lifted and the
control joystick is pulled towards the operator, the turret will move
in the clockwise (CW) direction. The speed at which the turret
moves is dependent on how far the joystick is pulled back. When
the joystick is pulled back to its maximum limit, the turret will
move CW at the maximum speed.
4. W DOWN/UP control joystick When the locking detent on the control joystick is lifted and the
control joystick is pushed away from the operator, the winch drum
will move in the CW (down) direction to pay out the wire rope. The
speed at which the winch operates is dependent on how far the joy-
stick is pushed forward. When the joystick is pushed to its maxi-
mum limit, the winch drum will move CW at its maximum speed.
When the locking detent on the control joystick is lifted and the
control joystick is pulled towards the operator, the winch drum will
move in the CCW (up) direction. The speed at which the winch
operates is dependent on how far the joystick is pulled back. When
the joystick is pulled back to its maximum limit, the winch drum
will move CCW at the maximum speed.

2-5
2-6

SG811-BV-MMA-010
Figure 2-3. Servo Valve Controls
 SG811-BV-MMA-010

Table 2-3. Servovalves Control Functions

ITEM CONTROL/INDICATOR FUNCTION

WARNING

When the boat crane is being powered by the hydraulic pump and operated with the servovalves, only slow speeds
shall be used as injury to personnel could occur.
1. J Servovalve control When the control is moved in the CW direction, the jib boom will move in
the outward direction. The speed at which the jib boom moves is dependent
on how far the control is turned. When the control is turned to its maximum
limit CW, the jib boom will move outward at the maximum speed. The con-
trol is spring loaded and will automatically return to the neutral position
when released.
When the control is moved in the CCW direction, the jib boom will move in
the inward direction. The speed at which the jib boom moves is dependent
on how far the control is turned. When the control is turned to its maximum
limit CCW, the jib boom will move inward at the maximum speed. The con-
trol is spring loaded and will automatically return to the neutral position
when released.
2. M Servovalve control When the control is moved in the CW direction, the main boom will move
in the downward direction. The speed at which the main boom moves is
dependent on how far the control is turned. When the control is turned to its
maximum limit CW, the main boom will move downward at the maximum
speed. The control is spring loaded and will automatically return to the neu-
tral position when released.
When the control is moved in the CCW direction, the main boom will move
in the upward direction. The speed at which the main boom moves is depen-
dent on how far the control is turned.
When the control is turned to its maximum limit CCW, the main boom will
move upward at the maximum speed. The control is spring loaded and will
automatically return to the neutral position when released.
3. S Servovalve control When the control is moved in the CW direction, the turret will rotate in the
CW (right) direction. The speed at which the turret moves is dependent on
how far the control is turned. When the control is turned to its maximum
limit CW, the turret will move CW (right) at the maximum speed. The con-
trol is spring loaded and will automatically return to the neutral position
when released.
When the control is moved in the CCW direction, the turret will rotate in
the CCW (left) direction. The speed at which the turret moves is dependent
on how far the control is turned. When the control is turned to its maximum
limit CCW, the turret will move CCW at the maximum speed. The control is
spring loaded and will automatically return to the neutral position when
released.
4. W Servovalve control When the control is moved in the CW direction, the winch drum will rotate
in the CW direction (down) to pay out the wire rope. The speed at which
the wire rope is paid out is dependent on how far the control is turned.
When the control is turned to its maximum limit CW, the wire rope will be
paid out (down) at the maximum speed. The control is spring loaded and
will automatically return to the neutral position when released.

2-7
SG811-BV-MMA-010

Table 2-3. Servovalves Control Functions - Continued

ITEM CONTROL/INDICATOR FUNCTION

When the control is moved in the CCW direction, the winch drum will
rotate in the CCW direction (up) to bring in the wire rope. The speed at
which the wire rope is brought in is dependent on how far the control is
turned. When the control is turned to its maximum limit CCW, the wire rope
will be brought in (up) at the maximum speed. The control is spring loaded
and will automatically return to the neutral position when released.

WARNING

The equipment shall be returned to its normal operating condition once the
emergency is secured, as injury to personnel and damage to the equipment
could occur.

2-2.4 Battle Short Lever. The battle short lever and BATTLE SHORT switch are used for emergency operation
to operate the motor when it is in a current overload condition. Figure 2-4 illustrates the location of the battle
short lever and switch. Table 2-4 describes the battle short lever and switch functions.

2-2.5 Slew Ring Locking Assembly. The slew ring locking assembly, figure 2-5, is located at the rear of the
crane. The slew ring locking assembly is used to lock the turret in the stowage position when not in use to ensure
that the boat crane does not rotate in the event that the hydraulic brake is released. The handle is stored on the
right side of the turret, to the right of the slew ring locking assembly. The handle is inserted into the locking
device and moved in the direction desired. The handle is then stored back in its holder until it is to be used again.

2-2.6 Hand Pump. The hand pump, figure 2-6, is located on the left-hand side of the revolving turret, just to
the left of the ladder going up to the operator seat. The pump handle is mounted on the side of the ladder. The
handle is removed from its stowage position and inserted into the pump. The handle is moved in an up and down
motion to move hydraulic fluid through the system.

2-2.7 Gauges. As shown in figure 2-7 and table 2-5, there is one temperature gauge (3), a submersible suction
filter pressure indicator (5), an oil level sight glass (1), a high pressure filter indicator (4), a low pressure filter
indicator (2), and a pressure gauge (6) located on the revolving turret.

2-3. PROTECTIVE DEVICES AND JACKS.

The protective devices on the boat crane are limited to the fuses incorporated in the ECU (supply circuit card)
and electric motor starter. Also, the boat crane is limited to an overload relay incorporated in the electric motor
starter. These devices create an open circuit when the current exceeds the rated value. Figure 2-8 and figure 2-9
illustrate the location of the fuses. Table 2-6 lists the protective devices of the ECU and the electric motor starter.
The jacks located on the ECU and the control panel provide connections for power and control signals. Figure
2-10 and figure 2-11 illustrate the location of the jacks and table 2-7 lists the functions.

2-8
 SG811-BV-MMA-010

Figure 2-4. Battle Short Lever/Switch

Table 2-4. Battle Short Lever Control
ITEM CONTROL/INDICATOR FUNCTION
1. Battle short lever When placed in the down position, the lever activates the BATTLE
SHORT switch on the front of the motor starter.
2. Reach rod mechanical linkage The reach rod mechanical linkage runs between the battle short
lever and the BATTLE SHORT switch.
3. BATTLE SHORT switch This switch is normally activated using the battle short lever via a
reach rod on the door. However, it can be manually operated
directly at the switch in an emergency.
In the OFF position, voltage to the motor is routed through the cur-
rent overload protection circuits.
In the ON position, the circuits for current overload/bypass of the
motor are overridden and the crane is allowed to be operated.
4. RESET switch When depressed, resets the electronic circuits in the motor starter.

2-9
SG811-BV-MMA-010

Figure 2-5. Slew Ring Locking Device Handle

2-10
 SG811-BV-MMA-010

Figure 2-6. Hand Pump

2-11
SG811-BV-MMA-010

Figure 2-7. Gauges Layout

2-12
 SG811-BV-MMA-010

Table 2-5. Gauge Indicators

ITEM INDICATOR FUNCTION

NOTE
The number in parentheses correlates to the valve identification number in the hydraulic diagram (figure FO-3) in
chapter 3.
1. Oil level sight glass (27) Displays the MAXIMUM-NORMAL-MINIMUM fluid level of the
sump
2. Low pressure filter indicator (24) Indicates pressure of fluid passing through the filter.
When needle is in green, pressure is within normal limits.
When needle is in red, indicates the pressure is too high and the
filter requires cleaning.
3. Temperature gauge (26) Displays the temperature of the hydraulic fluid in the sump at the
submersible suction filter. Temperature range is from -10°F to
180°F.
4. High pressure filter pressure indicator Indicates pressure of fluid passing through the filter. When the green
(11) band is showing it is normal and pressure is within limits.
When the red band is showing, it indicates the pressure is too high
and the filter is dirty and requires cleaning.
5. Submersible suction filter (29) indicator Indicates the pressure of fluid passing through the filter.
When needle is in green, pressure is within normal limits.
When needle is in red, indicates the pressure is too high and the
filter requires cleaning.
6. Pressure gauge (8) (on control panel) Displays the system hydraulic pressure from 0 to 3,000 pounds per
square inch (psi).

2-13
SG811-BV-MMA-010

Figure 2-8. ECU Fuse Locations

2-14
 SG811-BV-MMA-010

Figure 2-9. Electric Motor Starter Fuse Locations

2-15
SG811-BV-MMA-010

Table 2-6. Protective Devices

ITEM DEVICE FUNCTION
ECU
1. Fuse F1 & F2 (4 ampere (A)) Protects the input 115 vac to the ECU.
ECU Supply Circuit Card
2. Fuse F1 & F2 (3A) Protects the 115 vac supplying the ECU service transformer.
3. Fuse F5 (8A) Protects voltage supply to the ECU control circuits.
4. Fuse F4 (5A) Protects +24 volts direct current (vdc) supplying the electro-
hydraulic valves.
5. Fuse F6 (1A) Protects +24 vdc supplying the control sticks.
ELECTRIC MOTOR STARTER
1. Fuse F1 & F2 (2A) Protects the input 440 vac to transformer (TR1).
2. Fuse F3 & F4 (2A) Protects the output voltage from transformer (TR1) to the electric
motor starter circuits.
3. Fuse F5 & F6 (6A) Protects the input 115 vac to the ECUnit. (Figure FO-7)
4. Overload Auxiliary Relay OL1 Provides isolation of the 440 vac to the electric motor.

Figure 2-10. Control Panel Jack Locations

2-16
 SG811-BV-MMA-010

Figure 2-11. Electronic Control Unit Jacks

Table 2-7. Crane Jacks
ITEM DEVICE FUNCTION
CONTROL PANEL (See figure 2-10)
1. Connector J6 Provides electrical connection for control signals to/from the ECU
and the control panel.
ELECTRONIC CONTROL UNIT (See figure 2-11)
1. Connector J3 Provides connection for 115 vac input.
2. Connector J4 Provides connection for control signal/indicators/alarm signals
to/from the control panel.
3. Connector J1 Provides connection for signals to/from the control sticks W
(winch) and S (slew).
4. Connector J2 Spare.

2-4. OPERATING PROCEDURES.

The following paragraphs describe the operating procedures for the boat crane.

2-4.1 Operator Turn-On. Power is supplied to the boat crane from the 1S switchboard located in the central
control station 1-23-1-C, through the respective power cables. Prior to powering up or applying power to the boat
crane, the boat crane should be checked out (refer to the preoperational check procedures listed in table 2-8,
figure 2-12, and figure 2-13). When the operator has completed the preoperational procedures, the boat crane is
ready to be turned-on. Refer to the turn-on procedures listed in table 2-9. All controls for the crane are within
easy access when the operator is on-station.

WARNING

Operation of the servo valves using the local valve controls is inherently
dangerous to operating personnel especially for slewing the boat crane.

2-17
SG811-BV-MMA-010

2-4.2 Modes of Operation. The normal mode of operation of the boat crane is by manually controlling the jib
boom (J), main boom (M), winch (W), and rotation (S) servo valves using the operator control joysticks and
pushbutton switches mounted in front of the operator seat on the control console. Refer to table 2-10 for normal
boat crane operating procedures. The boat crane can also be operated in another manual mode using the hand
pump, and in a second manual mode by directly operating a switch at the servo valves. The hand pump is used
whenever the hydraulic pump is inoperable and any movement of the Boat Crane is required. The servo valves
should only be operated at the local servo valve controls to verify faults in the control joysticks.

2-4.2.1 Boat Hook Operation. The hook provided with the crane is designed for locking the load as soon as it
is attached. When lifting the boat, the hook should be released as soon as the boat is waterborne but before the
steadying lines to the boat are released. To release the load, the lanyard to the hook must be pulled as soon as
the wire cable slackens. There are three modes of operation (see figure 2-14):

WARNING

The hook should only be set for automatic release when ordered by the
Officer-in-Charge and under the direction of the boat COXSWAIN just
prior to launching the boat. Premature release could cause damage to per-
sonnel injury.

1. Closing and Locking. The hook is closed and locked by either inserting
the ring of the boat sling into the open ejector, or by rotating the ejector
cam down, by hand, into the closed and locked position.

2. Tripping and Opening. With the hook in the closed and locked position,
the ejector cam is tripped and pivoted to the open position by pulling
down on the release hook lanyard. The cam pivots with sufficient force to
eject the lifting ring, but only if the load has been removed.

3. Automatic Release. After the release hook is closed and locked, it can be
set for automatic release by loading the hook with a 50–pound minimum
load and briefly exerting a 25-pound pull on the release lanyard. The
hook will automatically permit the ejector cam to rotate to the open posi-
tion without having to pull the release lanyard a second time.

Table 2-8. Pre-Operational Checks

Step PROCEDURE

WARNING

Boat Crane operations have inherent hazards that cannot be mechanically safeguarded. Hard hats, safety glasses, and
safety shoes must be worn to prevent personal injury or death.

2-18
 SG811-BV-MMA-010

Table 2-8. Pre-Operational Checks - Continued

Step PROCEDURE

CAUTION

If the hydraulic fluid level in the boat crane sump is below the safe operating level (below minimum range) or any
physical defects are noted, tag the boat crane ″OUT-OF-SERVICE.″ Failure to comply may cause damage to the boat
crane.
1. Visually check the booms, sheaves, flex hoses, wire rope, hook, hook latch, and cylinders for any damage,
missing and loose bolts or pins, corrosion, or excessive wear.
2. Ensure the fluid level in the oil level sight glass is above the minimum range.
3. Ensure the slew ring locking assembly lever is in the unlock (LOCK OUT) position (figure 2-5).
4. At the 1S Switchboard, located in central control station 1-23-1-C, place circuit breaker to the ″ON″ position.
NOTE
Refer to Ship Information Book, Volume 3 for correct circuit breaker location and number.
5. Ensure a rigger is on standby when the operator is ready to turn on the boat crane to conduct lifting and hoist-
ing operations.
6. Remove spring split pin (1, figure 2-12) from locking pin (2) and remove the pin locking the boom head roller
in place to allow it to move freely.
7. Remove split pin (3) from locking pin (4) on boom head and remove locking pin to allow boom head to
swivel.
8. Check the position of all valves as follows, referring to figure 2-13:
Ball Valve 9 - open
Ball Valve 42 - closed
Ball Valve 43 - closed
Ball Valve 44 - open
Ball Valve 45 - closed
Ball Valve 48 - open
Ball Valve 49 - closed
Ball Valve 62 - closed
CAUTION

Ball valve 45 must be closed prior to normal operation of crane. Failure to close this valve prior to operation may
damage the hydraulic motor due to the hydraulic brake not being released when trying to slew the crane.
9. Free hoisting hook (5) from securing rail (6) of the jib boom. (Refer to figure 2-12.)

2-19
2-20

SG811-BV-MMA-010
Figure 2-12. Hook and Locking Pin Removal
 SG811-BV-MMA-010

Figure 2-13. Valve Locations

2-21
SG811-BV-MMA-010

Figure 2-14. Hook Assembly and Operation

Table 2-9. Turn-On Procedure

STEP PROCEDURE INDICATION

WARNING

Care should be taken when sitting in the operator seat, as the seat is not protected. Failure to comply may result in
injury to the operator.

WARNING

The seat belt shall be worn at all times while operating the boat crane. Failure to comply may result in personnel
injury.
CAUTION

Before performing the turn-on procedure, perform the preoperational checkout procedures in table 2-8. Failure to
comply may result in damage to the equipment.
NOTE
Ensure the ELECTRIC POWER indicator lamp illuminates green.
If there is a failure in any of the following procedures, remove switchboard power from the boat crane, tag the boat
crane ″OUT-OF-SERVICE,″ and refer to the troubleshooting section in this manual.
AT THE CONTROL PANEL
1. When operating the boat crane during DAY lamp illuminates yellow and all control panel lamps illumina-
hours of light or in bright light condition, tion is brighter.
depress the NIGHT/DAY pushbutton indi-
cator switch until DAY indicator is illu-
minated.
2. When operating the boat crane during NIGHT lamp illuminates yellow and all control panel lamps illumi-
hours of darkness or in limited light con- nation is dimmer.
ditions, depress the NIGHT/DAY
pushbutton indicator switch until the
NIGHT indicator is illuminated.
3. Depress MOTOR ON Pushbutton. a. MOTOR ON lamp illuminates indicator switch yellow (top) and
green (bottom).

2-22
 SG811-BV-MMA-010

Table 2-9. Turn-On Procedure - Continued

STEP PROCEDURE INDICATION

b. On the MOTOR OFF lamp the MOTOR lamp illuminates yellow.
The OFF lamp is extinguished.
c. Hydraulic motor/pump operates.
d. The STARTER ALARM indicator should illuminate for 15 sec-
onds and then extinguish.
4. Ensure the control panel hydraulic pres-
sure gauge reads 3,000 psi.
CAUTION

Partially clogged filters may have an adverse affect on the crane operation. The high pressure filter indicator, low
pressure filter indicator, and the submersible suction filter indicator should be checked for status as soon as possible
after the MOTOR ON pushbutton is pressed, as damage to the equipment may occur.
5. Be alert for unusual noises, fluid leaks,
and improper gauge and filter indicator
readings.
NOTE
The jib boom in the stowage position is only resting on the stowage stand. There is nothing physically connecting
the jib boom to the stowage stand and there are no special procedures for taking the boat crane out of the stowage
position.
6. The Boat Crane is ready for operation
using the control joysticks (refer to table
2-10 for control joystick operation).

Table 2-10. Boat Crane Operation

STEP PROCEDURE INDICATION

WARNING

Visually observe the lift area for personnel or obstructions before operating the control joysticks. Failure to comply
may result in personnel injury or damage to the equipment.
NOTE
The operator can perform any of the following control joystick steps, depending on the operators desired movement
of the boat crane.
If there is a failure in any of the following procedures, remove power from the boat crane circuit breaker, tag the
circuit breaker ″OUT-OF-SERVICE,″ and refer to the table 2-14 for manual procedures.
AT THE CONTROL JOYSTICKS
1. Move the jib boom outward by lifting the The jib boom will move outward. Speed movement is dependent on
locking detent on control joystick J and how far the joystick is pushed forward. When the joystick is pushed
push the control joystick away from the to its maximum limit, the jib boom will move outward at the maxi-
operator. mum speed.
2. Stop the jib boom movement by moving Jib boom movement stops.
control joystick J back to to the center
position. The control joystick is spring
loaded to automatically return to the cen-
ter position when released.

2-23
SG811-BV-MMA-010

Table 2-10. Boat Crane Operation - Continued

STEP PROCEDURE INDICATION

3. Move the jib boom inward by lifting the The jib boom will move inward. Speed movement is dependent on
locking detent on control joystick J and how far the joystick is pulled back. When the joystick is pulled to
pull the control joystick towards the its maximum limit, the jib boom will move inward at the maximum
operator. speed.
4. Stop the jib boom movement by moving Jib boom movement stops.
the control joystick J back to the center
position. The control joystick is spring
loaded to automatically return to the cen-
ter position when released.
5. Move the main boom downward by lift- The main boom will move downward. Speed movement is depen-
ing the locking detent on control joystick dent on how far the joystick is pushed forward. When the joystick
M and push the control joystick away is pushed to its maximum limit, the main boom will move down-
from the operator. ward at the maximum speed.
6. Stop the main boom movement by mov- Main boom movement stops.
ing control joystick M back to to the cen-
ter position. The control joystick is spring
loaded to automatically return to the cen-
ter position when released.
7. Move the Main boom upward by lifting The main boom will move upward. Speed movement is dependent
the locking detent on control joystick M on how far the joystick is pulled back. When the joystick is pulled
and pull the control joystick towards the to its maximum limit, the main boom will move upward at the
operator. maximum speed.
8. Stop the main boom movement by mov- Main boom movement stops.
ing control joystick M back to the center
position. The control joystick is spring
loaded to automatically return to the cen-
ter position when released.
9. Move the winch downward (pay out wire The wire rope will move downward. Speed movement is dependent
rope) by lifting the locking detent on con- on how far the joystick is pushed forward. When the joystick is
trol joystick W and push the control joy- pushed to its maximum limit, the wire rope will move downward at
stick away from the operator. the maximum speed.
10. Stop the wire rope downward movement Wire rope movement stops.
by moving control joystick W back to the
center position. The control joystick is
spring loaded to automatically return to
the center position when released.
11. Move the wire rope upward by lifting the The wire rope will move upward. Speed movement is dependant on
locking detent on control joystick W and how far the jotstick is pulled back. When the joystick is pulled to
pull the control joystick towards the its maximum limit, the wire rope will move upward at the maxi-
operator. mum speed.
12. Stop the wire rope movement by moving Wire rope movement stops.
control joystick W back to the center
position. The control joystick is spring
loaded to automatically return to the cen-
ter position when released.
13. Move the crane CCW (left) by lifting the The crane will move CCW (left). Speed movement is dependent on
locking detent on control joystick S and how far the joystick is pushed forward. When the joystick is pushed
push control joystick away from the to its maximum limit, the crane will move CCW (left) at the maxi-
operator. mum speed.

2-24
 SG811-BV-MMA-010

Table 2-10. Boat Crane Operation - Continued

STEP PROCEDURE INDICATION

14. Stop the crane CCW movement by mov- Crane movement stops.
ing control joystick S back to the center
position. The control joystick is spring
loaded to automatically return to the cen-
ter position when released.
15. Move the crane CW (right) by lifting the The crane will move right. Speed movement is dependent on how
locking detent on control joystick S and far the joystick is pulled back. When the joystick is pulled to its
pull the control joystick towards the maximum limit, the crane will move upward at the maximum speed.
operator.
16. Stop the crane CW movement by moving Crane movement stops.
control joystick S back to the center posi-
tion. The control joystick is spring loaded
to automatically return to the center posi-
tion when released.

2-4.3 Operator Turn-Off. The operator’s turn-off procedures of the crane are listed in table 2-11.

2-4.4 Battle Short Operation. The boat crane is designed with a battle short lever to override the boat crane’s
current protective device in the hydraulic motor. This lever is located on the turret side door near the operator
seat and is mechanically linked through a reach rod on the door to the BATTLE SHORT switch on the electric
motor starter. The battle short operating procedures are listed in table 2-12.

2-4.5 Battle Short Turn-Off. The only step required to turn the boat crane battle short off is to lift the battle
short lever located near the operator seat (refer to table 2-4, table 2-13, and figure 2-4).

2-5. MANUAL OPERATION.

The boat crane operates from 440 vac supplied to the electric motor, which causes the servo valves to per-
mit hydraulic fluid to the cylinders and hydraulic motors via the control joystick(s). In the event of electrical fail-
ure, the boat crane can be operated manually (table 2-14 and table 2-15) using the hand pump. The hand pump
is located near the ladder on the revolving turret. The handle is mounted near the pump. In the event of a fail-
ure of one of the control joysticks the crane can be operated locally at the valve block (refer to table 2-16). The
only operation of the winch that is possible in the manual mode, using the hand pump is to pay out the wire rope.

NOTE

The hand pump cannot be used to bring the wire rope back onto the winch drum.
For operating procedures for the winch, refer to table 2-14.

Table 2-11. Operator Turn-Off Procedure

STEP PROCEDURE INDICATION
1. Move boat crane into its stowage position
(refer to figure 2-12) via the control sticks.
(Refer to table 2-10 for control joysticks
operations.)

2-25
SG811-BV-MMA-010

Table 2-11. Operator Turn-Off Procedure - Continued

STEP PROCEDURE INDICATION

2. Depress MOTOR OFF indicator switch. MOTOR ON indicator green lamp extinguishes and MOTOR OFF
indicator lamp illuminates white.
3. Insert locking pin (4) into boom head.
(Refer to figure 2-12.)
4. Attach the hook (5) to securing rail (6) of
the jib boom. (Refer to figure 2-12.)
5. Insert the spring split pin (1) into locking
pin (2). (Refer to figure 2-12.)
6. Engage the slew ring locking assembly
lever in the locked (LOCK IN) position.
(Refer to figure 2-5.)

Table 2-12. Battle Short Operation

STEP PROCEDURE INDICATION
1. Place the battle short lever in the down- BATTLE SHORT indicator illuminates red.
ward (ON) position. (Refer to figure 2-4.)
2. At the 1S Switchboard, re-trip circuit MOTOR ON and ELECTRIC POWER indicator lamps illuminate.
breaker.
3. If power is not restored, proceed to table
2-14 for manual procedures.

Table 2-13. Battle Short Turn-Off

STEP PROCEDURE INDICATION
1. Place battle short lever in the up (OFF) BATTLE SHORT indicator extinguishes
position. (Refer to figure 2-4.)

Table 2-14. Manually Operating the Winch, Main Boom, and Jib Boom with
the Hand Pump
STEP PROCEDURE

CAUTION

If the hydraulic fluid level in the boat crane sump is below the safe operating level (below minimum range) or any
physical defects are noted, tag the boat crane ″OUT-OF-SERVICE.″ Failure to comply may cause damage to the boat
crane.
NOTE
If the power fails while the boat crane is in use, perform the following procedures. If manual procedure is required
for the boat crane initial setup, ensure the 1S switchboard circuit breaker is in the OFF position, tag the circuit
″OUT-OF-SERVICE,″ perform the pre-operational checks listed in the table 2-8, except step 4, and proceed to table
2-14, step 5.
1. At the 1S switchboard, place circuit breaker in the OFF position and tag circuit ″OUT-OF-SERVICE.″
2. Visually check the booms, sheaves, flex hoses, wire rope, hook, hook latch, and cylinders for damage, missing
and loose bolts or pins, and corrosion or excessive wear.
3. Ensure the fluid level in the oil level sight glass is between the minimum and the maximum range.

2-26
 SG811-BV-MMA-010

Table 2-14. Manually Operating the Winch, Main Boom, and Jib Boom with

the Hand Pump - Continued

STEP PROCEDURE
4. Ensure the slew ring locking assembly lever is in the unlock (LOCK OUT) position. (Refer to figure 2-5.)
5. Ensure that the removable stanchions are removed from the boat crane’s path of rotation.
NOTE
Due to reduced hydraulic flow when hand pump operation is performed, only one movement should be accomplished
at a time.
6. Ensure the following valves are set as follows. (Refer to figure 2-13 for location:)
a. Normally closed hydraulic brake ball valve (43) in the CLOSED position.
b. Normally open double control ball valve (44) in the OPEN position.
NOTE
The only operation that can be performed manually with the winch when using the hand pump is to lower a load.
It is not possible to manually lift a load using the hand pump.
c. Normally closed overcenter ball valve (45) in the CLOSED position.
d. Two normally closed drain valves (49) in the CLOSED position.
e. Two normally closed drain valves (62) in the CLOSED position.
f. Normally closed drain valve (42) in the CLOSED position.
g. Normally open sump return valve (48) in the OPEN position.
7. Remove the block of valves cover in accordance with chapter 6.
8. Perform the following steps to close all the drain valves (servovalves J, W, M, and S) on the valve block; (refer
to figure 2-3 for location.)
a. Remove the captive nut from each drain valve.
b. Loosen the drain valve lock down nut from each drain valve.
c. Insert an allen wrench into the drain valve slot and turn the valve fully CW and close the drain valves.
NOTE
For manual slewing of the crane, refer to table 2-15.
9. Open the drain valve on the servo valve for whichever action is to be performed, i.e., move jib boom (J servo
valve), move main boom (M servo valve) or move the winch drum (W servo valve).
NOTE
Manual operation requires two people to perform the following procedures.
10. Remove the handle from its stowage position and insert the handle into the hand pump shaft hole (refer to
figure 2-6 for handle stowage location).
11. Hold the appropriate manual override (servo valve J, W, or M being used for movement) up or down, while
vigorously moving the hand pump handle (refer to figure 2-3). When the desired movement is completed,
return the manual override to its normal position.
12. Close the drain valve opened in step 9.
13. If another movement is to be performed, ensure that only the appropriate drain valve is opened.
14. When manual operation is complete, open all of the drain valves (servo valves) on the valve block that were
closed in step 8.
a. Insert an allen wrench into the drain valve slot and turn the valve fully CCW.
b. Tighten the drain valve lock down nut on each drain valve.
c. Install the captive nut on each drain valve.
15. Remove the hand lever from the hand pump shaft hole and place the hand lever in its stowage position.

2-27
SG811-BV-MMA-010

Table 2-15. Manual Procedure for Rotating the Crane

STEP PROCEDURE

CAUTION

If the hydraulic fluid level in the boat crane sump is below the operating level (below minimum range) or any physi-
cal defects are noted, tag the boat crane ″OUT-OF-SERVICE.″ Failure to comply may cause damage to the boat
crane.
NOTE
If the power fails while the boat crane is in use, perform the following procedures. If manual pumping is used for
the boat crane initial setup, place the 1S switchboard circuit breaker in the OFF position, tag circuit ″OUT-OF-
SERVICE,″ perform the pre-operational checks listed in the table 2-8, except step 4, and proceed to table 2-15, step
4.
1. At the 1S Switchboard, place circuit breaker in the OFF position and tag circuit ″OUT-OF-SERVICE.″
2. Visually check the booms, sheaves, flex hoses, wire rope, hook, hook latch, and cylinders for damage, missing
and loose bolts or pins, and corrosion or excessive wear.
3. Ensure the fluid level in the oil level sight glass is between the minimum and maximum range.
4. Attach two tag lines to both sides of the jib boom to allow personnel to restrain the movement of the crane and
allow for rotating the crane using external means.
NOTE
There is a hydraulic brake on the revolving turret (rotating control reduction gear). The turret brake is hydraulically
operated by applying pressure to open the brake and removing pressure to lock the brake.

WARNING

Ball valve (45), must be in its normally closed position before proceeding with manually rotating the crane, to pre-
vent the crane from rotating freely, as injury to personnel or damage to the equipment may occur.
5. Ensure the normally closed ball valve (45) is in the CLOSED position. (Refer to figure 2-13 for location.)
6. Perform the following actions to close all drain valves (servovalves) on the valve block. (Refer to figure 2-3 for
location.)
a. Remove the captive nut from each drain valve.
b. Loosen the drain valve lock down nut from each drain valve.
c. Insert an allen wrench into the drain valve slot and turn the valve fully CW.
7. Place the normally closed ball valve (43) to the OPEN position.
8. Place the normally open ball valve (44) to the CLOSED position.
9. Remove the handle from its stowage position and insert the handle into the hand pump shaft hole. (Refer to
figure 2-6 for handle location.)
10. Vigorously move the hand pump handle (refer to figure 2-6) until the hydraulic brakes are released as indicated
by increased resistance when pumping.
NOTE
At this point the boat crane is prevented from rotating due to a hydraulic lock by overcenter valve (32).
11. Place the normally closed ball valve (43) to the CLOSED position to keep the brakes released.

WARNING

Ball valve (45) must not be opened at any time unless restraining tag lines are attached to the crane to prevent the
crane from rotating freely, as injury to personnel or damage to the equipment may occur.

2-28
 SG811-BV-MMA-010

Table 2-15. Manual Procedure for Rotating the Crane - Continued

STEP PROCEDURE
12. While keeping tension on the two tag lines, slowly open the normally closed ball valve (45), until the crane is
free to rotate.
13. Using the tag lines, direct the position of the crane by pulling on one while restraining with the other.
14. Insert an allen wrench into the slew drain valve and turn fully CCW.
15. To lock the turret brakes once the crane has been moved to the desired position, place the normally open ball
valve (44) to the OPEN position.
16. To lock the hydraulic motor, place the normally closed ball valve (45) to the CLOSED position.
17. To secure manual operations, open all drain valves (servovalves) on the valve block as follows.
a. Insert an allen wrench into the drain valve slot and turn the valve fully CCW.
b. Tighten the drain valve lock down nut on each drain valve using a crescent (adjustable) wrench or open end
wrench.
c. Install the captive nut on each drain valve.
18. Remove the handle from the hand pump shaft hole and place the handle in its stowage position.
NOTE
Before operating the crane in the normal mode, ensure that ball valve (45) is closed.

Table 2-16. Operation of the Crane from the Servovalves

ITEM CONTROL/INDICATOR FUNCTION

WARNING

When moving the boat crane while using the servovalves, care must be taken to use only slow speeds for the crane
movement and main boom movement as personnel injury could occur.
1. Operation of the jib boom outward. To move the jib boom outward, move the servovalve control in the
CW direction. The speed at which the jib boom moves is dependent
on how far the control is turned. When the control is turned to its
maximum limit CW, the jib boom will move outward at the maxi-
mum speed.
2. Operation of the jib boom inward. To move the jib boom inward, move the servovalve in the CCW
direction. The speed at which the jib boom moves is dependent on
how far the control is turned. When the control is turned to its
maximum limit CCW, the jib boom will move inward at the maxi-
mum speed.
3. Operation of the main boom downward. To move the main boom downward, move the servovalve in the
CW direction. The speed at which the main boom moves is depen-
dent on how far the control is turned. When the control is turned to
its maximum limit CW, the main boom will move downward at the
maximum speed.
4. Operation of the main boom upward. To move the main boom upward, move the servovalve in the CCW
direction. The speed at which the main boom moves is dependent
on how far the control is turned. When the control is turned to its
maximum limit CCW, the main boom will move upward at the
maximum speed.

2-29
SG811-BV-MMA-010

Table 2-16. Operation of the Crane from the Servovalves - Continued

ITEM CONTROL/INDICATOR FUNCTION

WARNING

When slewing the crane while standing next to the servovalves, care must be taken to watch the crane movement as
personnel injury could occur.
5. Slew the crane in the CW (right) direc- To move the crane in the CW (right) direction, move the servovalve
tion. in the CW (right) direction. The speed at which the turret moves is
dependent on how far the control is turned. When the control is
turned to its maximum limit CW, the turret will move CW (right) at
the maximum speed.
6. Slew the crane in the CCW (left) direc- To move the crane in the CCW (left) direction, move servovalve in
tion. the CCW (left) direction. The speed at which the turret moves is
dependent on how far the control is turned. When the control is
turned to its maximum limit CCW, the turret will move CCW at the
maximum speed.
7. Operation of the winch downward. To move the winch downward, move the servovalve in the CW
direction. The speed at which the winch moves is dependent on
how far the control is turned. When the control is turned to its
maximum limit CW, the winch will move downward at the maxi-
mum speed.
8. Operation of the winch upward. To move the winch upward, move the servovalve in the CCW
direction. The speed at which the winch moves is dependent on
how far the control is turned. When the control is turned to its
maximum limit CCW, the winch will move upward at the maximum
speed.

2-6. OPERATORS MAINTENANCE INSTRUCTIONS.

There are no special operator maintenance instructions to be performed on the crane.

2-7. STANDARD LOG FORM.

A standard crane log form is required for each lift, or series of lifts performed using the boat crane. The boat
crane operator should record the information as indicated in figure 2-15.

2-30
 SG811-BV-MMA-010

Figure 2-15. Standard Crane Log Form

2-31
SG811-BV-MMA-010

2-8. HYDRAULIC CROSS-CONNECT SYSTEM.

The cross-connect emergency operation permits the hydraulic power unit (HPU) of the boat crane to supply
hydraulic power to the multi-purpose crane (MPC) when it has lost normal system hydraulic pressure due to the
loss of 440 vac power to the electric motor or a failure or loss of control of the hydraulic pump. This interface
is for emergency operation of hydraulic power through a hydraulic cross-connect system. The hydraulic cross-
connect quick connect couplings are located on the back of the boat crane turret adjacent to the slew locking
device. The three boat crane quick disconnects are used to connect flexible hydraulic hose (equipped with quick
connect coupling halves) and ships piping for interface with the multi-purpose crane hydraulic power unit. Like-
wise the multi-purpose crane is capable of supplying hydraulic power to the boat crane. To connect and activate
the cross-connection of both cranes refer to table 2-17, table 2-18, table 2-19, and figure 2-16. The three lines
between the two cranes include the high pressure (pressure compensated pump output) 3/4-inch, low pressure
(return line) 1-inch, and the (motor case) drain 1/2-inch lines. The return lines and case drain lines are necessary
to ensure the sumps do not fill during operation. When cross connected, the supplying unit electric motor must
be on and the other unit’s electric motor must be off however electric power must be available to allow for
operation of the other unit’s joysticks/servo valves. If manual operation of the servo valves is required, follow
operating instructions, warnings and cautions provided in table 2-14, table 2-15, and table 2-16.

Table 2-17. Valve Positions for Boat Crane for Cross-Connect and Normal
Operation
Boat Crane Valve
Description MHC 51, Cross Connect Cross Connect
52, 55, 58, 59, 60, 61, Valve Designa- Normal (Boat Crane Sup- (Multi-Purpose
62 tion Handle Color Operation plying) Crane Supplying)
Slew Bypass 43 Red Closed Closed Closed
Brake Valve/Slew Brake 44 Red Open Open Open
Hand Pump/Slew Brake 45 Red Closed Closed Closed
LP Filter/Sump 48 White Open Open Closed
Pump Output/Quick 63 Red Closed Open Open
Disconnect
LP Filter/Quick Discon- 65 White Closed Open Open
nect
Hydraulic Motor Case 67 (3-Way) Yellow Horizontal- Horizontal-Open to Vertical-Open to
Drain Open to Sump Sump Quick Disconnect
Pump Output/Servo 69 Red Open Closed Open
Valve Block

Table 2-18. Boat Crane Supplying Hydraulic Power to the MPC

Step PROCEDURE
(A) Perform the following for preliminary actions.
CAUTION

Before operating the cross-connect make sure the oil level on both cranes is within the normal range. Sump of boat
crane may over flow if slewing and hoisting operations exceed 10 minutes total. See *NOTE below.

2-32
 SG811-BV-MMA-010

Table 2-18. Boat Crane Supplying Hydraulic Power to the MPC - Continued

Step PROCEDURE

WARNING

Before performing any operation on hydraulic valves, verify that the crane’s power is turned off to prevent injury to
personnel or damage to the equipment.
1. Connect the 3/4-inch high pressure flexible hose to the boat crane quick disconnect (64).
2. Connect the other end of the 3/4-inch high pressure flexible hose to the quick disconnect located on the ship’s
fixed tubing.
3. Connect the 1-inch low pressure flexible hose to the boat crane quick disconnect (66).
4. Connect the other end of the 1-inch low pressure flexible hose to the quick disconnect located on the ship’s
fixed tubing.
5. Connect the 1/2-inch drain flexible hose to the boat crane quick disconnect (68).
6. Connect the other end of 1/2-inch drain flexible hose to the quick disconnect located on the ship’s fixed tubing.
(B) Perform the following for hydraulic system set up (boat crane supplying hydraulic power to MPC).
NOTE
Before setting up the boat crane hydraulic system verify that the MPC is turned off and all preliminary actions are
performed as indicated in MPC TM SG811-BU-MMA-010/A4867.
1. For the high pressure line OPEN ball valve (63), identified with a red handle.
2. CLOSE ball valve (69), identified with a red handle.
3. OPEN ball valve (65), identified with a white handle.
(C) Perform the following to activate cross-connection.
NOTE
Before activating cross-connect, set up the MPC hydraulic system as indicated in MPC TM
SG811-BU-MMA-010/A4867.
1. Check that electric power is available to the boat crane motor starter (boat crane control panel is lit).
2. Press motor on pushbutton on boat crane control panel to supply electric power to the electric motor of the boat
crane.
3. Check the hydraulic pressure on MPC pressure gauge.
4. When the cross-connect is operative, check if the oil level of both cranes is correct. See *NOTE below.

5. Check that electric power is available to the MPC motor starter (MPC panel is lit).
6. Activate the MPC functions by control joysticks as it is controlled during normal use.

WARNING

Before performing any operation on hydraulic disconnect, verify that the MPC hydraulic pump switch is in the off
position and tagged out of service to prevent injury to personnel or damage to the equipment.
(D) Remove cross-connections.

WARNING

Before performing any operation on hydraulic valves, verify that the crane’s power is turned off to prevent injury to
personnel or damage to equipment.
1. Press the motor OFF pushbutton on the boat crane control panel.

2-33
SG811-BV-MMA-010

Table 2-18. Boat Crane Supplying Hydraulic Power to the MPC - Continued

Step PROCEDURE
2. For the high pressure line CLOSE ball valve (63), identified with a red handle.
3. OPEN ball valve (69), identified with a red handle.
4. For the low pressure line CLOSE ball valve (65), identified with a white handle.
5. Set up the hydraulic system of the MPC in a normal condition as indicated in MPC TM SG811-BU-MMA-010/
A4867.

WARNING

Wear safety goggles and rubber gloves while removing hydraulic hose to prevent personnel injury.
6. Remove the 3/4-inch high pressure hose from boat crane quick disconnect (64).
7. Remove the other end of the 3/4-inch high pressure hose from ship’s fixed tubing.
8. Remove the 1-inch low pressure hose from boat crane quick disconnect (66).
9. Remove the other end of the 1-inch low pressure hose from ship’s fixed tubing.
10. Remove the 1/2-inch drain hose from the boat crane quick disconnect (68).
11. Rmove the other end of 1/2-inch drain hose from ship’s fixed tubing.
CAUTION

Replace the oil in the flexible hoses every twelve months to prevent damage to flexible hoses.
CAUTION

Store the flexible hoses where they are not exposed to strong sunlight or severe cooling. Failure to comply may cause
damage to flexible hoses.

*NOTE
Minimize slewing and hoisting operations since these functions cause the boat crane sump to fill slowly
when the brake valves are cycled. The sump level will continually change as the cylinders are cycled. The sump
level should be at maximum when the cylinders are both fully retracted (main boom down with jib tucked under
the main boom).

Table 2-19. Multi-purpose Crane Supplying Hydraulic Power to the Boat

Crane
Step PROCEDURE
(A) Perform the following for preliminary actions.
CAUTION

Before operating the cross-connect make sure the oil level on both cranes is within the normal range. Sump of
multi-purpose crane may over flow if slewing and hoisting operations exceed 10 minutes total. See *NOTE below.

WARNING

Before performing any operation on hydraulic valves, verify that the crane’s power is turned off to prevent injury to
personnel or damage to the equipment.
1. Connect the 3/4-inch high pressure flexible hose to the boat crane quick disconnect (64).

2-34
 SG811-BV-MMA-010

Table 2-19. Multi-purpose Crane Supplying Hydraulic Power to the Boat

Crane - Continued

Step PROCEDURE
2. Connect the other end of the 3/4-inch high pressure flexible hose to the quick disconnect located on the ship’s
fixed tubing.
3. Connect the 1-inch low pressure flexible hose to the boat crane quick disconnect (66).
4. Connect the other end of the 1-inch low pressure flexible hose to the quick disconnect located on the ship’s
fixed tubing.
5. Connect the 1/2-inch drain flexible hose to the boat crane quick disconnect (68).
6. Connect the other end of 1/2-inch drain flexible hose to the quick disconnect located on the ship’s fixed tubing.
(B) Perform the following for hydraulic system set up (MPC supplying hydraulic power to boat crane).
1. OPEN ball valve (63), identified with a red handle.
2. OPEN ball valve (65), identified with a white handle.
3. For the drain line move the three-way ball valve (67) to the vertical position. Three-way ball valve (67) is iden-
tified with a yellow handle.
(C) Perform the following to activate cross-connection.
NOTE
Before activating cross-connect, set up the hydraulic system as indicated in MPC TM SG811-BU-MMA-010/A4867
1. Check that electric power is available to the MPC motor starter (MPC control panel is lit).
2. Press motor on pushbutton on MPC control panel to supply electric power to the electric motor of the MPC.
3. Check the hydraulic pressure on boat crane pressure gauge.
4. When the cross-connect is operative, check if the oil level of both cranes is correct. See *NOTE below.

5. Check that electric power is available to the boat crane motor starter (boat crane panel lit).

WARNING

Before performing any operation on hydraulic disconnect verify that the crane electric MOTOR ON switch is in the
off position and tagged ″OUT-OF SERVICE″ to prevent injury to personnel or damage to the equipment.
6. Activate the boat crane functions by the control sticks as it is controlled during normal use.
(D) Remove cross-connections.

WARNING

Before performing any operation on hydraulic valves verify that the crane power is turned off. To prevent injury to
personnel or damage to the equipment.
1. Press the MOTOR OFF pushbutton on the MPC control panel.
2. For the high pressure line CLOSE ball valve (63), identified with a red handle.
3. For the low pressure line CLOSE ball valve (65), identified with a white handle.
4. For drain line move three-way ball valve (67) handle in horizontal position. Three-way ball valve (67) is identi-
fied with a yellow handle.
5. Set up the hydraulic system of the MPC in a normal condition as indicated in MPC TM SG811-BU-MMA-0l0/
A4867.

2-35
SG811-BV-MMA-010

Table 2-19. Multi-purpose Crane Supplying Hydraulic Power to the Boat

Crane - Continued

Step PROCEDURE

WARNING

Wear safety goggles and rubber gloves while removing hydraulic hose to prevent personnel injury.
6. Remove the 3/4-inch high pressure hose from boat crane quick disconnect (64).
7. Remove the other end of the 3/4-inch high pressure hose from ship’s fixed tubing.
8. Remove the 1-inch low pressure hose from boat crane quick disconnect (66).
9. Remove the other end of the 1-inch low pressure hose from ship’s fixed tubing.
10. Remove the 1/2-inch drain hose from the boat crane quick disconnect (68).
11. Remove the other end of 1/2-inch drain hose from ship’s fixed tubing.
CAUTION

Replace the oil in the flexible hoses every twelve months to prevent damage to flexible hoses.
CAUTION

Store the flexible hoses where they are not exposed to strong sunlight or severe cooling. Failure to comply may cause
damage to flexible hoses.

*NOTE
Minimize slewing and hoisting operations since these functions cause the MPC sump to fill slowly when
the brake valves are cycled. The sump level will continually change as the cylinders are cycled. The sump level
should be at maximum when the cylinders are both fully retracted (main boom down with jib tucked under the
main boom).

2-36
 SG811-BV-MMA-010

Figure 2-16. Hydraulic Cross-Connect Valve Locations

2-37 / (2-38 Blank)

2-38
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

CHAPTER 3

FUNCTIONAL DESCRIPTION

3-1. INTRODUCTION.
This chapter provides a functional description of the boat crane and its major subassemblies. It describes how
the major subassemblies operate and interact with each other, while also providing a description of the interfaces
with other equipment. Where piece numbers are indicated refer to figure FO-3 or figure FO-4 unless otherwise
directed.

3-2. PRINCIPLES OF OPERATION.

The boat crane is electrically powered and hydraulically/electronically controlled. Boat crane movement is
accomplished by positioning electronically controlled hydraulic valves using the control joysticks or the manual
override spring loaded lever on the servo valves. The operator can control the position of the main boom, jib
boom, or winch to lift and position the load. The crane turret can also be slewed (rotated) to position the booms
load.
Once the operator activates the MOTOR ON pushbutton, the electric motor (13) drives the hydraulic pump
continually at 1,800 rpm. The main system pressure compensated hydraulic pump flow is immediately directed
to the sump via the pilot operated relief valve which protects the electric motor and main hydraulic pump dur-
ing startup. The pilot operated relief valve (7) is composed of three individual valves, including a pilot stage, a
solenoid operated directional valve, and a relief valve main stage. The solenoid valve which is energized on
startup, vents the fluid going to the pilot to tank (the sump) causing the main stage to open fully resulting in all
pump flow to be directed to the sump. After approximately 5 seconds, the solenoid is deenergized electrically
allowing fluid to be directed to the pilot stage of the valve causing the main stage to close. Once the relief valve
(7) is closed, pressure can be developed to the setting of the pump pressure compensator set at 3,000 psi. The
pump control allows hydraulic pressure to be available at the servo valve block (41). When the system pressure
reaches 3,000 psi, the boat crane is ready to be operated by control joysticks located on the control panel. The
operator can choose to top the booms, slew (rotate) the turret, and hoist or lower using the winch. The winch
rotation is controlled by control joystick (W) (38). Slewing (rotation) of the turret is controlled by control joy-
stick (S) (39) and topping of the jib boom and main boom is controlled by control joysticks (J) (17) and (M)
(40), respectively. Paragraph 3-2.1 through paragraph 3-2.3 describe the principles of operation when the control
joysticks (W), (J), (S), and (M) are moved in the UP/ DOWN, LEFT/RIGHT, and IN/OUT positions. Each
operation is obtained by rotating the individual joysticks which control the electrical input to the appropriate
servo valve and corresponding hydraulic circuit and hydraulic actuator.

3-2.1 Hoisting Operation. Hoisting operation refers to to rotation of the winch assembly resulting in the hoist-
ing/lowering of the load on the wire rope. The winch assembly consists of a hoist drum with integral reduction
gear driven by a hydraulic motor, incorporating a brake and a one way clutch. The bitter end of the wire rope is
connected to the winch drum and the hook that connects to the load is passed over a fairlead sheave at the end
of the jib boom. The hydraulic motor rotates the reducer shaft in both the haul-in and payout direction. The
hydraulic motor reducer drives a common planetary gear set enclosed in the winch drum hub. The hydraulic
motor shaft is connected to the reducer input shaft via the one way clutch. The outer hub of the one way clutch
is also connected to the brake. The spring set, hydraulically released brake mounted on the hydraulic motor, is
always spring set unless paying out. When hauling in, although the brake does not release, the one way clutch
disengages from the brake, allowing the reduction gear input shaft to rotate. The one way clutch contains several
rollers which are housed in a wedge shaped slot between the inner and outer hubs. Rotation of the one way clutch
in the haul-in direction will cause the rollers to move toward the larger ends of the wedge shaped slots allowing

3-1
SG811-BV-MMA-010

the inner hub to run free of the outer hub (the clutch is disengaged). Rotation of the one way clutch in the payout
direction causes the rollers to move to the narrow end of the wedge shape slots engaging the inner and outer hubs.
Engagement of the one way clutch causes connection of the motor shaft to brake and reducer input shaft when-
ever rotated in the payout direction. The hydraulic motor is powered by the winch hydraulic circuit.
The winch motor hydraulic circuitry is arranged to supply fluid to one port and return fluid from the other
port. The supply and return are separate legs from the servo valve to the hydraulic motor. Supply fluid is pro-
vided from the pump via the servo valve (36) to one port of the hydraulic motor. Return fluid is exhausted from
the other hydraulic motor port, through the servo valve back to the return circuit, terminating at the sump. Port-
ing within the servo valve maintains separation of the supply and return circuitry.
The winch hydraulic motor (1) control begins by the operator rotating the (W) (38) joystick in either direc-
tion (UP or DOWN), sending a proportional electrical signal to the winch servo valve (6). The servo valve torque
motor is positioned proportional to the electrical signal resulting in alignment/opening of the pressure port (P) to
an output port (A or B) and alignment/opening of the return/tank port to the remaining output port. The pump
automatically provides the fluid flow needed to move the motor pistons. The pump pressure compensator senses
a slight drop in pressure and responds by increasing the pump stroke (or swash plate angle) resulting in increased
output flow of fluid to the winch circuit. The servo valve sends the flow to either the hoist or lower side of the
winch circuit depending on the direction selected by the operator. The winch circuitry includes the servo valve,
antishock valve (5), overcenter valve (4), and double control valve (3). When paying out, the electrical signal
directs the sero valve to port hydraulic fluid to the winch hydraulic motor (1) and double control valve (3) simul-
taneously. The double control valve (3) (also referred to as the brake valve) directs the hydraulic fluid to release
the hydraulic brake only in the lower/payout direction. Starting and stopping of the hydraulic motor in the haul-in
direction is controlled by the overcenter valve (4). The overcenter valve is installed just prior to the hydraulic
motor port. Hydraulic motor rotation (haul-in only) is initiated by flow passing through a check valve incorpo-
rated in the overcenter valve. Once through the check valve the flow enters the motor port forcing motor rota-
tion. Prior to paying out the winch/hydraulic motor, the overcenter valve is opened via a pilot stage which is
pressurized by fluid in the payout (supply) leg of the winch hydraulic circuit. The pilot fluid acts on the end of
the spool within the valve causing the valve to open, allowing fluid to exit the motor. Motor (payout) rotation is
stopped when the pressure of the fluid in the pilot stage of the overcenter valve drops causing the spool in the
overcenter valve on the other winch motor port (haul-in side) to close, blocking flow from exiting the motor and
causing the winch motor to slow and stop. Additionally, the hydraulic brake sets (payout only) when fluid pres-
sure drops on the pilot stage of the double control valve causing the valve spool to shift, venting the brake line
fluid and setting the brake. The antishock valve (5) provides protection within the winch hydraulic circuit from
pressure spikes or overload. The antishock valve consists of two independently set cartridge type relief valves
which are normally closed, blocking flow between the two legs of the winch hydraulic circuit. When pressure
exceeds the setting of the antishock valve, the valve will open, allowing flow from one leg of the circuit to the
other. When this occurs, flow is in effect bypassing the slew hydraulic motors and rotation is stalled or halted.
The hydraulic motor consists of several pistons with shoes, cylinder barrel, shaft, bearings, holddown assem-
bly, port plate, valve block, cam plate, and housing. The motor shaft is driven by the pistons, which are driven
hydraulically by the pump via winch servo valve via the winch hydraulic circuit. The motor valve block includes
to separate ports that are connected by separate legs of the circuit to the winch servo valve. Pressurized fluid is
ported to one side of the valve block and the other side of the valve block is connected to the return leg that
leads to the sump via the servo valve. A port plate is mounted on the valve block incorporating two kidney shaped
ports which align with the piston ports in the end of the cylinder barrel. Fluid is forced through the valve block
and one side of the port plate into the cylinders behind the pistons. The piston shoes are forced against the cam
plate which has an angled face. As each piston is forced to extend from its cylinder, it also pushes against the
angled cam face causing the motor and connected shaft to rotate. When the piston reaches maximum extension,
the cylinder of that piston aligns with the end of the kidney shaped port of the port plate. The filled cylinder now
exits the pressurized port, then enters the return port. The piston shoe is forced up the inclined surface of the cam
causing the piston to push into the cylinder which causes all fluid to exhaust into the return side of the valve

3-2
 SG811-BV-MMA-010

block. The piston is at the bottom of the cylinder bore when the end of the return kidney shaped port is encoun-
tered and the cycle begins over for that piston. The motor speed is controlled by the volume of fluid entering the
hydraulic motor.
Winch drum rotation causes rotation of a geared limit switch assembly which includes an empty drum limit
switch and a full drum limit switch. The geared limit switch assembly is chain driven via a sprocket on a hub on
the winch drum and a small sprocket on the shaft of the geared limit switch assembly. When the empty drum
limit switch is actuated (when approximately 2-1/2 turns of wire rope remain on drum), the payout winch elec-
trical signal is cut off from the servo valve and the brake will stop the winch. When the full limit switch is actu-
ated, the winch haul-in electrical signal is cut off from the servo valve and overcenter valve and the brake will
stop and hold the winch motor.

3-2.2 Topping Operation. Topping identifies rotation of a boom about a horizontal pivot. The main boom and
jib boom are topped about a pivot by the action of hydraulic cylinders. The main and jib cylinder electrical con-
trol and hydraulic circuitry are basically the same. The cylinders (20 and 22) are basically a cylindrical housing,
end caps, piston and rod, and associated seals and hardware. The rod projects from one end of the cylinder iden-
tified as the head end. The other end is identified as the cap end. Cylinder motion is caused by porting pressur-
ized fluid to one end of the cylinder and allowing fluid to exit the other end. The speed of the cylinder is depen-
dent on the rate of fluid entering or leaving the cylinder and in this case is controlled by the servo valve. Topping
the main boom up requires filling the cap end of the cylinder with pressurized fluid. Topping the main boom
down requires filling the head (rod) end of the cylinder with pressurized fluid.
The cylinder hydraulic circuitry is arranged to supply fluid to one end of the cylinder and exhaust or return
fluid from the other end. The supply and return are separate legs from the servo valve to the cylinder. Supply
fluid is provided from the pump via the servo valve to one end of cylinder. Return fluid is exhausted from the
cylinder through the servo valve back to the return circuit, terminating at the sump. Porting within the servo valve
maintains separation of the supply and return circuitry.
Cylinder control begins by the operator rotating the (M (40) or J (17)) joystick in either direction, sending a
proportional electrical signal to the cylinder servo valve (12 and 37) respectively. The servo valve torque motor
is positioned proportional to the electrical signal resulting in alignment/opening of the pressure port to an output
port (A or B) and alignment/opening of the tank port to the remaining output port. The pump automatically pro-
vides the fluid flow needed to move the cylinder. The pump (16) pressure compensator senses a slight drop in
pressure and responds by increasing the pump stroke (or swash plate angle) resulting in increased output flow of
fluid to the cylinder circuit. The servo valve sends the flow to either the rod end (to retract) or other end of the
cylinder (to extend) depending on the direction selected by the operator.
Starting and stopping of the cylinder at any point, is controlled by the overcenter valves (21 and 23). An
overcenter valve is installed at each end of the cylinder. Cylinder movement is initiated by flow passing through
a check valve incorporated in the overcenter valve. Then the flow directed to the cylinder end of the valve is
connected. The valve at the other end of the cylinder is hydraulically opened by a pilot line providing pressur-
ized fluid from the inlet of the other overcenter valve. This pilot fluid acts on the end of a spool causing the valve
to open, allowing fluid to exit the cylinder. Cylinder movement is stopped when the pressure of the fluid in the
pilot stage drops causing the spool in the overcenter valve on the other end of the cylinder to close, blocking
flow from exiting the cylinder and causing the cylinder to slow and stop. The main cylinder up overcenter valve
(21) incorporates two flow control valves (57) on the pilot stage of the cap end overcenter valve. This restriction
acts to slow the flow to and from the pilot stage of the overcenter valve to eliminate any erratic motion of the
main boom.
The supply and return legs of the cylinder circuit are protected by an antishock valve (34 and 35), which is
also commonly referred to as a relief valve. The antishock valve is normally closed, allowing no flow between
the supply and return legs of the circuit. When pressure exceeds the setting of the antishock valve, the valve will

3-3
SG811-BV-MMA-010

open, allowing flow from one leg of the circuit to the other. When this occurs, flow is in effect bypassing the
cylinder and cylinder motion is stalled or halted. This condition will occur if the boom interferes with any struc-
ture and when the cylinder piston is at the end of travel.

3-2.3 Slewing Operation. Slewing refers to the rotation of the booms and the turret assembly relative to the
pedestal. The slew drive consists of a slew hydraulic motor (31), which drives a reduction gear fitted with a pin-
ion gear, driving against the stationary gear ring fixed to the pedestal. A hydraulic brake (60) is mounted between
the reduction gear and hydraulic motor. The brake is hydraulically released to allow the hydraulic motor to be
powered via the slew hydraulic circuit causing the turret to slew. The turret is supported by a large bearing, which
includes rollers, allowing the relative motion and supporting the load between the pedestal and the turret.
The slew motor hydraulic circuitry is arranged to supply fluid to one port and return fluid from the other port.
The supply and return are separate legs from the servo valve to the hydraulic motor. Supply fluid is provided
from the pump via the servo valve (36) to one port of the hydraulic motor. Return fluid is exhausted from the
other hydraulic motor port, through the servo valve back to the return circuit, terminating at the sump. Porting
within the servo valve maintains separation of the supply and return circuitry.
The supply and return legs of the slew circuit are protected by an antishock valve (33) which is also referred
to as a relief valve. The antishock valve is normally closed allowing no flow between the supply and return legs
of the circuit. When pressure exceeds the setting of the antishock valve, the valve will open, allowing flow from
one leg of the circuit to the other. When this occurs, flow is in effect bypassing the slew hydraulic motors and
rotation is stalled or halted.
Slew motor control begins by the operator rotating the S joystick in either direction, sending a proportional
electrical signal to the slew servo valve (36). The servo valve torque motor is positioned proportional to the elec-
trical signal resulting in alignment/opening of the pressure port to an output port (A or B) and alignment/open-
ing of the return/tank port to the remaining output port. The pump automatically provides the fluid flow needed
to move the motor pistons. The pump pressure compensator senses a slight drop in pressure and responds by
increasing the pump stroke (or swask plate angle) resulting in increased output flow of fluid to the slew circuit.
The servo valve sends the flow to either the right or left leg of the slew circuit depending on the direction selected
by the operator.
Starting and stopping of the turret/hydraulic motors at any point, is controlled by the overcenter valves (32),
the hydraulic brake (60), and brake valve (2). An overcenter valve is installed at each hydraulic motor port and
a brake is installed on the hydraulic motor output shaft. Hydraulic motor rotation is initiated by flow passing
through a check valve incorporated in the overcenter valve. The flow is then directed to the leg of the slew
hydraulic motor where the valve is connected. The overcenter valve at the other port of the slew motor is
hydraulically opened by a pilot line providing pressurized fluid from the inlet of the other overcenter valve. This
pilot fluid acts on the end of a spool within the overcenter valve causing the valve to open, allowing fluid to exit
the motor. Motor rotation is stopped when the pressure of the fluid in the pilot stage drops causing the spool in
the overcenter valve on the other slew motor port to close, blocking flow from exiting the motor and causing the
slew motor to slow and stop. Additionally, the hydraulic brake sets when fluid pressure drops the pilot on the
brake valve (2) causing the valve spool to shift, venting brake line fluid causing the brake to set.
(For MHC 52, 55, 58 and 59) When the slew limit proximity switches (figure FO-5) arrive at either the
clockwise or counterclockwise proximity sensing plate, the crane stops due to the slew limit relay energizing and
opening the circuitry of the solenoid for the servo valve (36).

3-2.4 Emergency Operation. The boat crane can be operated in emergency using various methods. A hand
pump (19) is provided to allow manual operation when electric power is not available or control circuitry is not
functioning. During emergency operation using the hand pump, several manual valves must be opened or closed

3-4
 SG811-BV-MMA-010

in sequence as described in paragraph 2-5, table 2-14, and table 2-15. The operator can only operate one hydrau-
lic motor or cylinder at a time. Also, the winch cannot be hoisted or payed out when using the hand pump.
The boat crane can be operated by cross connecting with the multi-purpose crane (MPC). This is accom-
plished basically by attaching three hydraulic hoses from quick connects on the boat crane (pressure, return, and
case return) and quick connects on the MPC (pressure, return, and case return) to three quick connects at either
end of piping installed permanently between the two cranes. If the boat crane electric motor or the pump or its
control is defective, the boat crane and MPC can be cross connected and used for normal operations utilizing
paragraph 2-8, table 2-17, table 2-18, and table 2-19. Additionally, the boat crane can be used to power the MPC.
Should a problem arise during operation, the boat crane can be controlled using the manual levers on the
servo valves. The manual operation is extremely sensitive and should only be used to retrieve the unit. Observe
operational instructions and cautions provided in paragraph 2-5 and table 2-16.

3-3. OVERALL HYDRAULIC SYSTEM DESCRIPTION.

The hydraulic system consists of an hydraulic pump (16), main boom cylinder (20), jib boom cylinder (22),
hydraulic fluid sump, and servo valves (36, 37, 12, and 6). It also consists of hydraulic motors (1 and 31), and
two hydraulic brakes (one located on the winch assembly and one on the revolving turret). Solid tubing is used
throughout the system except for the flexible hoses used on the jib boom, main boom, and winch where move-
ment could occur. Also check valves, relief valves, double control valves, antishock valves, and servo valves are
used within the system.

3-3.1 Overall Hydraulic Cross-Connect System Description. The boat cranes installed on board the MHC 51,
MHC 52, MHC 55, and MHC 58 through MHC 62 ships, have the capability to interface to the hydraulic power
unit of the multi-purpose crane (MPC), through permanently mounted hydraulic lines on the ship. This allows
the boat crane hydraulic power unit to supply hydraulic power to the MPC in case of failure of the MPC’s
hydraulic power unit. The cross-connect system (figure 1-3, figure 2-16, figure FO-4) consists of three quick dis-
connect couplings (64, 66 and 68) and four ball valves (63, 65, 67 and 69.) The MPC is also capable of using
its own hydraulic power unit to provide external power to the boat crane.

3-4. FUNCTIONAL HYDRAULIC SYSTEM DESCRIPTION.

When the power switch on the control panel supplies 440 vac power to the electric motor (13,), the electric
motor (13), which is mechanically coupled to the hydraulic pump (16), causes the hydraulic pump (16) to rotate.
This causes hydraulic fluid to be pulled from the hydraulic fluid sump through the submersible suction filter (29).
The submersible suction filter (29) removes any foreign material from the hydraulic fluid preventing damage to
the hydraulic pump (16). The output of hydraulic pump (16) goes through the high pressure filter (11) and check
valve (28). The high pressure filter (11) removes any foreign material missed by the submersible suction filter
(29). Indicators on both filters are provided to allow the operator to monitor the output pressure of the filters to
determine if they are clogged and require cleaning. The output of check valve (28) is supplied to the hydraulic
pressure gauge (8) mounted on the control panel through normally opened cock (9). The output of check valve
(28) is also supplied to servo valves (36, 37, 12, and 6) and pilot operated relief valve (7).
The following description starts with the main boom cylinder (20) completely retracted. When the main boom
cylinder control stick (M) is pushed towards the out position, the ECU generates the main boom control signal
to servo valve (12). This signal causes servo valve (12) to release fluid through the rear of the main boom cyl-
inder (20) through overcenter valve (21). As the piston in the main boom cylinder is moved out, the fluid in the
low pressure side is forced out through the other overcenter valve (21) and back through the servo valve (12) to
the hydraulic sump return line. The antishock valve (34) is used to keep the system from experiencing shock
waves when fluid flow is started or stopped. One way restrictors (57) are used to prevent the pressure in the main

3-5
SG811-BV-MMA-010

boom cylinder from leaking off if the main boom is extended and thereby preventing any movement of the main
boom except by the control joystick. This is required especially when the main boom is extended with a heavy
load attached. If the main boom cylinder piston is extended and is to be retracted, the control joystick causes the
servo valve to direct the high pressure fluid to the left side of the piston through the overcenter valve (21). As
the cylinder moves to the right, the fluid at the rear of the cylinder goes through the overcenter valve (21) and
through the servo valve (12) to the hydraulic sump return line.
Operation of the jib boom cylinder (22) hydraulics is identical to the main boom cylinder (20), except that
there are no one way restrictors in the jib boom cylinder hydraulic system.
When the control joystick (39) is moved to slew the crane to the right, the slew control signal allows high
pressure fluid through the servo valve (36) through overcenter valve (32) to the hydraulic motor (31). Fluid passes
through the motor through overcenter valve (32), through servo valve (36), and back to the hydraulic sump return
line. The hydraulic brake (60) is released by the flow of high pressure fluid through double control valve (2). The
output of the double control valve (2) goes through ball valve (44) and directly to the brake (60). With this line
pressurized, the brake will be released. As soon as pressure is removed, the brake (60) will automatically be
reapplied. Moving the turret in the other direction is identical except fluid goes through the other side of the sys-
tem.
Operation of the winch hydraulic system is identical to the slew hydraulic system.
The pilot operated relief valve (7) is set to relieve should the pressure of the system rise above 2,030 pounds
per square inch (psi). If this occurs, the pressure is vented back to the sump through the hydraulic sump return
line. The hydraulic return line goes through check valve (10), through the low pressure filter (24), and ball valve
(48) and into the hydraulic fluid sump.
When the hydraulic motor (13) or hydraulic pump (16) are not working, the system can be operated by using
the hand pump (19). In this configuration, hydraulic fluid is taken directly from the hydraulic sump through hand
pump (19) and check valve (18). Operation is accomplished by closing all of the drain valves (53, 54, 55, or 56).
The only valve left open is the one that the system is to be operated from. By opening valve (43), closing valve
(44), and pumping the hand pump, the hydraulic brake for slewing the crane can be operated. To move the main
boom, jib boom, or winch, the associated drain valve must be opened to allow the flow of hydraulic fluid through
the associated system.

3-4.1 Functional Hydraulic Cross-Connect System Description. The following description is for the hydraulic
cross-connect system (figure FO-4) on board the MHC 51, MHC 52, MHC 55, and MHC 58 through MHC 62
ships. The hydraulic power unit on the boat crane is required to interface with the hydraulic power unit on the
MPC. This will allow the boat crane to be powered by the MPC hydraulic power unit should the boat crane
hydraulic unit fail. This will also allow the boat crane to power the MPC. When the hydraulic power unit fails,
the three flexible hoses are connected to the three quick disconnects, high pressure (64), low pressure (66) and
drain hose (68). The other ends are connected to ship’s fixed tubing for transfer to the MPC. To receive hydrau-
lic power from the MPC, open ball valves (63 and 69) for high pressure, close ball valve (48), and open ball
valve (65) for low pressure, and for the drain line, vertically open the three-way ball valve (67). Now activate the
hydraulic system on the MPC for hydraulic power.

3-5. HYDRAULIC SYSTEM DETAILED FUNCTIONAL DESCRIPTION.

The following paragraphs provide a detailed functional description of the major components in the hydrau-
lic system. Refer to figure FO-3 or figure FO-4.

3-5.1 Hydraulic Pump. The hydraulic pump (figure 3-1) consists of a drive shaft, several pistons with shoes,
cylinder barrel, bearings, holddown assembly, port plate, valve block, cam plate and housing. The pump shaft is

3-6
 SG811-BV-MMA-010

driven by the electric motor at a continuous 1,800 rpm. The shaft is mechanically connected to the cylinder bar-
rel incorporating the several pistons. Each piston is forced up and down within its individual cylinder creating
the pumping action as the barrel is rotated. The pump valve block includes two separate ports referred to as the
suction and discharge ports. A port plate is mounted on the valve block which incorporates two kidney shaped
ports which align with the piston ports in the end of the cylinder barrel. Fluid is drawn from the sump via the
suction filter, through the valve block and one side of the port plate into the cylinders behind the pistons. The
piston’s shoes are forced against the swash plate which has an angled (variable) face. As each piston shoe slides
up the angled swash plate and the piston extends from its cylinder, it is filled with fluid from the sump. When
the piston reaches maximum extension, the cylinder of that piston aligns with the end of the kidney shaped port
of the port plate. The filled cylinder now enters the discharge kidney shaped port. The piston shoe is forced down
the inclined surface of the angled swash plate causing the piston to push into the cylinder which causes all fluid
to exhaust into the discharge side of the valve block. The piston is at the bottom of the cylinder bore when the
end of the return kidney shaped port is encountered and the cycle begins over for that piston. The pump flow is
controlled by varying the pump swash plate angle. This is achieved by the pump pressure compensator control
and a stroking piston. The stroking piston is connected to the angled swash plate and can move (stroke) it from
about zero to approximately 17 degrees. The piston is positioned by the amount of fluid in its cylinder. The com-
pensator is basically a pressure control valve which ports fluid to or from the cylinder to control the pump out-
put pressure. The compensator is set at 3,000 psi and will cause the pump to maintain the pressure at this level
no matter the flow demand by the various actuator hydraulic circuits. When no command is generated by the
operator on the joysticks, the pump flow is near zero and the pump swash plate angle is near zero degrees. When
one of the servo valves is opened, the pump flow is directed to the associated actuator (motor or cylinder) caus-
ing a flow demand. The system pressure is reduced and the compensator responds by sending fluid to the strok-
ing cylinder causing the piston to continue to stroke until the system pressure once again reaches the set value
at 3,000 psi. Each time an actuator is hydraulically driven, the pump must meet the flow demand and maintain
the pressure from the pump to the servo valve at 3,000 psi. The operator can also select two operations at one
time such as topping the jib and main boom simultaneously. This creates a large flow demand and may result in
some temporary slowing due to the limited availability of fluid. The pressure may fluctuate somewhat during
acceleration and during large flow demands such as simultaneous operations; however the pressure will always
be sufficient to support the load. The pilot operated relief valve (7) is set to relieve should the pressure of the
system rises above 3,300 psi. If this occurs, fluid is directed back to the sump through the hydraulic sump return
line. This is not normal operation; however, it provides some system overload protection, should a malfunction
occur.

3-5.2 Valve Block. The valve block (figure 3-2) consists of four servo valves, figure 3-3, one pilot relief valve,
and four drain cock valves. The following paragraphs provide the detailed functional description of the valve
block.

3-5.2.1 Servo Valves. The servo valves (36, 37, 12, and 6) receive an electrical signal from the control joy-
sticks. This signal directs hydraulic fluid through the servo valve figure 3-3, to the antishock valves, (33, 35, 34,
and 5; double control valves (2 and 3); and overcenter valves (32, 21, and 4) to the hydraulic motors (1 and 31)
for operation. The servo valves consist of an electromagnetic torque motor, a double nozzle pilot stage, and a
spool as the main stage. As shown in figure 3-4, as the operator moves the control stick, a DC electrical signal
is sent to the torque motor and, based on signal polarity, applies a clockwise or counterclockwise torque on the
armature. This torque displaces the flapper between the pair of nozzles. Consequently, the exit area of one nozzle
is increased and that of the other is decreased. This results in a pressure difference at the ends of the main stage
spool which causes the spool to shift and direct main system flow to the actuator (cylinder or motor). A feedback
wire fixed to the armature of the torque motor engages in a slot in the main stage spool. This wire bends with
spool displacement and provides feedback torque. Displacement of the spool stops when the wire feedback torque
equals the motor electromagnetic torque. In this condition, the armature-flapper assembly is recentered and a

3-7
SG811-BV-MMA-010

hydraulic balance results. The main stage spool remains at this position until the operator changes the magnitude
of the input signal by moving the control stick. Spool displacement (actuator speed) is directly proportional to
the electrical input signal to the torque motor (control joystick movement). This valve also incorporates a
mechanical zero which is adjustable. The adjustment sets the output (usually zero) valve when no electrical sig-
nal is sent to the torque motor.

3-5.2.1.1 Mechanical Override. These servo valves have a mechanical override feature which provides for
standby operation in the event of electrical failure. A lever is located on the torque motor cap. Manual rotation
of the lever causes a force to be applied to the pilot stage flapper via springs. The force is proportional to the
angle of rotation of the lever and acts to displace the main stage spool directing hydraulic flow to the actuator.

3-5.2.2 Pilot Relief Valve. The main system pilot-operated relief valve (7) will protect the system from dam-
age due to over pressurization by relieving fluid to the tank should system pressure reach 3,300 psig. Since the
system maximum pressure is controlled by the pump pressure compensator at 3,000 psig, the main system relief
valve remains closed under normal conditions. The pilot stage consists of a spring-loaded needle valve and seat,
and the main stage consists of a spring-loaded spool. As pressure builds to the pilot stage set point, the needle
is lifted from its seat. This causes a flow path which creates a differential pressure across the main stage spool.
The differential pressure lifts the spool off its seat to provide high flow relief to the tank. When pressure drops
below the pilot stage setting, the needle valve closes against its seat disrupting flow. A pressure balance across
the spring-loaded spool is restored closing the spool. This valve also has a normally closed solenoid-vented relief
option. When the solenoid-operated directional valve is deenergized, the relief functions as a standard pilot-
operated relief. When the solenoid valve is energized, the pilot stage is vented to the tank. This creates a differ-
ential pressure across the main spool fully venting main system flow to the tank. The solenoid valve is energized
for a short time during startup to allow the pump to generate flow under no-load conditions. The solenoid valve
will remain energized to prevent pressure buildup should the crane monitoring system sense a no-go condition
during startup.

3-5.2.3 Drain Cock Valves. The drain cock valves (53, 54, 55 and 56) are used in emergency operation, when
the hydraulic power unit is inoperative.

3-5.3 Control Valves. The control valves (figure 3-5) consists of four antishock valves, two double control
valves, and six overcenter valves. The following paragraphs provide the detailed description of the control valves.

3-5.3.1 Antishock Valves. The antishock valves (33, 34, 35, and 5) smooth out the hydraulic fluid pressure
coming from valve block (41) servo valves to prevent sudden pressure changes during topping of the booms,
rotating the turret or rotation of the winch.

The antishock valves are direct-acting, crossport relief valves. These valves are called antishock vice relief
valves because of their intended function and location in the hydraulic circuit. The valve is intended to relieve
system pressure spikes resulting from rapid flow changes which can occur during servo or control valve opera-
tion.

3-5.3.2 Overcenter Valves. These valves are used to control the flow to and from the hydraulic actuators (cyl-
inder or hydraulic motor) especially during the starting and stopping. Overcenter valves, figure 3-6, are installed
at each cylinder port or motor port. Overcenter valves are used in each of the hydraulic circuits to control the
main and jib cylinders and the slew and winch motors.

3-8
 SG811-BV-MMA-010

3-5.3.2.1 Cylinder Overcenter Valves. Two overcenter valves (23) are installed on the jib cylinder to control
the jib boom cylinder (22) flow/motion. Two overcenter valves (21) are installed on the main cylinder to control
the main boom cylinder (20) flow/motion. One overcenter valve is installed at each cylinder port.
The valve incorporates a stationary disc shaped valve body with two seats and several port holes. This valve
body is located between the cylinder port and the pressure/return port. The ball seat and ball are located on the
pressure/return port side. The check valve seat is located on the cylinder port side of the valve body. The ball is
held in place with the spring and ball/spring retainer. The spring is adjustable with an external adjustment screw.
The check valve is held on its seat by a light spring and retainer. The pilot piston and pin are also mounted on
the cylinder port side. The pilot port is isolated from the cylinder port by a seal about the pilot piston outside
diameter. The other side of the piston is exposed to the pressure/return port pressure via an internal pilot port
within the valve body. The piston pin bears against the piston center at one end and bears against the seated ball
at the other end. Any flow through the valve must travel through the valve body. The direction of flow is depen-
dent on which device is unseated due to the forces/pressure acting on it.
The overcenter valve includes three external ports which are identified as cylinder port, pressure/return port
(to servo valve), and the pilot port. The flow path between the cylinder port and pressure/return port can occur
three ways. Refer to figure 3-7, figure 3-8, and figure 3-9.

1. A flow path occurs when pressure at the pressure/return port is greater than the pressure in the cylinder port.
The check valve disc moves from its seat allowing free flow from the servo valve (pressure port) to the cyl-
inder port.
2. A flow path occurs when the overcenter valve pilot is pressurized, causing the pilot piston to push the pin
against the ball and compressed spring. When the pilot force on the piston exceeds the spring force on the
ball, the ball is lifted from the ball seat and flow will occur from the cylinder to the servo valve return port.
3. A flow path occurs when the force on the seated ball due to pressure in the cylinder port exceeds the spring
force on the other end of the ball.
The cylinder will extend when pressurized fluid is directed from the servo valve to the cap end overcenter
valve and the servo valve return port is aligned with the rod end port to create a flow path for the exhausted fluid.
The flow path described in item 1 above will occur through the cap end overcenter valve and the flow path
described in item 2 will occur through the rod end overcenter valve simultaneously. The cylinder will retract
when pressurized fluid is directed from the servo valve to the rod end overcenter valve and the servo valve return
port is aligned with the cap end port to create a flow path for the exhausted fluid. The flow path described in item
1 above will now occur through the rod end overcenter valve and the flow path described in item 2 will occur
through the cap end overcenter valve simultaneously. The speed will be limited due to the throttling of the flow
as described item 2 when fluid is exhausted from the cylinder. If the cylinder speed increases enough, the pilot
pressure will drop and the pilot will begin to close and the ball will nearly seat resulting in throttling of the
exhaust flow.

3-5.3.2.2 Hydraulic Motor Overcenter Valves. The dual overcenter valve (32), and figure 3-10, primary func-
tion is to start, slow, stop, and hold the slew motor, similar to a brake. The valve is connected to four external
ports, including two supply/return port and two motor inlet/outlet ports. The valve body includes four valve
assemblies including two check valves and two reliefs like valves assemblies. The relief like assemblies can be
pressure actuated or mechanically actuated with a pilot assembly. The supply/return ports act are connected to
the two servo valve outlet ports. The supply/return ports act as either supply ports or return ports depending on
whether the servo valve outlet ports are aligned with the servo valve pressure port (supply) or tank port (return).
When the operator rotates the slew joystick to slew to the right, the servo valve is actuated proportionally, allow-
ing proportional flow to pass from the P port to the supply leg of the motor circuit into the overcenter valve. At
the same time, the servo valve tank port is connected to the motor circuit return leg connected to the overcenter

3-9
SG811-BV-MMA-010

valve. The pressurized fluid in the supply leg passes through the check valve and out the valve the hydraulic
motor causing it to rotate and the crane to slew to the right. Simultaneously, pressurized fluid is directed via an
external pilot line to the pilot valve assembly which causes the relief like valve to shift, opening a flow path from
the motor outlet to the return leg. Pressurized fluid is directed via an external pilot line to the pilot valve assem-
bly which causes the relief like valve to shift, opening a flow path from the motor outlet to the return leg. When
the operator rotates the joystick to slew left, the servo valve now directs fluid to the other leg (previously the
return leg for right slewing) through the check valve and to the motor causing rotation to the left. Simultaneously,
pressurized fluid is directed via an external pilot line to the second pilot valve assembly which causes the sec-
ond relief like valve to shift, opening a flow path from the motor to the return leg (previously the supply leg for
right slewing). When the operator returns the joystick to the centered or neutral (hands-off) position, the servo
valve center and pressurized fluid is no longer passed through the valve to the overcenter valve. This causes the
check to close and the pilot shift back closing the relief valve. This will hold the motor in place hydraulically.
The two relief like valves will open the motor to tank when no pressure is supplied to the valve and motor pres-
sure exceeds the setting of the relief valve adjustable spring. This situation would only occur if an external force
was inadvertently applied to the crane causing excessive opposing torque at the slew brake and hydraulic motor.
The overcenter valve (4) controls flow to the winch motor (1) especially when starting and stopping. The
valve is similar to the dual overcenter valve discussed above, however, it only incorporates a single set of check
and relief like valves. A single overcenter can be used since the winch hydraulic motor is only loaded in one
direction. Note the load on the winch is additionally held by a brake whenever the winch is stopped. Also, the
winch brake will assist slowing/stopping of the load whenever paying out since the one way clutch only engages
the brake when the hydraulic motor causing rotation in the payout direction only.

3-5.3.3 Double Control Valves. The double control valve (3), and figure 3-11, releases and sets the winch brake
whenever fluid is directed via the servo valve (6) (this is only on payout leg of the winch circuit) to the hydrau-
lic motor and brake simultaneously. The other double control valve (2) releases and sets the slew brake whenever
fluid is directed via the servo valve (36) to the hydraulic motor and brake simultaneously.
The double control valves (2 and 3) are used to release and set the brake (60) on the winch (payout only) and
the slew motor. The brake valve is a cartridge type valve assembly. The cartridge assembly fits in a special
machined bore in a valve block. The block includes several ports and passages, figure 3-11 and figure 3-12.
External ports include a pressure (P) port, brake (BR) port and a tank (T) port. The valve connects the brake (BR)
port to the tank (T) port when no pressurized fluid is supplied to the valve and connects the pressure (P) port to
the brake (BR) port when pressurized fluid is supplied to the pressure (P) port. The cartridge incorporates a spool
and spring enclosed in the cartridge valve body. The cartridge valve body is stationary and configured to provide
to align with the three external ports, pressure (P) port, brake (BR) port and a tank (T) port. The threaded plug
end of the valve is visible outside of the valve. The other end of the cartridge valve body aligns with a internal
port which leads to the pressure (P) port. The cartridge spool end is exposed to this port. The pressure (P) inter-
nal passage also leads to the area between the plug end and the largest diameter of the cartridge valve body. The
external brake (BR) port aligns directly with the area between the largest and second largest diameter of the car-
tridge valve body. The external Tank port aligns directly with the area between the second largest and the small-
est (at end) diameter of the cartridge valve body. When no pressure is supplied to the valve, the spring pushes
the spool against the end. The spool is configured with lands which are positioned to connect two ports at a time.
With the spool at the end (spring forced) the brake and tank areas/ports are connected. When pressure is supplied
to the valve at the pressure (P) port, the pressurized fluid presses against the exposed end of the spool at the end
of the cartridge and shifts the valve when the force on the spool end is greater than the spring force. When the
valve shifts, the pressure (P) port is connected to the brake (BR) port. Once shifted, fluid will flow through the
valve to the brake causing the brake to release. When the pressure is reduced to near zero, the spring will force
the spool to the end opening the brake (BR) to tank (T) allowing the pressurized fluid to pass through the spool/
valve back to the sump. The brake will set when the pressure is reduced. The pressurized fluid (P) which passes
through the cartridge valve also passes through a shuttle valve which shifts to allow the pressurized leg of the

3-10
 SG811-BV-MMA-010

circuit to provide fluid to the cartridge. The shuttle valve consists of a stationary valve body. The shuttle device
is a ball which is force to block the lower pressure port while opening the inlet pressure port to the outlet pres-
sure (P) port leading to the cartridge valve.

3-5.3.4 One Way Restrictor Valves. The two one way restrictor valves (57) prevent erratic motion of the main
boom cylinder (20) by dampening the pilot stage of the cap end overcenter valve (21). These valves are com-
monly referred to as flow control valves which are configured for free flow in one direction and variable restricted
flow in the other.

3-5.4 Cylinder Assembly (Main and Jib). The main and jib boom cylinders (figure 3-13) are the hydraulic
actuators which control the motion and position of the main and jib booms respectively. Each cylinder incorpo-
rates overcenter valves (23 and 21) at each end of the cylinder. The cylinders (20 and 22) are basically a cylin-
drical housing, end caps, piston and rod, and associated seals and hardware. The rod projects from one end of the
cylinder identified as the head end. The other end is identified as the cap end. Cylinder motion is caused by port-
ing pressurized fluid to one end of the cylinder and allowing fluid to exit the other end. The speed of the cylin-
der is dependent on the rate of fluid entering or leaving the cylinder and in this case is controlled by the servo
valve. Topping the main boom up requires filling the cap end of the cylinder with pressurized fluid. Topping the
main boom down requires filling the head (rod) end of the cylinder with pressurized fluid. For more information
concerning, the operation of the cylinder, refer to paragraph 3-2.2 Topping Operation.

The cylinder incorporates piston seals, rod seals, and a rod wiper to eliminate external fluid leakage and
internal fluid leakage across the piston. The piston seals act to separate the rod end from the other end. Most of
the seals are O-ring seals, which include a back-up ring. The O-rings are designed to fit into a groove with very
little initial compression. The pressure causes the O-ring to compress and fill one end of the groove sealing the
joint. The back-up ring helps to keep the O-ring from entering into the joint (or extruding). The wiper seals are
specially designed to wipe any dirt from the rod before entering the cylinder bore. Failure of an external seal will
lead to visible leakage. Failure of a piston seal results in internal leakage and can lead to noticeable cylinder
speed decrease.

Another feature of the cylinders is the cushion assemblies. These assemblies slow and stop the cylinders at
the end of travel to avoid shock loading and cylinder damage. The cylinders also incorporate stop tubes, which
provide additional support for the rod when extended a long distance.

3-5.5 Reduction Gear. The reduction gear (figure 3-14) output gear meshes to the slew ring assembly to drive
the revolving turret. The reduction gear is directly connected to the hydraulic motor shaft which provides the
input torque and speed. The reduction gear and hydraulic motor shaft are stopped fully by the slew hydraulic
brake.

3-5.6 Turret Hydraulic Brake. The turret hydraulic brake (figure 3-15) is sealed and operated through spring
action to stop or release the rotation of the boat crane revolving turret by hydraulic pressure. The brake is inter-
locked with the hydraulic motor so its brake will set when the control is in the neutral position and upon loss of
power. The brake is controlled by a pilot-operated hydraulic valve referred to as a double control valve. Removal
of electric power will automatically lock the brake.

3-11
SG811-BV-MMA-010

Figure 3-1. Hydraulic Pump

3-12
 SG811-BV-MMA-010

Figure 3-2. Valve Block

3-13
3-14
SG811-BV-MMA-010

Figure 3-3. Servo Valve

 SG811-BV-MMA-010
Figure 3-4. Control Joysticks
3-15
3-16

SG811-BV-MMA-010
Figure 3-5. Control Valves
 SG811-BV-MMA-010

Figure 3-6. Overcenter Valve

3-17
SG811-BV-MMA-010

Figure 3-7. Overcenter Valve Flow

3-18
 SG811-BV-MMA-010

Figure 3-8. Overcenter Valve Flow

3-19
SG811-BV-MMA-010

Figure 3-9. Overcenter Valve Flow

3-20
 SG811-BV-MMA-010

Figure 3-10. Dual Overcenter Valve

3-21 / (3-22 Blank)

3-22
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

Figure 3-11. Double Control Valve

3-23 / (3-24 Blank)

3-24
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

Figure 3-12. Double Control Valve Flow

3-25
SG811-BV-MMA-010

3-5.7 Turret Hydraulic Motor. The slew drive components including the hydraulic motor (31), are connected
directly to the slew reduction gear assemblies and slew brakes (60) installed on the turret. The slew gear ring is
installed on the pedestal and engages the drive gear on the output shafts of the slew reduction gears. Rotation of
the output shaft gear against the stationary slew gear ring results in rotation of the turret. The slew hydraulic
motors mount directly to the hydraulic brakes and input of reduction gears.
The turret hydraulic motor (figure 3-16) consists of several pistons with shoes, cylinder barrel, shaft, bear-
ings, hold down assembly, port plate, valve block, cam plate and housing. The motor shaft is driven by the sev-
eral pistons, which are driven hydraulically by the pump via the slew hydraulic circuit. The motor valve block
includes two separate ports that are connected by separate legs of the circuit to the slew servo valve. Pressurized
fluid is ported to one side of the valve block and the other side of the valve block is connected to the return leg
that leads to the sump via the servo valve. A port plate is mounted on the valve block which incorporates two
kidney shaped ports which align with the piston ports in the end of the cylinder barrel. Fluid is forced through
the valve block and one side of the port plate into the cylinders behind the pistons. The piston shoes are forced
against the cam plate which has an angled face. As each piston is forced to extend from its cylinder, it also pushes
against the angled cam face causing the motor and connected shaft to rotate. When the piston reaches maximum
extension, the cylinder of that piston aligns with the end of the kidney shaped port of the port plate. The filled
cylinder now exits the pressurized port, then enters the return port. The piston shoe is forced up the inclined sur-
face of the cam causing the piston to push into the cylinder causes all fluid to exhaust into the return side of the
valve block. The piston is at the bottom of the cylinder bore when the end of the return kidney shaped port is
encountered and the cycle begins over for that piston. The motor speed is controlled by the volume of fluid enter-
ing the hydraulic motor.

3-5.8 Winch Hydraulic Motor. The winch hydraulic motor (1) is a fixed displacement axial piston design which
is directly connected to the winch reducer. The motor shaft is also connect to a one way clutch (47) which
engages or disengages to and from the winch hydraulic brake.
The winch hydraulic motor (figure 3-17) consists of several pistons with shoes, cylinder barrel, shaft, bear-
ings, holddown assembly, port plate, valve block, cam plate, and housing. The motor shaft is driven by the sev-
eral pistons, which are driven hydraulically by the pump via the slew hydraulic circuit. The motor valve block
includes two separate ports that are connected by separate legs of the circuit to the slew servo valve. Pressurized
fluid is ported to one side of the valve block and the other side of the valve block is connected to the return leg
that leads to the sump via the servo valve. A port plate is mounted on the valve block which incorporates two
kidney shaped ports which align with the piston ports in the end of the cylinder barrel. Fluid is forced through
the valve block and one side of the port plate into the cylinders behind the pistons. The piston shoes are forced
against the cam plate which has an angled face. As each piston is forced to extend from its cylinder, it also pushes
against the angled cam face causing the motor and connected shaft to rotate. When the piston reaches maximum
extension, the cylinder of that piston aligns with the end of the kidney shaped port of the port plate. The filled
cylinder now exits the pressurized port, then enters the return port. The piston shoe is forced up the inclined sur-
face of the cam causing the piston to push into the cylinder causes all fluid to exhaust into the return side of the
valve block. The piston is at the bottom of the cylinder bore when the end of the return kidney shaped port is
encountered and the cycle begins over for that piston. The motor speed is controlled by the volume of fluid enter-
ing the hydraulic motor. The amount of flow to the motor is dependant on the servo valve opening which is pro-
portional to the commanded signal via the joystick. The pressure at the pressure gage adjacent to the control panel
will remain at the pressure compensator pressure at 3,000 psi unless full speed is commanded. When the servo
valve is fully open (the joystick at or near full speed ), full pump volume is used and the pressure will be
observed to drop at the pressure gage adjacent to the control panel to a value as low as 500-600 psi (no load) and
proportionally greater pressure when loaded.

3-5.9 Winch Hydraulic Brake. The winch hydraulic brake is mounted between the winch hydraulic motor and
the reducer. The hydraulically operated brake is capable of stopping and holding a dynamic test load greater than

3-26
 SG811-BV-MMA-010

150 percent of the rated load (when payed out slowly) and of holding a static test load (200 percent or rated load)
with the wire rope passing through the fairlead sheave. The brake is interlocked with the hydraulic motor so its
brake will set when the control is in the neutral position and upon loss of power. The brake is controlled by a
pilot-operated hydraulic valve referred to as a double control valve. Removal of electric power will automatically
lock the brake.

The winch hydraulic brake (figure 3-18) consists of a brake housing, piston and a series of disc-shaped plates.
The disc-shaped plates include stationary separator plates and rotating friction discs. The separator plates are
connected to the housing with tabs mounted at the outer edge of the plates. The friction discs are mounted to a
shaft with tabs mounted on the inner edge of the discs. The separator and friction discs will not rotate when
pressed together. This brake discs are forced together by belville springs. The brake is released by pushing (using
pressurized hydraulic fluid) a sealed piston against the springs, reducing the pressure applied to the friction discs.
The brake is set by removing the fluid from the piston, allowing the springs to force the piston against the discs.

The shaft is connected to the motor and reducer shaft by a one way clutch. The one way clutch only engages
in the payout direction. The brake only releases (via the double control valve) when the hydraulic motor is driven
in the payout direction. The one way clutch allows rotation of the motor and reducer shaft when hauling in by
effectively declutching the brake from the shaft.

The winch also incorporates a limit switch assembly which includes an empty drum limit switch and a full
drum limit switch. The geared limit switch assembly is chain driven via a sprocket on a hub on the winch drum
and a small sprocket on the shaft of the geared limit switch assembly. The empty drum limit switch prevents the
operator from paying out too much wire rope. The full drum limit switch prevents the operator from two block-
ing the wire rope thimble into the snubber or passing the tear drop through the pressure roller and fairlead sheave.
The geared limit switch includes an adjustor which is used to set the various limit switches at different settings
when necessary.

3-5.10 Hydraulic Power Cross-Connect System. The hydraulic cross-connect (figure 3-19)permits the hydrau-
lic power unit of the MPC to supply hydraulic power to the boat crane when it has lost normal system hydrau-
lic pressure due to a loss of electrical power or failure of a pump. Likewise, the boat crane is capable of supply-
ing hydraulic power to the MPC. The MPC being powered through the hydraulic cross-connect is capable of
performing all normal crane operations at the rated load with no specified speed.

This interconnection was accomplished by adding quick disconnect couplings, isolation valves, and all
required tubing necessary to allow interconnection to both cranes. In addition, fixed tubing is installed between
the starboard side of the main deck near the MPC and run to the port side of the 01-1/2 deck to the boat crane.
The MPC and boat crane both interface to the ship’s fixed tubing through flexible hoses with quick disconnect
coupling halves.

3-5.10.1 Functional Hydraulic Cross-Connect System Description. The cross-connect system basically consists
of interconnection of three hydraulic circuits including a high pressure circuit, a return circuit, and a motor case
return circuit. The pressure circuit allows the pump output of one unit (supplying crane) to be diverted to the
servo valve block of the other unit (receiving crane), since the primary hydraulic circuits, slew, main cylinder, jib
cylinder and winch in conjunction with the pump are open loop circuits. Open loop circuits draw fluid from a
sump and return it to a sump. When cross connected, the volume of fluid supplied to a circuit comes directly
from the supplying units sump and is replenished via the return circuit. The hydraulic motor case drains do not
end up in the return circuit, however are directly returned to the sump separately. The location of several manual
ball type valves installed within the high pressure, return and motor case circuits allows the diversion of flow
from one unit to another, alignment of the receiving units return circuit with the supplying units sump and rerout-
ing of hydraulic motor flow.

3-27
SG811-BV-MMA-010

When cross connected, the receiving unit is controlled by rotating the joysticks. This requires power be
available to the receiving unit (the circuit breaker for the unit is on (electric motor must remain off)) so the joy-
sticks will control the receiving units servo valves. The pressure observed on the receiving units gauge will be
the setting of the pump compensator of the supplying unit. The pressure observed on the supplying unit will be
zero psi. The relief valve (7 (boat crane) or 26 (MPC)) on the receiving unit will provide protection for overpres-
surization when cross connected. The setting of the relief should be at 3,300 psi for the boat crane and MPC to
allow proper cross-connect operation. It is extremely important to align the return line valves properly since the
entire circuit will be over pressurized or the wrong sump will be filled/over filled.

3-6. ELECTRICAL SYSTEM DESCRIPTION.

Figure FO-5 provides the cabling interconnection of all the units on the boat crane. As shown in figure FO-6,
440 vac, 60 Hertz (Hz), 3-phase power (from the ships 1S switchboard) is supplied to the crane through connec-
tor J1 and the flexible unit. The 440 vac output from the flexible unit is input to the electric motor starter, located
under the operator seat.
The electric motor starter reduces the 440 vac to 115 vac for use in the ECU. The ECU uses the 115 vac to
develop +24 vdc. The +24 vdc is used in the control joysticks and the control panel. The ECU generates and
supplies the various units with the required signals and voltages for system operation. The +24 vdc is supplied
to the control joysticks and is used to provide topping, rotating and hoisting signals to the servo valves. The jib
boom cylinder and main boom cylinder servo valves receives their control signals directly from the control joy-
sticks. The winch and slew servo valve signals are sent through then ECU to ensure limit signals for both the
crane rotation and the winch empty/full are proper prior to allowing movements. The control panel provides the
switches required to supply control signal to the ECU and electric motor starter. The ECU, in turn, supplies indi-
cation responses to the control panel to inform the operator of the system status.

3-7. ELECTRICAL SYSTEM DETAILED FUNCTIONAL DESCRIPTION.

The following paragraphs provide the detailed functional description of the electrical system major subas-
semblies. Refer to figure FO-6 for signal destination/interconnection.

3-7.1 Electric Motor Starter. The electric motor starter (figure FO-7) receives 440 vac, 60 Hz, 3-phase power
(signal numbers 21, 22, and 23) from the 1S switchboard. When the EMERGENCY and MOTOR OFF switches
on the control panel are not depressed and the MOTOR ON switch is depressed, contactor CO1 is energized. This
causes 440 vac, 60 Hz, 3-phase power to be sent to the electric motor (signals 18, 19, and 20). The electric motor
is mechanically coupled to the hydraulic pump. As the electric motor turns, it drives the hydraulic pump. Trans-
former TR1 is a stepdown transformer used to reduce 440 vac to 115 vac for use in the ECU and control panel.
The output 115 vac is also used to energize the overload tripped aux relay R1, the running contactor CO1,
and the alarm aux relay R2. Each 115 vac output is protected by two in-line 2 ampere (A) fuses.
The electric motor starter also provides contacts for illuminating the MOTOR ON indicator, MOTOR OFF
indicator, BATTLE SHORT indicator, and the THERMAL ALARM indicator on the control panel.
The RELAY ALARM CONTACT 1 and 2 signals are jumpered together in the ECU so that relay R2 is ener-
gized at all times.
The BATTLE SHORT switch, when closed, allows the overload tripped aux relay R1 to be bypassed. The
switch also illuminates the BATTLE SHORT indicator on the control panel.
The RELAY switch on the front of the electric motor starter is connected to the overload relay OL1 and is
used to reset the relay when tripped.

3-28
 Figure 3-13. Cylinder Assembly (Main-Jib)

SG811-BV-MMA-010
3-29
SG811-BV-MMA-010

Figure 3-14. Reduction Gear

3-30
 SG811-BV-MMA-010

Figure 3-15. Turret Hydraulic Brake

3-31
SG811-BV-MMA-010

Figure 3-16. Turret Hydraulic Motor

3-32
 SG811-BV-MMA-010
Figure 3-17. Winch Hydraulic Motor
3-33
SG811-BV-MMA-010

Figure 3-18. Winch Hydraulic Brake

3-34
 SG811-BV-MMA-010
Figure 3-19. Hydraulic Power Cross-Connect
3-35
SG811-BV-MMA-010

3-7.2 Control Panel. The control panel contains all the operator controls and indicators used to operate the
crane and show its operational status. The control panel (figure FO-8) receives the 6 vac LAMP SUPPLY DAY
signal and the 3 vac LAMP SUPPLY NIGHT signal from the ECU. The NIGHT/DAY switch is used to select
either source as the supply voltage to the panel indicator lamps. The 115 vac MOTOR OFF, MOTOR ON and
POWER ON/OFF control signals from the electric motor starter are routed through the MOTOR ON, EMER-
GENCY, and MOTOR OFF switches and back to the electric motor starter. The +24V and 0V signals are sup-
plied to the control panel but are not used.

3-7.3 Control Joytick. The four control joysticks (figure 3-4) receive +24 vdc from the electronic control unit
and, in turn, provide control signals to the servo valves. The signals for controlling the main and jib boom servo
valves are sent directly to the valves. The signals for the winch and slew are sent via the electronic control unit.

3-7.4 Electric Motor. The electric motor receives 440 vac, 60 Hz, 3-phase power from the electric motor starter.
The motor is a 440 vac induction type motor, rated at 15 horsepower. Its main components include the stator,
rotor, motor housing, and rotor shaft bearings. Rotor shaft bearings are secured at opposite ends of the motor
housing. The bearings support the rotor against large radial forces created on startup. At operating speed, the well
balanced rotor spins freely within opposing magnetic fields.
The high efficiency ac motor is a 3-phase, squirrel cage, induction type motor. The motor has a primary
winding (stator) that is connected to the power source, and a secondary winding (rotor) that has no electrical
connection to the power source. Current flow in the primary winding sets up a rotating magnetic field that induces
voltage and current in the secondary winding. This provides the mechanical force that turns the rotor. The motor
operates at a single speed. The rotor shaft of the motor is coupled to the hydraulic pump shaft. Rotation of the
motors rotor shaft drives the hydraulic pump rotor shaft at a constant speed of 1,800 (rpm).

3-7.5 Electronic Control Unit. The electronic control unit (figure FO-9) provides +24 vdc to the control joy-
sticks, servo valves, and relief valve. The electronic control unit consists of a dirty box (electromagnetic inter-
ference (EMI) filters), power supply section a control board CST 103 and a supply board CST 102. The power
supply section consists of transformers TO47 and TO48; power transistors Q1 and Q2; power resistors R1, R2,
R3, and R4; capacitor C1; and diodes D1, D2, D3, and D4. The following paragraphs provide a detailed descrip-
tion of the major components.

3-7.5.1 Dirty Box (EMI Filters). The dirty box (EMI filters) (figure 3-20) signals are filtered and protected by
low pass filters. These filters consists of one shunt capacitor, one shunt zener diode, and two inductors in series.
The filter series is designed for high impedance valves with predominant reactive losses at high frequencies.
There are fifteen of these groups mounted on a printed circuit board in the ECU. To further reduce EMI trans-
missions connections between the ECU, electric motor starter, and junction box ferret connetors as shown in
figure 3-21.

3-7.5.2 Control Board. The control board (figure FO-10) is a printed circuit board that consists of a relay sec-
tion, a logic unit, and an analog unit. The relay section provides nine relays for signal control. Relays RL1 and
RL2 are used to allow/inhibit the operation of the winch, depending on the winch drum full/empty limit switches.
Relays RL5 and RL6 are used to allow/inhibit rotation of the crane in either the clockwise or counterclockwise
direction, depending on the rotation limit switches.
When the MOTOR ON pushbutton on the control panel is depressed, the LAMP MOTOR ON signal is input
to the opto-isolator U6. This signal is used to drive a comparator circuit U8A. The output of U8A is input to a
resistance/capacitance filter U8B and also to the relay driver circuit U8C and U8D. The relay driver circuit out-
puts a 2.4 microsecond signal to energize relay RL9 and operate the relief valve during initial motor startup.

3-36
 SG811-BV-MMA-010

3-7.5.3 Supply Board CST 102. The supply board (figure FO-11) receives 32 vac, 18 vac, 6 vac, and 3 vac
from transformer TO48. The 3 vac and 6 vac lines are isolated through fuses F1 and F2 and sent to the control
panel via the control board CST 103. The 18V1 and 18V2 lines are not used in the boat crane. The 32 vac line
is used to develop the +24 vdc for use in the servo valves, control panel and control board CST 103. The sup-
ply board is also connected to ECU transistors Q1 and Q2. These transistors provide the current source required
for the circuits in the boat crane.

3-7.6 Slew Limit Relay Box. (MHC 52, 55, 58, 59). The slew limit relay box (see figure 3-22 and figure FO-6)
provides two relays. When the slew limit proximity switch arrives at either the clockwie or counterclockwise
proximity sensing plates, relay #1 (cw) or relay #2 (ccw) energize and open solenoid circuitry of servo valve #36.
It causes the crane to stop slewing.

3-37
SG811-BV-MMA-010

Figure 3-20. EMI Filter Board (Dirty Box)

3-38
 SG811-BV-MMA-010

Figure 3-21. EMI Protective Devices

3-39 / (3-40 Blank)

3-40
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

Figure 3-22. Slew Limit Stop Schematic (MHC 52, 55, 58 & 59 ONLY)

3-41 / (3-42 Blank)

3-42
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

Figure FO-3. Hydraulic System Schematic Diagram

3-43 / (3-44 Blank)

3-44
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

Figure FO-4. Hydraulic System (With Cross-Connects) Schematic Diagram

3-45 / (3-46 Blank)

3-46
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

Figure FO-5. Electrical System Block Diagram

3-47 / (3-48 Blank)

3-48
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

Figure FO-6. Electrical System Wiring Diagram

3-49 / (3-50 Blank)

3-50
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

Figure FO-7. Electric Motor Starter Wiring Diagram

3-51 / (3-52 Blank)

3-52
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

Figure FO-8. Control Panel Wiring Diagram

3-53 / (3-54 Blank)

3-54
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

Figure FO-9. Electronic Control Unit Wiring Diagram

3-55 / (3-56 Blank)

3-56
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

Figure FO-10. Control Board Schematic

3-57 / (3-58 Blank)

3-58
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

Figure FO-11. Supply Board

3-59 / (3-60 Blank)

3-60
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

CHAPTER 4

SCHEDULED MAINTENANCE

4-1. INTRODUCTION.

4-1.1 Planned Maintenance System. Required preventive maintenance procedures to be performed on a sched-
uled basis are provided in Planned Maintenance System (PMS) documentation. OPNAVINST 4790.4 describes
this system, which also covers departmental and work center record keeping, as well as Maintenance Index Page
(MIP) and Maintenance Requirement Cards (MRC’s)

4-2. MAINTENANCE ACTIONS.

Preventive maintenance required for the boat crane is identified in the Maintenance Index Page (MIP) 5831/
019-C7. The MIP identifies the Maintenance Requirement Cards (MRC’s) to be used for various maintanance
actions.

4-1 / (4-2 Blank)

4-2
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

CHAPTER 5

TROUBLESHOOTING

5-1. INTRODUCTION.
This chapter contains organizational, intermediate and depot level procedures for isolating faults in the elec-
tromechanical systems of the boat crane.

5-2. TEST EQUIPMENT.

Test equipment required to perform fault isolation on the crane is listed in table 5-1.

5-3. FAULT LOCATION.

The following paragraph provides the technician with a logical progression of locations within the boat crane
electrical and hydraulic systems for troubleshooting.

5-4. SYSTEMS FAULT ISOLATION.

To fault isolate the electromechanical systems, perform the steps provided in table 5-2, through table 5-9 and
as shown in figure 5-1 through figure 5-8. All removals, repair and replacements on the boat crane will be per-
formed at organizational level unless otherwise indicated.

WARNING

Troubleshooting procedures frequently require that checks be made while

power is on. Extreme care should be used to prevent contact with live cir-
cuit parts. Touching these parts could result in electrical shock. The voltage
used in the boat crane can cause injury or death.

Table 5-1. List of Test Equipment

NOMENCLATURE MODEL OR PART NUMBER
Multimeter Hewlett Packard HP 3490A or equivalent
Inductive Ammeter Amprobe Model RS-3 or equivalent
High Potential Tester Associated Research Model 4030 or equivalent
Circuit Card Tester Motorola R4000A Master tech or equivalent

Table 5-2. Boat Crane Fault Isolation

SYMPTOM IMMEDIATE ACTION PROBABLE CAUSE REMEDY
A. Electric Motor Will Not Start.
a. Boat Crane inoperative. 1. Observe electric power 1. Circuit breaker at Power 1. Place breaker in ON posi-
indicator is illuminated. distribution (PDP 2-45-2) is tion.
in OFF position

5-1
SG811-BV-MMA-010

Table 5-2. Boat Crane Fault Isolation - Continued

SYMPTOM IMMEDIATE ACTION PROBABLE CAUSE REMEDY

2. Check for 450 vac at 2. Defective connector to 2. Replace connector, figure
input side of fuses to motor motor starter. FO-5.
starter.
3. Check for 450 vac at out- 3. Defective cable to crane. 3. Replace cable. (Refer to
put of connector to crane. figure FO-6.)
4. Observe ″MOTOR ON″ 4. Defect in control panel. 4. Fault isolate control
indicator is illuminated. panel. (Refer to table 5-8
and figure 5-6.)
5. Check that the 15 horse- 5. Defect in motor starter. 5. Fault isolate motor starter.
power (HP) motor is run- (Refer to table 5-9 and
ning. figure 5-7.)
B. Electric Motor Starts.
a. BOAT CRANE inopera- 1. Observe hydraulic pump 1. Defective coupling 1. Replace defective cou-
tive (Electric motor starts is not running pling. (Refer to pararagraph
with no pressure on gauge 6-4.16.)
or intermittent pressures)
2. Observe hydraulic pump 2. Problem with pump or 2. Faulit isolate hydraulic
is running and thermal alarm related hydraulic controls. pump and controls. (Refer to
light illuminates for about 3 table 5-3.)
seconds (on startup) at con-
trol panel.
3. Observe thermal alarm 3. Problem with control 3. Faulit isolate control
light does not illuminate (on panel or electronic control panel and electronic control
startup) at control panel. unit. unit. (Refer to table 5-8 and
table 5-7 respectively.)
b. Hydraulic pressure gauge 1. Check manual valve 1. Valve (normally open) is 1. Open manual valve (69,
indicates 3,000 psi and crane alignment. closed blocking flow to con- figure FO-3 or figure FO-4).
will not slew, top booms or trol block and servo valves.
hoist winch when operator
rotates joysticks.
2. Valves are aligned prop- 2. Power supply problems 2. If solenoid is energized
erly. fault isolate electronic con-
trol unit. (Refer to table
5-7.)
3. Pilot operate relief valve 3. Pilot operate relief valve 3. Adjust pilot operate relief
(7, figure FO-3 or figure (7, figure FO-3 or figure valve (7, figure FO-3 or
FO-4) is extremely hot. FO-4) is not adjusted prop- figure FO-4) to 3,300 psi
erly and adjust pressure compen-
sator to 3,000 psi.
c. Hydraulic pressure gauge 1. Observe slew electrical 1. Problem in slew electrical/ 1. Fault isolate slew sys-
indicates 3,000 psi and the and hydraulic components electronic system or hydrau- tems. (Refer to table 5-5.)
turret will not slew when for operation. lic circuitry components.
operator rotates joystick.
d. Hydraulic pressure gauge 1. Observe main boom elec- 1. Problem in main boom 1. Fault isolate main boom
indicates 3,000 psi and main trical and hydraulic compo- electrical/electronic system systems. (Refer to table
boom will not top when nents for operation. or hydraulic circuitry com- 5-11.)
operator rotates joystick. ponents.

5-2
 SG811-BV-MMA-010

Table 5-2. Boat Crane Fault Isolation - Continued

SYMPTOM IMMEDIATE ACTION PROBABLE CAUSE REMEDY

e. Hydraulic pressure gauge 1. Observe jib boom electri- 1. Problem in jib boom elec- 1. Fault isolate jib boom
indicates 3,000 psi and jib cal and hydraulic compo- trical/electronic system or systems. (Refer to table
boom will not top when nents for operation. hydraulic circuitry compo- 5-12.)
operator rotates joystick. nents.
f. Hydraulic pressure gauge 1. Observe winch electrical 1. Problem in winch electri- 1. Fault isolate winch sys-
indicates 3,000 psi and and hydraulic components cal/electronic system or tems. (Refer to table 5-4.)
winch will not rotate when for operation. hydraulic circuitry compo-
operator rotates joystick. nents.

Table 5-3. Hydraulic Pump Fault Isolation

SYMPTOM IMMEDIATE ACTION PROBABLE CAUSE REMEDY
a. Hydraulic pressure gauge 1. Observe direction of rota- 1. Pump is rotating incorrect1. Change electric motor
is not indicating pressure tion (Only required if electri- direction due to electric cable connection. (Refer to
(electric motor/pump is cal cable changes/repairs motor cable connected incor- figure FO-5, figure FO-6,
rotating). have been completed). rectly to starter or slip ring.
and figure FO-7.)
2. Check pressure gauge 2. Pressure gauge valve (9, 2. Repair/replace pressure
valve (9, figure FO-3 or figure FO-3 or figure FO-4) gauge valve (9, figure FO-3
figure FO-4). may be defective. or figure FO-4.)
3. Observe oil level indica- 3. Oil level is low. 3. Fill sump to normal oper-
tor. ating level.
4. Some noise and heat at 4. Pilot operated relief valve 4. If solenoid is energized,
pilot operated relief valve (7, (7, figure FO-3 or figure fault isolate electronic con-
figure FO-3 or figure FO-4). FO-4) solenoid operated por- trol unit. (Refer to table 5-7
tion of valve is frozen caus- and figure 5-5.) If valve is
ing fluid to vent to sump at frozen, repair or replace.
full pump volume.
5. Sump empty for repairs, 5. Pump suction line must be 5. Open suction line fittings
etc. filled. until oil is observed.
Attempt restart.
6. Noise in pump or metallic 6. Catastrophic failure of 6. Repair/replace pump
particles found in HP or LP pump. using SIMA or DEPOT
filters or extremely hot at facility.
pump case return line to
sump.
7. No signs of damage. 7. Pump controls are not 7. Adjust pressure compen-
adjusted properly. sator, or stroke limiter.
b. Hydraulic pressure gauge 1. May not lift dynamic 1. Pressure compensator is 1. Adjust pressure compen-
indicates less than 3,000 psi. load. not adjusted properly. sator.
2. Pilot operated relief valve 2. Pilot operated relief valve 2. Adjust pilot operated
(7, figure FO-3 or figure (7, figure FO-3 or figure relief valve (7, figure FO-3
FO-4) is extremely hot. FO-4) is not adjusted prop- or figure FO-4) to 3,300 psi
erly. and adjust pressure compen-
sator to 3,000 psi.
3. No signs of damage. 3. Pump controls are not 3. Adjust pressure compen-
adjusted properly. sator or stroke limiter.
c. Pump noisy. 1. Sump contains air 1. Pump suction line is not 1. Repair/seal pump suction
bubbles. sealed properly allowing air line.
to enter.

5-3
SG811-BV-MMA-010

Table 5-3. Hydraulic Pump Fault Isolation - Continued

SYMPTOM IMMEDIATE ACTION PROBABLE CAUSE REMEDY

2. Pump case and return line 2. Catastrophic failure of 2. Repair/replace pump
may be hot and particles pump. using SIMA or DEPOT
found in HP and LP filters. facility.

Table 5-4. Winch Fault Isolation

SYMPTOM IMMEDIATE ACTION PROBABLE CAUSE REMEDY
a. Winch does not operate Observe if winch operates Defective servo valve. Replace servo valve. (Refer
from control joystick. (Refer when servo valve is operated to paragraph 6-4.15.10.)
to figure 5-2.) manually. (Repair at intermediate
level.)
b. Winch does not operate 1. Check ECU for 24 vac 1. Defect in control joystick. 1. Replace control joystick.
from control joystick. (Refer output to servo valve. (Refer to paragraph
to figure 5-2.) 6-4.5.10.)
2. Check servo valve for 24 2. Defect in electronic con- 2. Fault isolate ECU. (Refer
volt direct current (vdc). trol unit (ECU). to table 5-7).
c. Winch does not operate 1. Check antishock valve 1. Defective antishock valve. 1. Replace antishock valve.
smooth. (Refer to figure operation. (Refer to paragraph
5-2.) 6-4.15.13.)
2. Check if winch locks 2. Defective overcenter 2. Replace overcenter valve.
when changing direction. valve. (Refer to paragraph
6-4.15.11.)
3. Check output is present 3. Defect in ECU. 3. Fault isolate ECU. (Refer
from tachometer. to table 5-7.)
d. The winch does not rotate 1. Check manual valve 1. Valve (69, figure FO-3 or 1. Align valves in accor-
when the operator rotates alignment. figure FO-4) blocking flow dance with table 2-8.
the joystick. to winch circuit.
2. Check mechanical and 2. Faulty joystick compo- 2. Replace joystick. (Refer
electrical connections to joy- nent, potentiometer, power to paragraph 6-4.5.10.)
stick components. Check supply, or wiring.
power supply voltages and
joystick output voltages.
3. Check operation of the 3. Defective servo valve, 3. Replace servo valve.
servo valve using manual electrical input or wiring. (Refer to paragraph
(butterfly lever. Check servo 6-4.15.10).
valve input voltages and
electrical connections.
4. Servo valve operates 4. Defective double control 4. Replace defective double
manually. valve (3, figure FO-3 or control valve (3, figure FO-3
figure FO-4) (brake valve). or figure FO-4) (brake
valve).
5. Manual valve alignment is 5. Defective hydraulic brake 5. Replace defective brake
correct and servo valve oper- piston or cylinder seals. piston/cylinder seals.
ates manually.
6. Check for heat at 6. Antishock valve (5, figure 6. Remove antishock valve
antishock valve manifold. FO-3 or figure FO-4) is not (5, figure FO-3 or figure
set to proper value. FO-4) and verify setting
using test bench. Install in
system.

5-4
 SG811-BV-MMA-010

Table 5-4. Winch Fault Isolation - Continued

SYMPTOM IMMEDIATE ACTION PROBABLE CAUSE REMEDY

7. Defective antishock valve 7. Disassemble each valve
(5, figure FO-3 or figure (5, figure FO-3 or figure
FO-4). (Possible cross port FO-4) and note condition of
leakage). all components especially
moveable parts, seats, and
seals. Replace defective
antishock valve components
and assembly.
8. Defective overcenter valve 8. Disassemble overcenter
(7, figure FO-3 or figure valve (7, figure FO-3 or
FO-4). figure FO-4) and note condi-
tion of all components espe-
cially moveable parts, seats
and seals. Replace defective
overcenter valve components
and assembly.
9. Check for heat on motor 9. Defective hydraulic motor. 9. Replace defective hydrau-
especially motor case line lic motor.
during rotation. Check LP
filter element for metallic
particles.
e. The winch does not stop 1. Defective double control 1. Replace defective double
immediately when the joy- valve (3, figure FO-3 or control valve (3, figure FO-3
stick is returned to nuetral figure FO-4) (brake valve) or figure FO-4) (brake
position. possibly not shifting, block- valve).
ing fluid to brake.
2. Defective hydraulic brake 2. Replace defective brake
piston or cylinder seals. piston/cylinder seals.
3. The winch servo valve (6, 3. Adjust the winch servo
figure FO-3 or figure FO-4) valve (6, figure FO-3 or
mechanical null requires figure FO-4) mechanical null
adjustment. to provide equal maximum
speed for up and down.
f. Hoist speed is faster than 1. The winch servo valve (6, 1. Adjust the winch servo
lower speed or vice versa. figure FO-3 or figure FO-4) valve (6, figure FO-3 or
mechanical null requires figure FO-4) mechanical null
adjustment. to provide equal maximum
speed for up and down.
g. Winch wire rope is 1. Measure drift of sus- 1. The winch servo valve (6, 1. Adjust the winch servo
observed to drift when a pended load. Maximum figure FO-3 or figure FO-4) valve (6, figure FO-3 or
load is applied. (No com- allowed for static load is 1 null may not be zeroed prop- figure FO-4) mechanical
mand given by operator). inch. erly. null.
h. Suspended load falls to 1. Check no load operation 1. Defective one way clutch 1. Replace one way clutch
deck/pier. of winch braking. in winch hydraulic brake assembly and zero servo
assembly and servo valve valve null.
null is not zeroed properly.

5-5
SG811-BV-MMA-010

Table 5-5. Slewing Control Fault Isolation

SYMPTOM IMMEDIATE ACTION PROBABLE CAUSE REMEDY
Boat Crane does not rotate. 1. Check if slew ring lock- 1. Slew ring locking assem- 1. Disengage slew ring
(Refer to figure 5-3.) ing assembly is disengaged. bly engaged. assembly. (Refer to figure
2-5.)
2. Check if noise is evident 2. Defective double control 2. Return valves to original
at rotation drive units and valve (2, figure FO-3 or position and and replace
open ball valve (45, figure figure FO-4). double control valve (2,
FO-3 or figure FO-4) and figure FO-3 or figure FO-4).
close ball valve (44, figure (Refer to paragraph
FO-3 or figure FO-4). 6-4.15.11.)
3. Check for flowing 3. Defective antishock valve 3. Replace antishock valve
hydraulic noise at antishock (33, figure FO-3 or figure (33, figure FO-3 or figure
valve (33, figure FO-3 or FO-4). FO-4). (Refer to paragraph
figure FO-4). 6-4.15.13.)
4. Check that slewing con- 4. Slewing control servo 4. Remove and replace.
trol joystick voltage is valve (36, figure FO-3 or (Refer to paragraph
present at slewing control figure FO-4) defective. 6-4.15.10.) (Repair at inter-
servo valve. mediate level.)
5. Check that slewing con- 5. Slewing control joystick 5. Replace control joystick
trol joystick voltage is (39, figure FO-3 or figure (39, figure FO-3 or figure
present at terminal board FO-4) defective. FO-4). (Refer to paragraph
below control panel. 6-4.5.10.)
6. Check for defective fuses 6. Fuses defective. 6. Replace fuses. (Refer to
in ECU. Figure FO-9.)
7. Check rotation of crane. 7. Defective ECU. 7. Replace ECU. (Refer to
paragraph. 6-4.5.11.)
8. Check if rotation is nor- 8. Defective overcenter valve 8. Replace overcenter valve
mal. (32, figure FO-3 or figure (32, figure FO-3 or figure
FO-4). FO-4). (Refer to paragraph
6-4.15.11.)
9. Check if hydraulic motor 9. Defective hydraulic motor 9. Replace hydraulic motor
drive unit is hot to the (31, figure FO-3 or figure (31, figure FO-3 or figure
touch. FO-4). FO-4). (Refer to paragraph
6-4.10.1.) (Repair
atintermediate level.)
10. Check if crane rotation 10. Defective hydraulic 10. Remove, replace and
is normal. brake (60, figure FO-3 or repair hydraulic brake (60,
figure FO-4). figure FO-3 or figure FO-4)
at intermediate level. (Refer
to paragraph 6-4.11.)
11. Check if crane rotation 11. Defective drive unit, 11. Remove and replace at
is normal. reduction gear. intermediate level. (Refer to
paragraph 6-4.12.) (Repair at
depot.)
12. Check rotation of crane. 12. Defective slew ring. 12. Remove, repair and
replace at depot level. (Refer
to paragraph 6-4.9.)
13. Check if slew limit relay 13. Defective slew limit 13. Replace/adjust slew limit
is energized. (MHC 52, 55, proximity switch or sensing proximity switch or sensing
58 & 59) plate. plate.

5-6
 SG811-BV-MMA-010

Table 5-5. Slewing Control Fault Isolation - Continued

SYMPTOM IMMEDIATE ACTION PROBABLE CAUSE REMEDY

b. Boat Crane does not stop 1. Test if 24 vdc is not 1. Slew limit relays are not 1. Check and fix the 24 vdc
when proximity switch is present between TB-6 and energized. power supply in the ECU.
within 1/2″ of sensing dis- TB-11 in the slew limit (Refer to figure FO-9).
tance of sensing plate. (See relay box. (Refer to figure
figure 5-9.) (MHC 52, 55, FO-6.)
58 & 59)
2. Test if 24 vdc is not 2. Defective cw slew limit 2. Replace or adjust cw slew
present between TB-11 and proximity switch and/or its limit proximity switch and/or
TB-12 in the slew limit sensing plate. its sensing plate.
relay box. (Refer to figure
FO-6).
3. Test if 24 vdc is not 3. Defective slew limit relay 3. Replace slew limit relay
present between TB-11 and No. 1 (cw) in the slew limit No. 1 (cw) in the slew limit
TB-12 in the slew limit relay box. relay box.
relay box. (Refer to figure
FO-6).
4. Test if 24 vdc is not 4. Defective ccw slew limit 4. Replace or adjust ccw
present between TB-5 and proximity switch and/or its slew limit proximity switch
TB-11 in the slew limit sensing plate. and/or its sensing plate.
relay box. (Refer to figure
FO-6).
5. Test if 24 vdc is not 5. Defective slew limit relay 5. Replace slew limit relay
present between TB-5 and No. 2 (ccw) in the slew limit No. 2 (ccw) in the slew limit
TB-11 in the slew limit relay box. relay box.
relay box. (Refer to figure
FO-6).
c. The turret does not slew 1. Check manual valve 1. Manual slew bypass 1. Align valves properly and
when the operator rotates the alignment and slew locking valve, (45, figure FO-3 or ensure slew lock lever is
joystick. lever. figure FO-4) may be disengaged.
engaged or slew brake valve
(44, figure FO-3 or figure
FO-4) (normally open) is
closed.
2. Check mechanical and 2. Faulty joystick compo- 2. Replace joystick. (Refer
electrical connections to joy- nent, potentiometer, power to paragraph 6-4.5.10)
stick components. Check supply, or wiring.
power supply voltages and
joystick output voltages.
3. Check operation of the 3. Defective servo valve (36, 3. Replace servo valve (36,
servo valve using mechani- figure FO-3 or figure FO-4) figure FO-3 or figure FO-4)
cal (butterfly) handle. Check electrical input or wiring. (Refer to paragraph
servo valve input voltages 6-4.15.10.)
and electrical connections.

5-7
SG811-BV-MMA-010

Table 5-5. Slewing Control Fault Isolation - Continued

SYMPTOM IMMEDIATE ACTION PROBABLE CAUSE REMEDY

4. Temporarily close valve 4. Defective double control 4. Replace defective double
(44, figure FO-3 or figure valve (2, figure FO-3 or control valve (2, figure FO-3
FO-4) and open valve (43, figure FO-4) (slew brake or figure FO-4) (slew brake
figure FO-3 or figure FO-4) valve) may be blocking flow valve).
to operate brake. (Rotate to brake.
joystick minimum to observe
rotation and turn electric
motor off.)
5. Valve alignment is correct 5. Defective hydraulic brake 5. Replace defective brake
and servo valve operates piston or cylinder seals. piston/cylinder seals.
mechanically.
6. Check for heat at 6. Antishock valve (33, 6. Remove antishock valve
antishock valve manifold. figure FO-3 or figure FO-4) (33, figure FO-3 or figure
is not set to proper value. FO-4) and verify setting
using test bench. Install in
system.
7. Defective antishock valve 7. Disassemble each valve
(33, figure FO-3 or figure (33, figure FO-3 or figure
FO-4). (Possible cross port FO-4) and note condition of
leakage). all components especially
moveable parts, seats, and
seals. Replace defective
antishock valve (33) compo-
nents or assembly.
8. Defective overcenter valve 8. Disassemble valve (32,
(32, figure FO-3 or figure figure FO-3 or figure FO-4)
FO-4). and note condition of all
components especially
moveable parts, seats, and
seals. Replace defective
overcenter valve components
or assembly.
9. Check for heat on motor 9. Defective hydraulic motor 9. Replace defective hydrau-
especially motor case line (31, figure FO-3 or figure lic motor (31, figure FO-3 or
during rotation. Check LP FO-4). figure FO-4).
filter element for metallic
particles.
d. The turret does not stop 1. Check manual valve 1. Brake is not setting due to 1. Close valve (43, figure
immediately when the joy- alignment. manual valve (43, figure FO-3 or figure FO-4).
stick is returned to nuetral FO-3 or figure FO-4) is
position. open.
2. Defective double control 2. Replace defective double
valve (2, figure FO-3 or control valve (2, figure FO-3
figure FO-4) (slew brake or figure FO-4) (slew brake
valve). valve).

5-8
 SG811-BV-MMA-010

Table 5-5. Slewing Control Fault Isolation - Continued

SYMPTOM IMMEDIATE ACTION PROBABLE CAUSE REMEDY

3. Temporarily close valve 3. Defective hydraulic brake 3. Replace defective brake
(44, figure FO-3 or figure (60, figure FO-3 or figure (60, figure FO-3 or figure
FO-4) and bleed any pres- FO-4) piston or cylinder FO-4) piston/cylinder seals.
surized fluid from brake. seals.
(This will set brake.)
Observe for brake slip with
minimal slew command.
4. The slew servo valve (36, 4. Adjust the slew servo
figure FO-3 or figure FO-4) valve (36, figure FO-3 or
mechanical null requires figure FO-4) mechanical null
adjustment. to provide equal maximum
speed right or left.
e. Slew speed is faster in 1. The slew servo valve (36, 1. Adjust the slew servo
one direction than the other. figure FO-3 or figure FO-4) valve (36, figure FO-3 or
mechanical null requires figure FO-4) mechanical null
adjustment. to provide equal maximum
speed right or left.

Table 5-6. Control Systems Fault Isolation

SYMPTOM IMMEDIATE ACTION PROBABLE CAUSE REMEDY
a. Boat crane does not move 1. Check if crane will move 1. Defective slewing opera- 1. Fault isolate crane
with slew control joystick. with manual valve control. tion. slewing (refer to table 5-5.)
(Refer to figure 5-4.)
2. Check fuses and output 2. Defective ECU. 2. Fault isolate ECU. (Refer
voltage from ECU. (Refer to to table 5-7.)
figure FO-9).
b. Main boom does not 1. Check if main boom will 1. Defective main boom 1. Fault isolate hydraulic
move with main boom con- move with manual valve hydraulic system. system. (Refer to table
trol joystick. (Refer to figure control. 5-10.)
5-4.)
2. Check fuses and output 2. Defective ECU. 2. Fault isolate ECU. (Refer
voltage from ECU. (Refer to to table 5-7.)
figure FO-9.)
c. Jib boom does not move 1. Check if jib boom will 1. Defective jib boom 1. Fault isolate hydraulic
with jib boom control joy- move with manual valve hydraulic system. system. (Refer to table
stick. (Refer to figure 5-4.) control. 5-10.)
2. Check fuses and output 2. Defective ECU. 2. Fault isolate ECU. (Refer
voltage from ECU. (Refer to to table 5-7.)
figure FO-9.)
d Winch does not move with 1. Check if winch will move 1. Defective winch hydraulic 1. Fault isolate hydraulic
winch control joystick. with manual valve control. system. system. (Refer to table
(Refer to figure 5-4.) 5-10.)
2. Check fuses and output 2. Defective ECU. 2. Fault isolate ECU. (Refer
voltage from ECU. (Refer to to table 5-7.)
figure FO-9.)
e. All controls are inopera- 1. Check if 115 vac is 1. Defect in motor starter. 1. Fault isolate motor starter.
tive. (Refer to figure 5-4.) present at ECU connector J3. (Refer to table 5-9.)
(Refer to figure FO-9.)

5-9
SG811-BV-MMA-010

Table 5-6. Control Systems Fault Isolation - Continued

SYMPTOM IMMEDIATE ACTION PROBABLE CAUSE REMEDY

2. Check that 24 vdc is 2. Defective fuses in ECU. 2. Replace fuses. (Refer to
present at ECU terminal figure FO-9.)
board TB1. (Refer to figure
FO-9.)
3. Check that 24 vdc is 3. Defective cable W-7. 3. Replace cable W-7. (Refer
present on ECU connector to figure FO-9.)
J4. (Refer to figure FO-9.)
4. Check cable W7 for 24 4. Defective ECU. 4. Fault isolate ECU. (Refer
vdc. (Refer to figure FO-6.) to table 5-7.)

Table 5-7. Electronic Control Unit Fault Isolation

SYMPTOM IMMEDIATE ACTION PROBABLE CAUSE REMEDY
No output voltage from 1. Check if 115 vac is 1. No voltage, defect in 1. Fault isolate motor starter.
ECU. (Refer to figure 5-5.) present at connector J3. motor starter. (Refer to table 5-9.)
(Refer to figure FO-9.)
2. Check if 115 vac is 2. No voltage, defect in dirty 2. Replace dirty box. (Refer
present at dirty box. (Refer box. to paragraph 6-4.5.12.4.)
to figure FO-9.)
3. Check fuses F1 and F2. 3. Defective fuses. 3. Replace fuses. (Refer to
(Refer to figure FO-9.) figure FO-9.)
4. Check if 32 vac is present 4. No voltage at output 4. Replace transformer
on transformer (TO48, figure defective trensformer (TO48, (TO48). (Refer to figure
FO-9) output. figure FO-9.) FO-9.)
5. Check if 24 vdc is present 5. No voltage at TB4. 5. Replace CST 102. (Refer
at TB4, pins 1 and 8 on CST to figure FO-9.)
102, (figure FO-9.)
6. Check if 24 vdc is present 6. No voltage at pins 20 and 6. Replace CST 103. (Refer
at pins 20 and 8 on CST 8. to figure FO-9.)
103, (figure FO-9.)
7. Check if 24 vdc is present 7. No voltage at J4 pins F 7. Replace dirty box. (Refer
at connector J4 pins F and S and S. to paragraph 6-4.5.12.4.)
on dirty box. (Refer to figure
FO-9.)
8. Check if 24 vdc is present 8. Defective cable W7. 8. Replace cable W7. (Refer
at TB-1 pin 18.(Refer to to figure FO-6 and figure
figure FO-9.) FO-9.)

Table 5-8. Control Panel Fault Isolation

SYMPTOM IMMEDIATE ACTION PROBABLE CAUSE REMEDY
a. Boat Crane inoperative. 1. Check continuity at con- 1. No continuity at pins, 1. Replace S2 ″MOTOR
(Refer to figure 5-6.) nector J6 pins W and V with defective switch. ON″ switch. (Refer to
″MOTOR ON″ switch paragraph 6-4.5.4.)
depressed. (Refer to figure
FO-6.)

5-10
 SG811-BV-MMA-010

Table 5-8. Control Panel Fault Isolation - Continued

SYMPTOM IMMEDIATE ACTION PROBABLE CAUSE REMEDY

2. Check for continuity at S3 2. No continuity at terminals 2. Replace switch S3. (Refer
MOTOR OFF switch termi- C and NC. Defective switch to paragraph 6-4.5.4.)
nals C and NC. (Refer to S3.
figure FO-8.)
3. Check for continuity at 3. No continuity at pins. 3. Replace switch S2. (Refer
connector J6 pins W and V Defective Switch S2. to paragraph 6-4.5.4.)
with ″MOTOR OFF.″ (Refer
to figure FO-6.)
4. Check for continuity 4. No continuity at terminals 4. Replace switch S1. (Refer
between terminals C and NC C and NC. Defective switch to paragraph 6-4.5.4.)
on switch S1 EMERGENCY S1.
ON switch. (Refer to figure
FO-8.)
5. Check for continuity at 5. No continuity at pins, 5. Replace cable W4. (Refer
connector J6 pins V and U. defective cable W4. to figure FO-8.)
(Refer to figure FO-6).
6. Check control panel inter- 6. Open in control panel wir- 6. Replace internal wiring.
nal wiring. ing. (Refer to figure FO-8.)
b. Day/Night function defec- 1. Check continuity between 1. No continuity between 1. Replace switch S4. (Refer
tive. (Refer to figure 5-6.) switch S4 terminal C and terminal C and pin Z, defec- to paragraph 6-4.5.4.)
connector J6 pin Z, with tive switch S4.
switch S4 depressed. (Refer
to figure FO-6.)
2. Check continuity between 2. No continuity between 2. Replace switch S4. (Refer
switch S4 terminal C and terminal C and pin X, defec- to paragraph 6-4.5.4.)
connector J6 pin X with tive switch S4.
switch S4 not depressed.
(Refer to figure FO-6.)
c. Indicator lights inopera- 1. Check control panel inter- 1. Open in wiring. 1. Replace wiring. (Refer to
tive. (Refer to figure 5-6.) nal wiring and connections. figure FO-6.)
2. Check if indicator lights 2. Lights operate by substitu- 2. Return control to system
operate by substitution. tion. readiness.

Table 5-9. Electric Motor Starter Fault Isolation

SYMPTOM IMMEDIATE ACTION PROBABLE CAUSE REMEDY
a. Control panel indicators 1. Check if fuses F5 and F6 1. Fuses defective. 1. Replace defective fuses.
do not illuminate for motor are defective. (Refer to FO-7.)
STARTER ALARM, THER-
MAL ALARM, MOTOR
ON, MOTOR OFF, ELEC-
TRIC POWER on and
BATTLE SHORT on. (Refer
to figure 5-7 and FO-7.)
2. Continuity check of indi- 2. Continuity check shows 2. Replace wiring. (Refer to
cator lamp circuitry. defect in wiring. figure FO-6.)
b. No 115 vac to electronic 1. Check fuses F5 and F6 for 1. Fuses defective. 1. Replace fuses, (refer to
control unit. (Refer to figure open. paragraph 6-4.5.14.5.)
5-7 and FO-7.)

5-11
SG811-BV-MMA-010

Table 5-9. Electric Motor Starter Fault Isolation - Continued

SYMPTOM IMMEDIATE ACTION PROBABLE CAUSE REMEDY

2. Check 115 vac from trans- 2. Transformer TR1 defec- 2. Replace transformer TR1.
former TR1. tive. (Refer to FO-7.)
3. Check 115 vac at F5 and 3. Voltage present. 3. Replace cable W6.
F6.
c. No 450 vac to electric 1. Check fuses F1 and F2 for 1. Fuses defective. 1. Replace fuses. (Refer to
motor. (Refer to figure 5-7 open. FO-7.)
and FO-7.)
2. Check contactor coil for 2. Contactor coil defective.
2. Replace contactor coil.
open. (Refer to paragraph
6-4.5.14.2.)
3. Check for 115 vac from 3. No voltage at transformer 3. Replace transformer TR1.
transformer TR1. TR1. (Refer to paragraph
6-4.5.14.4.)
4. Check contacts of thermal 4. Open contacts. 4. Replace thermal alarm
alarm relay R2 for for open. relay R2. (Refer to
paragraph 6-4.5.14.3.)
5. Check overload contacts 5. Overload trip switch open. 5. Reset overload tripped
for open. switch.
6. Check overload contacts 6. Overload contacts did not 6. Replace overload relay
are closed. close. OL1. (Refer to paragraph
6-4.5.14.1.)

Table 5-10. Hydraulic System Fault Isolation

SYMPTOM IMMEDIATE ACTION PROBABLE CAUSE REMEDY
Hydraulic pressure is low. 1. Check operation of pump. 1. Defect in pump. 1. Repair pump. (Refer to
(Refer to figure 5-8.) paragraph 6-4.13.)
2. Check the level of 2. Defect in system. 2. Check system for leaks.
hydraulic fluid in sump. (Refer to figure FO-3 or
figure FO-4.)
Hydraulic pressure is low. 3. Check if system lines up. 3. Defect in system line up. 3. Line up system.
(Refer to figure 5-8.)
4. Check for a clogged filter. 4. Filter clogged. 4. Replace filter. (Refer to
paragraph 6-4.15.7.)
5. Check if relief valve is 5. Defective relief valve. 5. Replace relief valve.
hot. (Refer to paragraph
6-4.15.12.) (Repair at inter-
mediate level.)

Table 5-11. Main Boom Cylinder Fault Isolation

SYMPTOM IMMEDIATE ACTION PROBABLE CAUSE REMEDY
a. Main boom cylinder does 1. Check mechanical and 1. Faulty joystick (40, figure 1. Check power supply volt-
not extend or retract when electrical connections to joy- FO-3 or figure FO-4) com- ages and joystick (40, figure
the joystick is moved (up or stick (40, figure FO-3 or ponent, potentiometer, power FO-3 or figure FO-4) output
down direction). figure FO-4) components. supply or wiring. voltages. Replace joystick
(40, figure FO-3 or figure
FO-4.) (Refer to paragraph
6-4.5.10.)

5-12
 SG811-BV-MMA-010

Table 5-11. Main Boom Cylinder Fault Isolation - Continued

SYMPTOM IMMEDIATE ACTION PROBABLE CAUSE REMEDY

2. Check operation of the 2. Defective servo valve 12, 2. Check servo valve 12
servo valve 12 using electrical input or wiring. input voltages. Replace
mechanical (butterfly) servo valve. (Refer to
handle. Check servo valve paragraph 6-4.15.10).
mechanical and electrical
connections.
b. Main boom cylinder does 1. Check for heat at 1. Antishock valve (34, 1. Remove antishock valve
not extend or retract when antishock valve (34, figure figure FO-3 or figure FO-4) (34, figure FO-3 or figure
the joystick is moved (in or FO-3 or figure FO-4) mani- is not set to proper value. FO-4) and verify setting
out direction). fold. (Possible cross port using test bench. Install in
leakage). system.
NOTE
Joystick, servo valve
and associated controls
and wiring are not
defective.
2. Defective antishock valve 2. Disassemble each valve
(34, figure FO-3 or figure and note condition of all
FO-4). components especially
moveable parts, seats and
seals. Replace defective
antishock valve components
or assembly.
3. Defective over center 3. Disassemble valve and
valve (21, figure FO-3 or note condition of all compo-
figure FO-4). nents especially moveable
parts, seats and seals.
Replace defective over cen-
ter valve components or
assembly.
c. Main boom cylinder is 1. Defective cylinder (20, 1. Replace cylinder (20,
sluggish when extending or figure FO-3 or figure FO-4) figure FO-3 or figure FO-4)
retracting when the joystick piston seals. seals if cylinder bore and
is moved. piston rod are in good con-
dition. If rod or cylinder
surfaces are questionable
repair or replace.
2. Check mechanical appear- 2. Mechanical problem in 2. Repair cylinder pivots.
ance and motion. joint or cylinder. Repair or replace cylinder.
d. Main boom cylinder 1. Adjust restrictor valves 1. Defective, contaminated Clean restrictor valve (57,
oscillates when the joystick (57, figure FO-3 or figure or misadjusted restrictor figure FO-3 or figure FO-4)
is moved in the down direc- FO-4) to (cw) to reduce flow (flow control) valves (57, internals or replace valves.
tion. in pilot stage of overcenter figure FO-3 or figure FO-4.)
valves.

5-13
SG811-BV-MMA-010

Table 5-11. Main Boom Cylinder Fault Isolation - Continued

SYMPTOM IMMEDIATE ACTION PROBABLE CAUSE REMEDY

e. Main boom is observed to 1. Place tape on rod and 1. Drift/slippage in excess of 1. Repair or replace a defec-
drift (top down) when a load note position change relative 1 inch requires isolation of tive overcenter valve (21,
is applied to boom (No to cylinder with a static load the cylinder or winch figure FO-3 or figure FO-4.)
command given by opera- applied to the wire rope responsible. A defective
tor). thimble. overcenter valve (21, figure
FO-3 or figure FO-4) will
cause excessive drift.
f. Main boom topping speed 1. The main boom servo 1. Adjust the main boom
is faster in one direction valve (12, figure FO-3 or servo valve (12, figure FO-3
than the other. figure FO-4) mechanical null or figure FO-4) mechanical
requires adjustment. null to provide equal maxi-
mum speed for up and
down.

Table 5-12. Jib Boom Cylinder Fault Isolation

SYMPTOM IMMEDIATE ACTION PROBABLE CAUSE REMEDY
a. Jib boom cylinder does 1. Check mechanical and 1. Faulty joystick compo- 1. Replace joystick. (Refer
not extend or retract when electrical connections to joy- nent, potentiometer, power to paragraph 6-4.5.10).
the joystick is moved (in or stick (17, figure FO-3 or supply or wiring.
out direction). figure FO-4) components.
Check power supply volt-
ages and joystick output
voltages.
2. Check operation of the 2. Defective servo valve (37, 2. Replace servo valve.
servo valve (37, figure FO-3 figure FO-3 or figure FO-4) (Refer to paragraph
or figure FO-4) using electrical input or wiring. 6-4.15.10.)
mechanical (butterfly)
handle. Check servo valve
input voltages and electrical
connections.
b. Jib boom cylinder does 1. Check for heat at 1. Antishock valve (35, 1. Remove antishock valve
not extend or retract when antishock valve manifold. figure FO-3 or figure FO-4) (35, figure FO-3 or figure
the joystick is moved (in or (Possible cross port leakage). is not set to proper value. FO-4) and verify setting
out direction). using test bench. Install in
system.
NOTE
Joystick, servo valve
and associated controls
and wiring are not
defective.
2. Defective antishock valve 2. Disassemble each valve
(35, figure FO-3 or figure (35, figure FO-3 or figure
FO-4). FO-4) and note condition of
all components especially
moveable parts, seats and
seals. Replace defective
antishock valve components
or assembly.

5-14
 SG811-BV-MMA-010

Table 5-12. Jib Boom Cylinder Fault Isolation - Continued

SYMPTOM IMMEDIATE ACTION PROBABLE CAUSE REMEDY

3. Defective over center 3. Disassemble valve (23,
valve (23, figure FO-3 or figure FO-3 or figure FO-4)
figure FO-4). and note condition of all
components especially
moveable parts, seats and
seals. Replace defective over
center valve components or
assembly.
c. Jib boom cylinder is slug- 1. Defective cylinder (22, 1. Replace cylinder (22,
gish when extending or figure FO-3 or figure FO-4) figure FO-3 or figure FO-4)
retracting when the joystick piston seals. seals if cylinder bore and
is moved. piston rod are in good con-
dition. If rod or cylinder
surfaces are questionable
repair or replace.
2. Check mechanical appear- 2. Mechanical problem in 2. Repair cylinder pivots.
ance and motion. joint or cylinder. Repair or replace cylinder.
d. Jib boom is observed to 1. Place tape on rod and 1. Drift/slippage in excess of 1. Repair or replace a defec-
drift (top down) when a load note position change relative 1 inch requires isolation of tive overcenter valve (23,
is applied to boom (No to cylinder with a static load the cylinder or winch figure FO-3 or figure FO-4).
command given by opera- applied to the wire rope responsible. A defective
tor). thimble. overcenter valve (23, figure
FO-3 or figure FO-4) will
cause excessive drift.
e. Jib boom topping speed is 1. The Jib boom servo valve 1. Adjust the Jib boom servo
faster in one direction than (37, figure FO-3 or figure valve (37, figure FO-3 or
the other. FO-4) mechanical null figure FO-4) mechanical null
requires adjustment. to provide equal maximum
speed for up and down.

5-15
SG811-BV-MMA-010

Figure 5-1. Boat Crane Fault Logic Diagram (Sheet 1 of 2)

5-16
 SG811-BV-MMA-010

Figure 5-1. Boat Crane Fault Logic Diagram (Sheet 2 of 2)

5-17
SG811-BV-MMA-010

Figure 5-2. Winch Fault Logic Diagram

5-18
 SG811-BV-MMA-010

Figure 5-3. Crane Slewing Fault Logic Diagram (Sheet 1 of 2)

5-19
SG811-BV-MMA-010

Figure 5-3. Crane Slewing Fault Logic Diagram (Sheet 2 of 2)

5-20
 SG811-BV-MMA-010

Figure 5-4. Control System Fault Logic Diagram.

5-21
SG811-BV-MMA-010

Figure 5-4. Control System Fault Logic Diagram (Sheet 2 of 2)

5-22
 SG811-BV-MMA-010

Figure 5-5. Electronic Control Unit Fault Logic Diagram

5-23
SG811-BV-MMA-010

Figure 5-6. Control Panel Fault Logic Diagram (Sheet 1 of 2)

5-24
 SG811-BV-MMA-010

Figure 5-6. Control Panel Fault Logic Diagram (Sheet 2 of 2)

5-25
SG811-BV-MMA-010

Figure 5-7. Motor Starter Fault Logic Diagram (Sheet 1 of 2)

5-26
 SG811-BV-MMA-010

Figure 5-7. Motor Starter Fault Logic Diagram (Sheet 2 of 2)

5-27
SG811-BV-MMA-010

Figure 5-8. Hydraulic System Fault Logic Diagram.

5-28
 SG811-BV-MMA-010
5-29 / (5-30 Blank)

Figure 5-9. Crane Slewing Limit Fault Logic Diagram. (MHC 52, 55, 58, & 59)
5-30
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

CHAPTER 6

CORRECTIVE MAINTENANCE

SECTION I
ADJUSTMENTS AND CALIBRATION PROCEDURES

6-1. INTRODUCTION.

This chapter provides organizational, intermediate, and depot level corrective maintenance procedures for the
boat crane. Detailed instructions, with illustrations referenced, describe and show how to perform the required
maintenance.

WARNING

Shipboard tagout procedures must be followed when tagging equipment

″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel.

6-2. ADJUSTMENTS/CALIBRATION.

Maintenance procedures are presented in two sections. Section I provides necessary adjustment and calibra-
tion procedures. Section II provides the procedures necessary to remove, disassemble, repair, replace, reassemble,
and reinstall the boat crane components.

The adjustment and calibration procedures are provided in paragraph 6-2.1 through 6-2.6 and consist of the
following:

a. Servo Valve Null (Mechanical) Adjustment.

b. Pump Compensator Adjustment.

c. Relief Valve (Solenoid-Controlled) Adjustment.

d. Geared Limit Switch Adjustment.

e. Hydraulic Valve Adjustment (Post-Repair, Prior to Installation in System).

f. Gauge Calibration.

6-2.1 Servo Valve Null (Mechanical) Adjustment. This adjustment may be necessary for the winch, main boom,
jib boom, and slew servo valves. It should be accomplished when the speeds of any of these assemblies are faster
in one direction than the other direction (speed balance). The speed difference may be effected somewhat by load.
If the slew or winch servo valve are out of adjustment significantly, the brake may release somewhat allowing
movement of the winch or turret.

6-1
SG811-BV-MMA-010

CAUTION

Adjust the servo valves in small increments. Verify direction of adjustment

provides speed balance or increase in speed in one direction at release point.

a. Ensure no load is on the crane and movement of the crane will avoid all obstacles and ships structure.
b. Remove the slotted screw on the cap of the servo valve which requires adjustment.
c. Using an allen wrench, adjust the set screw approximately 1/8 to 1/4 turn clockwise.
d. Test operate the crane to verify direction of adjustment provides speed balance or note increase in speed dif-
ference (i.e. compare right rotation speed to left rotation speed of turret).
e. Continue servo valve null set screw adjustment if required. If the speed difference (difference between both
directions) has increased, adjust 1/8 to 1/4 turns in the counterclockwise direction. If test indicates a decrease
in speed difference, adjust in clockwise direction.
f. Repeat step d. if adjustment was made per step e.
g. If the speeds appear to be balanced (very little visible difference in speed) install the slotted screw in the cap
of the servo valve.

6-2.2 Pump Compensator Adjustment. This adjustment may be necessary due to repair or symptoms indicating
it is not adjusted properly such as the pressure gauge showing pressure less than or greater than 3,000 psi. Dur-
ing startup, the relief valve solenoid is energized for approximately 3 seconds, causing the pump compensator to
pump full volume to the sump via the relief valve at minimum pressure (near zero psi).
To set the pump compensator to 3,000 psi, it must be set in conjunction with the relief valve as described in
paragraph 6-2.3.

6-2.3 Relief Valve (Solenoid-Controlled) Adjustment. This adjustment may be necessary due to repair or symp-
toms indicating it is not adjusted properly such as excessive heat is noted at the valve body. Additionally, this
valve will need to be set once installed in the system if installed new. A flow noise may also be noted indicat-
ing the valve is relieving. It is normal for flow (full pump volume) to pass through this valve on startup of the
electric motor. During startup, the solenoid is energized for approximately 3 seconds, causing the pump flow to
be directed to sump at minimum pressure (near zero psi) This valve should not open during normal operation.
This valve should only be set by qualified hydraulic technicians since system damage may result if valve mal-
functions or procedure is not fully followed or understood.

a. Depress the motor ON pushbutton and allow the system to operate until hydraulic fluid temperature reaches
100-110 degrees F.
b. Remove the cover to the main pump.
c. Set main system relief valve pressure.
1. Deenergize the main pump.
2. Loosen the pressure compensator jamnut and turn adjustment screw counterclockwise 2 full turns. (See
figure 3-1.)
3. Loosen main system relief valve jamnut and turn adjustment screw clockwise 1 full turn. (See figure 3-2.)

6-2
 SG811-BV-MMA-010

CAUTION

Do not allow the system to run for more then 15 seconds before adjusting
the pressure compensator back temporarily to 3,000 psi. Operation of the
system over the relief setting for extended periods of time causes excessive
heat and can damage equipment.
4. Energize main pump.
5. Observe main system pressure.
6. Increase pressure compensator setting to 3,400 psi by turning adjustment screw clockwise. If 3,400 psi
cannot be reached, the relief valve is set too low, return to step 3 and increase one quarter turn at a time.
7. Decrease main system relief valve setting to 3,300 psi by turning adjustment screw counterclockwise while
observing main system pressure gauge and tighten jamnut.
8. 8. Decrease pressure compensator setting to 3,000 psi by turning the adjustment screw counterclockwise
while observing main system pressure gauges and tighten jamnut.

6-2.4 Geared Limit Switch Adjustment. Geared limit switch adjustment requires setting of the empty drum and
full drum limit switches.

a. Empty drum limit switch adjustment.

1. Position the crane with the main boom aft and parallel to the deck and jib boom in line with the main
boom. Position the main boom as close to the deck as possible to allow access to the limit switch mounted
on the winch. Pay out the winch until the drum stops due to the empty drum limit switch contacts open-
ing or 2-1/2 to 3 turns of wire rope remain on the drum.
2. Remove the four screws, lockwashers, cover and gasket from the adjustor shafts of the geared limit switch
assembly.
3. Remove the six screws, lockwashers, cover and gasket from the limit switch assembly.
4. Using a screwdriver, loosen the clamp locking screw, force the adjustor shaft clamp down and push the
adjustor for the empty drum contacts in so the clamp engages with the outer groove of the adjustor.
5. If the empty drum contacts are open and more than 2-1/2 and 3 wraps remain on the drum, turn the adjus-
tor clockwise (to decrease the wraps of wire rope on the drum) and the empty drum contacts close. Go to
step 8 and verify adjustment. Repeat step 5 and step 8 until the proper adjustment is obtained. If the empty
drum contacts are closed, and the winch has more than 2-1/2 to 3 wraps of wire rope on the drum, turn the
adjustor counterclockwise until the contacts open.
6. Using a screwdriver, force the adjustor shaft clamp down and pull the adjustor out so the clamp engages
with the middle groove of the adjustor. Tighten the clamp locking screw.
7. Reinstall gaskets and covers on limit switch assembly.
8. Test operate. Pay out the winch until the drum stops due to the empty drum limit switch contacts opening.
Verify 2-1/2 to 3 turns of wire rope remain on the drum.
b. Full drum limit switch adjustment.
1. Position the crane in the stowed position. Connect the hook to the stowage pad on the jib boom. Haul-in
the winch until the drum stops due to the full drum limit switch contacts opening or the wire rope is slightly
tensioned.
2. Remove 4 screws, lockwashers, cover and gasket from adjustor shafts of geared limit switch assembly.
3. Remove 6 screws, lockwashers, cover and gasket from limit switch assembly.

6-3
SG811-BV-MMA-010

4. Using a screw driver, loosen the clamp locking screw, and force the adjustor shaft clamp down and pull
the adjustor for the full drum limit switch out so that the clamp engages with inner groove of adjustor.
5. If the full drum limit switch contacts are closed (wire rope slightly tensioned), turn the adjustor clockwise
until the full drum limit switch contacts just open. Go to step 8 and verify adjustment. Repeat step 5 and
step 8 until proper adjustment is obtained. If the full drum limit switch contacts are open, turn the adjus-
tor counter clockwise until the contacts close. Tighten the clamp locking screw.
6. Force the adjustor shaft clamp down and pull the adjustor out so the clamp engages with the middle groove
of the adjustor. Tighten the clamp locking screw.
7. Reinstall gaskets and covers on limit switch assembly.
8. Test operate. Release the hook from the stowage pad. Haul-in the winch until the drum stops due to the
full drum limit switch contacts opening. Verify the wire rope stops in a position which corresponds to the
hook stowed position.

6-2.5 Hydraulic Valve Adjustment (Post-Repair, Prior to Installation in System). Several of the hydraulic valves
require an adjustment prior to installation and cannot be adjusted to the recommended value once installed. These
valves must be set on a hydraulics test stand or ordered from the manufacturer preset to the value listed in table
6-1. All valve pressure setting value tolerance is ± 25 psi on a test bench and ± 50 psi when set shipboard at
110-120 degrees F.

Table 6-1. Hydraulic Valve Pressure Settings

Valve Setting (bar) Setting (psi)
Pilot Operated Relief Valve (7, figure FO-3 or figure FO-4). 227.5 bar 3,300 psi
Slew Antishock Valve (33, figure FO-3 or figure FO-4). 180 bar 2,610 psi
Slew Overcenter Valve (32, figure FO-3 or figure FO-4). 140 bar 2,030 psi
Main Cylinder Antishock Valve (34, figure FO-3 or figure FO-4). 180 bar 2,610 psi
Main Overcenter Valve (21, figure FO-3 or figure FO-4). 140 bar 2,030 psi
Jib Cylinder Antishock Valve (35, figure FO-3 or figure FO-4). 180 bar 2,610 psi
Jib Overcenter Valve (23, figure FO-3 or figure FO-4). 140 bar 2,030 psi
Winch Antishock Valve (5, figure FO-3 or figure FO-4). 180 bar 2,610 psi
Winch Overcenter Valve (4, figure FO-3 or figure FO-4). 140 bar 2,030 psi

6-2.6 Gauge Calibration. The following gauges require periodic calibration per ship’s calibration requirements:

a. Pressure gauge (0-5,000 psi).

b. Sump Thermometer (0-150 degrees F).

SECTION
REPAIR PROCEDURES

6-3. BOAT CRANE REMOVAL AND INSTALLATION.

The boat cranes hydraulic system is a self air bleeding system. When power is removed from the boat crane,
the hydraulic pressure drops to zero pounds per square inch (psi). The hydraulic fluid drains from the hydraulic
system into the sump. The exception to this is the main boom and jib boom cylinders. These components retain
hydraulic fluid pressure due to the one way restriction valve (figure FO-3 or figure FO-4) to keep the main boom
and jib boom from collapsing if a loss of power occurs during crane operation and when power is removed with

6-4
 SG811-BV-MMA-010

the boat crane in the stowed position. Before performing any maintenance on the boat crane, it must be in the
stowed position. When performing maintenance on a hydraulic component, during the removal tasks there will
be residual hydraulic fluid in the component that must be cleaned up in accordance with shipboard approved
environmental procedure. All hydraulic connections must be capped or covered during the maintenance process.
Air bleeds (61 and 46) have been added per government request. Refer to figure FO-3 or figure FO-4.) Air bleeds
(61 and 46) are not needed for boat crane operation per Marine Equipment Pellegrini (MEP).
The following paragraphs provide step-by-step procedures to remove and reinstall the Boat Crane onto the
pedestal.

NOTE

Lifting eyes are required on all crane components weighing over 75 pounds.

6-3.1 Boat Crane Removal From Pedestal. Remove the boat crane from the pedestal as follows, refer to figure
FO-12 or figure FO-13:

WARNING

Before performing any maintenance action notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel.

a. Depress ″MOTOR ON″ pushbutton on control panel (215) to energize boat crane.
b. Move the main boom (67) to a horizontal position.
c. Depress the ″MOTOR OFF″ pushbutton on the control panel (215) to deenergize the boat crane.

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply may result in injury or
death to maintenance personnel.

WARNING

Ensure the slew ring locking device is engaged to prevent injury and dam-
age to equipment from boat crane movement.
d. Deenergize electrical power to crane by opening circuit breaker on the 1S switchboard located in the Central
Control Station (CCS), and tag ″OUT-OF-SERVICE.″ Refer to Ship’s Information Book (SIB) Volume 3 for
exact location of circuit breaker.

6-5
SG811-BV-MMA-010

e. Remove 14 screws (3) and washers (4) that secure access panel (2) to pedestal (1).
f. Remove access panel (2) from pedestal (1).
g. Disconnect electrical connector J1 from the wall mounting receptacle (103).
h. Install access panel (2), using 14 washers (4) and screws (3).

WARNING

Ensure the mobile crane being used to move the Boat Crane is adequate for
the weight of the boat crane as injury or death to maintenance personnel
could occur.
i. Attach mobile crane chain lifting hooks to four lifting points on boat crane (refer to chapter 8 for the lifting
point locations).

CAUTION

Care must be taken when removing the reduction gear (27) as damage to the
slew ring (10) can occur.
j. Remove reduction gear in accordance with paragraph 6-4.12.1.
k. Disengage slew ring locking device (93).
l. Remove 36 screws (11), 36 nuts (13) and 72 washers (12) that secure the turret (9) to slew ring (10).

WARNING

The lifting points for the crane reflect the center of gravity with the pedes-
tal attached. Care should be used when lifting the crane with pedestal
removed as the balance will be off. Injury to personnel could occur.
m. Lift Boat Crane turret with jib boom and main boom from the pedestal.
n. Place Boat Crane on ground, supported by blocks.

6-3.2 Boat Crane Installation on Pedestal. Install the Boat Crane on the pedestal as follows:

WARNING

The lifting points for the crane reflect the center of gravity with the pedes-
tal attached. Care should be used when lifting the crane with pedestal
removed as the balance will be off. Injury to personnel could occur.

6-6
 SG811-BV-MMA-010

CAUTION

The slew ring is made of aluminum. Care should be taken when performing
the following steps to ensure the weight of the crane is not dropped on or
does not bump the slew ring as damage to the equipment will occur.

a. Using a mobile crane, carefully place the turret (9) over the slew ring (10).
b. Slowly lower the turret down on the slew ring (10). Stop before the turret (9) is resting on or touching the
slew ring (10).

NOTE

There should be enough room to make slight movements of the crane to allow
insertion of screws (11) and washers (12) through the holes.
c. Place one screw (11), with washer (12) through one hole and place washer (12) and nut (13) onto the screw
and hand tighten.
d. Working in both directions from starting point, insert screws (11) and washers (12) into every fourth hole, with
washers (12) and nuts (13).
e. When this is completed all around the slew ring (10), go back and insert the remaining hardware.
f. Lower turret (9) down onto the pedestal (1).
g. Torque all bolts in a star pattern in accordance with table 6-2.

CAUTION

Take care when inserting pinion gear (86) attached to the reduction gear
(27). The slew ring (10) is made of aluminum and can be damaged very eas-
ily.
h. Install reduction gear with hydraulic brake (28) and hydraulic motor (29) in accordance with paragraph
6-4.12.4.
i. Remove 14 screws (3) and washers (4) securing access panel (2) to pedestal (1) and remove panel (2).
j. Connect electrical connector J1 to wall mounting receptacle (103).
k. Install access panel (2) using 14 washers (4) and screws (3).
l. Remove all tags on circuit breakers and energize circuit breakers.

Table 6-2. Boat Crane Assembly Torque Values

ITEMS FOOT-POUNDS (FT-LB) NEWTON METERS (Nm)

NOTE
Item numbers list boat crane components corresponding to figure FO-12 or figure FO-13 and chapter 7 Parts List,
table 7-3.
3 31.13 42.20
6 31.13 42.20

6-7
SG811-BV-MMA-010

Table 6-2. Boat Crane Assembly Torque Values - Continued

ITEMS FOOT-POUNDS (FT-LB) NEWTON METERS (Nm)

11 131.66 178.50
13 131.66 178.50
14 131.66 178.50
18 31.13 42.20
21 180.71 245.00
23 180.71 245.00
25 180.71 245.00
30 54.28 73.60
32 15.92 21.58
34 131.66 178.50
36 31.13 42.20
39 54.28 73.60
43 54.28 73.60
47 15.92 21.58
51 54.28 73.60
56 54.28 73.60
60 54.28 73.60
65 54.28 73.60
70 54.28 73.60
74 54.28 73.60
76 54.28 73.60
82 257.05 348.50
84 257.05 348.50
88 31.13 42.20
90 54.28 73.60
92 54.28 73.60
95 31.13 42.20
100 31.13 42.20
101 31.13 42.20
104 1.92 2.60
106 1.92 2.60
107 15.92 21.58
115 15.92 21.58
121 6.44 8.73
125 3.76 5.10
136 3.76 5.10
138 3.76 5.10
140 3.76 5.10
142 3.76 5.10
144 3.76 5.10
146 3.76 5.10
148 3.76 5.10
152 3.76 5.10
153 15.92 21.58
154 15.92 21.58
155 15.92 21.58
159 889.91 1206.50

6-8
 SG811-BV-MMA-010

Table 6-2. Boat Crane Assembly Torque Values - Continued

ITEMS FOOT-POUNDS (FT-LB) NEWTON METERS (Nm)

162 6.44 8.73
163 1.92 2.60
168 3.76 5.10
169 3.76 5.10
172 31.13 42.20
175 31.13 42.20
177 15.92 21.58
179 15.92 21.58
181 31.13 42.20
186 15.92 21.58
188 31.13 42.20
191 31.13 42.20
194 15.92 21.58
197 15.92 21.58
199 31.13 42.20
202 54.28 73.60
204 31.13 42.20
205 31.13 42.20
208 31.13 42.20

6-4. REPAIR OF THE BOAT CRANE.

The following paragraphs provide the procedures required to remove, install, disassemble, and assemble the
winch assembly, main boom, jib boom, operator seat, control panel, electronic control unit, electric motor starter,
electric motor, slew ring, hydraulic brake, reduction gear, hydraulic motor, hydraulic pump, access panel and
associated filters, valves, gauges and hand pump.

In some case lifting eyes are not provided as part of the equipment and it is required that they be installed
by maintenance personnel to allow equipments to be lifted using a mobile crane. These items are identified in
each paragraph when and where required.

6-4.1 Jib Boom. Remove the major components from the Jib boom as follows, referring to figure FO-12 or
figure FO-13.

6-4.1.1 Jib Boom Cylinder Removal. Remove the jib boom cylinder from the crane as follows, referring to
figure 6-1.

WARNING

Before performing any maintenance action notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel.

6-9
SG811-BV-MMA-010

a. Lower jib boom so that it is resting in a position to take any strain off the jib boom cylinder.

WARNING

Boat crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply may result in injury or
death to maintenance personnel.
b. At control panel depress ″MOTOR OFF″ pushbutton to shutdown the hydraulic pump.

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply may result in injury or
death to maintenance personnel.
c. Deenergize electrical power to crane by opening circuit breaker on the 1S switchboard and tag ″OUT-OF-
SERVICE.″ Refer to SIB Volume 3 for exact location of circuit breaker.
d. Lock the boat crane by engaging the slew ring locking device (93, figure FO-12 or figure FO-13).

CAUTION

Care must be taken to ensure no contamination to the system occurs. When

hydraulic lines are disconnected they must be capped immediately to pre-
vent contamination and damage to the equipment.
e. Place a pan under hydraulic lines (9) on cylinder and loosen fittings, and let the oil in the cylinder drain into
pan. Remove lines (9).
f. Screw in four lifting eyes (type mount 2947) into bottom (3) and cover (22). (Refer to figure 6-2.)

WARNING

When performing the following procedures, ensure adequate hoisting equip-

ment is used as the jib boom weighs 356 pounds and jib boom cylinder
weighs 265 pounds. Injury or death to maintenance personnel could occur if
these equipments are mishandled.
g. Using a mobile winch, secure to lifting eyes on jib boom cylinder.
h. Remove 6 screws (1) and washers (2) securing cover (3) and spacer (4) to pin (5) from both sides of pin (5)
securing jib boom cylinder to jib boom.
i. Use a rubber mallet and a block of wood to knock out pin (5) and lower the front of the cylinder to help sup-
port it.

6-10
 SG811-BV-MMA-010

j. Repeat step h. for pin (5) securing jib boom cylinder (6) to main boom.

k. Lower jib boom cylinder and remove lifting device.

6-4.1.1.1 Jib Boom Cylinder Disassembly. Disassemble the jib boom cylinder as follows, referring to figure
6-2.

a. Remove tubing between overcenter valves (30), front feeding block (29), and rear feeding block (37).

b. Loosen screws (32) and washers (33) to relieve any residual hydraulic pressure in cylinder.

c. Remove 4 screws (31) and separate overcenter valve (30) and front feeding block (29) from bottom (3).

d. Remove O-ring (36) from front feeding block (29) and bottom (3).

e. Separate block (29) and valve (30) and remove O-rings (36) from between block (29) and valve (30).

f. Remove 4 screws (31) and separate overcenter valve (30) and back feeding block (37) from cover (22).

g. Remove O-ring (36) from back feeding block (37) and cover (22).

h. Remove 2 retaining rings (1) and spherical joint (2) from each of the bottom (3) and front connection (27).

i. Remove 14 screws (8) from bottom (3) and blocking ring nut (14) and remove bottom (3) by unscrewing it
from the pipe (19).

j. Remove backing ring (9) and O-ring (12) from the bottom (3).

k. Remove circlip (10) and braking bushing (7) from back braking system (6). Pull piston rod (18) from pipe
(19).

l. Remove screw (4) and washer (5) from end of piston rod (18).

m. Remove piston (28) and screw (11), with front braking system (17), backing ring (34), and O-ring (16).

n. Remove 2 gaskets (13), and gasket (15).

o. Unscrew front connection (27) from piston rod (18).

p. Remove 14 screws (24) from cover (22) and blocking ring nut (14).

q. Slide cover (22) off piston rod (18) and remove 2 gaskets (23) and gasket (26).

r. Unscrew cover guide (25, figure 6-2) and remove O-ring (20) and backing ring (21).

s. Unscrew top and bottom blocking ring nut (14) from pipe (19).

6-11
6-12

SG811-BV-MMA-010
Figure 6-1. Jib Boom Cylinder Removal
 SG811-BV-MMA-010
Figure 6-2. Jib Boom Cylinder Disassembly
6-13
SG811-BV-MMA-010

6-4.1.1.2 Jib Boom Cylinder Assembly. Reassemble the jib boom cylinder in the reverse order of the disassem-
bly procedure listed in paragraph 6-4.1.1.1. Apply a light coating of petroleum jelly on all 24 O-rings. Lubricate
all mating surfaces with hydraulic fluid. Torque screws (8) and (24) and blocking ring nuts (14) to 220.69 ft-lbs
(299.2 nm).

6-4.1.2 Jib Boom Cylinder Installation. Install the jib boom cylinder as follows:

WARNING

Proper equipment must be used to support the jib boom during installation
of the jib boom cylinder. Failure to comply may result in injury or death to
maintenance personnel.

a. After performing step a - step e of paragraph 6-4.1.1, perform the following:

WARNING

Boat Crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn-off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply may result in injury or
death to maintenance personnel.

b. Remove screw (32) and washer (33) from bottom (3) or cover (22) to bleed air from jib boom cylinder. (Refer
to figure 6-2).

c. When hydraulic fluid starts to leak from bottom (3) or cover (22) replace screw (32) and washer (33) and
complete step d - step a of paragraph 6-4.1.1.

6-4.1.3 Winch Assembly Removal. Remove the winch assembly as follows refer to figure FO-12 or figure
FO-13 and figure 6-3.

6-14
 SG811-BV-MMA-010
Figure 6-3. Wire Rope Removal (Sheet 1 of 2)
6-15
SG811-BV-MMA-010

Figure 6-3. Wire Rope Removal (Sheet 2 of 2)

6-16
 SG811-BV-MMA-010

WARNING

Before performing any maintenance action notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel.

WARNING

Boat crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply may result in injury or
death to maintenance personnel.

a. Move the main boom/jib boom so that the winch assembly is in a comfortable working position.
b. On the control panel depress ″MOTOR OFF″ pushbutton to reduce hydraulic pressure to zero. Hydraulic
pressure will automatically go to zero. Tag switch ″OUT-OF-SERVICE.″
c. Engage slew ring locking assembly (93, figure FO-12 or figure FO-13) to lock (Lock In) position.

WARNING

Leather gloves should be worn anytime personnel are handling the wire rope
as personnel injury could occur.

CAUTION

Use care when removing wire rope as kinking or damage to the wire rope
can occur.
d. Remove wire rope (4, figure 6-3) from boom head assembly (7) as follows:
(1) Remove shackle (8) and hook from thimble on the end of the wire rope (4) by removing pin (6) and hook
(1).
(2) Remove spring pin (3) from side of boom head (7) and remove pin (2).
(3) Lift roller (5) and pull wire rope (4) through boom head (7).

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply may result in injury or
death to maintenance personnel.

6-17
SG811-BV-MMA-010

e. Deenergize electrical power to the boat crane by opening circuit breaker on the 1S switchboard and tag
″OUT-OF-SERVICE.″ Refer to SIB Volume 3 for exact location of circuit breaker.

CAUTION

Care must be taken to ensure no contamination to the system occurs. When

hydraulic lines are disconnected they must be capped immediately to pre-
vent contamination and damage to the equipment.
f. Disconnect hydraulic lines to the hydraulic motor that connects with the overcenter valve on the jib boom
cylinder.
g. Place a pan under lines and remove four hydraulic fittings from the hydraulic motor.
h. Remove fitting from limit switches, tag and disconnect wires.
i. Remove ground strap from winch assembly to jib boom assembly.

WARNING

The winch assembly weighs 381 pounds. Failure to support it properly dur-
ing handling may result in injury to maintenance personnel or damage to
equipment.

WARNING

Crane operations have inherent hazards that cannot be mechanically safe-

guarded. Hard hats and safety shoes are required when performing mainte-
nance as injury or death to personnel could occur.
j. Attach lifting device to winch (73, figure FO-12 or figure FO-13).
k. Remove 2 self-locking nuts (138, figure FO-12 or figure FO-13), 2 washers (137), and ground strap (129).
l. Remove 6 screws (74), 6 washers (75) and 6 self-locking nuts (76).
m. Lift winch (73) away from jib boom (77) and lower winch assembly to the deck.

6-4.1.3.1 Removal and Disassembly of the Hydraulic Motor Assembly. Remove and disassemble the hydraulic
motor assembly as follows, refer to figure FO-14.

a. Remove screws (6) from load bearing flange (86) located at the right side of the winch frame (75).
b. Remove hydraulic motor (20), brake casing (48) and reduction gear box (7) from right side of winch frame
(75).
c. Remove four screws (43) and remove hydraulic motor (20) from motor fixing flange (45).
d. Remove six screws (30) and remove brake casing (48) from reduction gear box (7).
e. Slide bevel pinion (52) out of transmission shaft (49).

6-18
 SG811-BV-MMA-010

f. Remove self-locking ring nut (23) from bevel pinion (52) and remove taper roller bearing (22).

g. Remove brake enclosure flange (50) and remove O-ring (25).

h. Remove retaining ring (28) and ball bearing (24) from sleeve (47).

i. Remove retaining ring (27) and remove one way clutch (29).

j. Slide transmission shaft (49) out of sleeve (47).

k. Remove needle roller bearing (41) from transmission shaft (49).

l. Remove steel disks (38) and bronze disks (39).

m. Remove braking casing (48, figure FO-14) and O-ring (26).

n. Remove O-ring (36), backing ring (37), O-ring (33), and backing ring (32) from braking piston (46).

o. Remove braking piston (46), remove O-ring (31) and remove springs (35).

p. Remove ball bearing (40) and O-ring (42).

q. Remove three screws (12) and three screws (19) from enclosure flange (4) and remove O-ring (18).

r. Remove enclosure flange (4) from reduction box (7) and remove O-ring (5).

s. Remove taper roller bearing (8) from shaft (14).

t. Remove shaft (14) from reduction box (7).

u. Remove bevel gear (9) and tongue (13) from shaft (14).

v. Remove six screws (10) from reduction box (7).

w. Remove cover (15) and taper roller bearing (11) from reduction box (7).

x. Remove taper roller bearing (21) from reduction box (7).

6-4.1.3.2 Assembly and Installation of Hydraulic Motor Assembly. Assembly and installation of the hydraulic
motor are in the reverse order of the disassembly, listed in paragraph 6-4.1.3.1. During reassembly all O-rings
and seals should be replaced. Apply a thin film of petroleum jelly on all O-rings.

6-4.1.3.3 Removal and Disassembly of the Gear Limit Switch Assembly. Remove the gear limit switch assem-
bly as follows, refer to figure 6-4.

a. Remove cover (1).

b. Remove two screws (7) from chain enclosure (8) and separate chain enclosure from frame (18).

6-19
SG811-BV-MMA-010

Figure 6-4. Gear Limit Switch Removal

6-20
 SG811-BV-MMA-010

c. Remove screw (10) from sprocket (9) and separate sprocket (9) from gear limit switch (14) shaft.
d. Remove chain (11) from sprocket (9) and remove sprocket (9).
e. Remove limit switch (14) and support (17) from the frame (18) by removing two screws (16) and washer (15).

6-4.1.3.4 Assembly and Installation of Gear Limit Switch. Assembly of the gear limit switch is done in the
reverse order of the disassembly procedure listed in paragraph 6-4.1.3.3.

6-4.1.3.5 Disassembly of the Cable Drum Assembly. Disassemble the cable drum assembly as follows, refer to
figure FO-14.

a. Remove hydraulic motor (20) and reduction box (7) from winch by removing ten screws (6) and O-ring (18).
b. Remove gear limit switch in accordance paragraph 6-4.1.3.3.

WARNING

Leather gloves should be worn anytime personnel are handling the wire rope
as personnel injury could occur.

CAUTION

Use care when removing wire rope as kinking or damage to the wire rope
can occur.
c. If the wire rope is still on the drum it will be necessary to take it off. With the hydraulic motor and the limit
switch removed, then it is possible to remove the wire rope from drum. Loosen the two screws (2) on fixing
plate (106, figure FO-14). Pull the wire rope from the fixing plate (106).
d. On the right half of the cable drum assembly, remove 8 screws (57) from lebus half shells (58).
e. Separate and remove lebus half shells (58) from spacer (77).
f. Remove screws (54) from frame (75).
g. Remove spacers (53) from between frame (75).
h. Remove screws (74) from right drum flange (63).
i. Separate the drum assemblies by separating pinion (72) from coupling (76).
j. Remove screws (91) and remove planetary gear support (87).
k. Remove ring (17) and spring pin (90).
l. Remove pinion (72) and shimming (88).
m. Remove spring pin (97), needle (93), planetary gear (92), slew ring (94), and spring pin (96).
n. Remove spacer (89), flange (62) and spacer (69).
o. Remove ten screws (67) and remove antirotation flange (73).

6-21
SG811-BV-MMA-010

p. Remove retaining ring (66), and remove ball bearing (68) and oil seal (70).

q. Remove spring pin (59), remove O-ring (60) and planetary ring (61).

r. On the left half of the cable drum assembly, remove ring (17) and coupling joint (76).

s. Remove three screws (105) and washers (104).

t. Remove flange (78) and remove spacer (99).

u. Remove shimming (98).

v. Remove planetary gear (100), slew ring (103), needle (101) and pin (102).

w. Remove eight screws (55), spacer (77), spring pin (79) and O-ring (60).

x. Separate pinion (71) from shaft (14).

y. Remove retaining rings (81) and (82).

z. Remove ball bearing (83) and oil seal (84).

aa. Remove four screws (56) and load bearing flange (86).

6-4.1.3.6 Assembly of Cable Drum. Assembly of the cable drum is in the reverse order of the disassembly pro-
cedures, listed in paragraph 6-4.1.3.5. During reassembly all O-rings and seals should be replaced. Coat all
O-rings with a light coat of petroleum jelly prior to reassembly.

6-4.1.4 Installation of Winch Assembly. Install the winch assembly on the jib boom in reverse order of the
removal procedures listed in paragraph 6-4.1.3. Torque values are provided in table 6-3. Reconnect all hydraulic
and electrical connections removed when the winch was removed.

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE″. Failure to comply may result in injury or
death to maintenance personnel.

WARNING

The winch assembly weighs 381 pounds. Failure to support properly during
handling may result in injury to maintenance personnel or damage to equip-
ment.

6-4.1.5 Boom Head Assembly Removal. Remove the boom head assembly as follows, referring to figure FO-12
or figure FO-13.

6-22
 SG811-BV-MMA-010

WARNING

Before performing any maintenance action notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel.

WARNING

Crane operations have inherent hazards that cannot be mechanically safe-

guarded. Hard hats and safety shoes are required when performing mainte-
nance as injury or death to personnel could occur.

WARNING

When performing the following procedures, ensure adequate hoisting equip-

ment is used as the boom head assembly weighs 246 pounds. Injury or death
to maintenance personnel could occur if these equipments are mishandled.

Table 6-3. Winch Assembly Torque Values

Item FT-LB Nm

NOTE
Item numbers list winch assembly components corresponding to figure FO-14 and chapter 7 Parts List table 7-4.
2 31.13 42.20
6 15.92 21.58
10 15.92 21.58
19 6.44 8.73
30 15.92 21.58
43 31.13 42.20
51 15.92 21.58
54 86.08 116.70
55 31.13 42.20
56 15.92 21.58
57 31.13 42.20
65 6.44 8.73
67 31.13 42.20
74 31.13 42.20
91 36.88 50.00
105 18.80 25.50
107 15.92 21.58
110 1.92 2.60
116 31.13 42.20

6-23
SG811-BV-MMA-010

a. Remove hook from wire rope.

b. Remove spring (217, figure FO-12 or figure FO-13) from pin (216), and remove pin (216) from boom head
(78).

WARNING

Leather gloves should be worn anytime personnel are handling the wire rope
as personnel injury could occur.

CAUTION

Use care when removing wire rope as kinking or damage to the wire rope
can occur.
c. Lift upper sheave and pull wire rope (81) through boom head (78).
d. Connect mobile crane to boom head (78).
e. Remove six screws (90), washers (91) and nuts (92).
f. Remove boom head assembly and lower to deck.

6-4.1.5.1 Boom Head Assembly Disassembly. Disassemble the boom head assembly as follows, referring to
figure 6-5.

a. Remove two screws (22) from ring nut (3) and unscrew ring nut (3) off of wire channel of boom head (1).
b. Remove O-ring (23) from ring nut (3).
c. Slide out taper roller bearing (24) from ring nut side of wire channel of boom head (1).
d. Remove spring split pin (44) from pin (43) and slide pin (43) from boom head support (2).
e. Separate boom head support (2) and boom head (1) by sliding boom head support (2) from wire channel of
boom head (1).
f. Slide taper roller bearing (24) from wire channel of boom head (1).
g. Ensure surface of wire channel and internal surfaces of boom head support (2) are free of lubricants and for-
eign matter.
h. Remove two screws (32) and two washers (31) from boom head pin (30).
i. Remove spring split pin (29) from pin (33) and remove pin (33).
j. Remove roller assembly (27).
k. Remove pin (30) and two bushings (41) from each side of bracket (28).
l. Remove two screws (35) and two washers (34) from bracket (28).
m. Remove pin (36) by tapping out from side of bracket (28) and slide roller assembly (27) out of bracket (28).

6-24
 SG811-BV-MMA-010

Figure 6-5. Boom Head Assembly Disassembly

6-25
SG811-BV-MMA-010

n. Remove spacer (38), oil seal (39), retaining ring (40) and ball bearing (37) from each side of roller (27).
o. Remove nine screws (10, figure 6-5) and nine washers (11) securing semi-rings (9) from both sides of boom
head (1).
p. Remove screw (7), lockwasher (6) and washer (8) from boom head (1).
q. While supporting sheave assembly, remove pin (4) by tapping it out through hole removing lockwasher (6).
r. Slide sheave (5) assembly and both semi-rings (9) clear of the boom head (1).
s. Remove spacer (13), twelve screws (15), two covers (16), and ball bearing (12) from sheave (5).
t. Remove eight screws (19), sixteen washers (18), eight nuts (17), and two rings (20) from sheave (5).
u. Separate two halves of the sheave (5) and separate the two semi-rings (20).

6-4.1.5.2 Assembly of Boom Head Assembly. Assemble the boom head assembly in reverse order of the dis-
assembly procedure listed in paragraph 6-4.1.5.1. During reassembly all O-rings and seals should be replaced.
Coat all O-rings with a light coat of petroleum jelly prior to reassembly. Lubricate all moving parts before reas-
sembly.

NOTE

Fill the internal gap between the boom head support and the wire channel of the
boom head assembly before initial operation.

6-4.1.6 Installation of Boom Head Assembly. Installation of the boom head assembly is the reverse of the
removal procedure listed in paragraph 6-4.1.5.

6-4.2 Remove/Replace Wire Rope. Remove and replace the wire rope as follows, refer to figure 6-3 and figure
FO-12 or figure FO-13.

WARNING

Before performing any maintenance action notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel.

WARNING

Crane operations have inherent hazards that cannot be mechanically safe-

guarded. Hard hats and safety shoes are required when performing mainte-
nance as injury or death to personnel could occur.

a. Rotate crane towards the center of the ship.

6-26
 SG811-BV-MMA-010

b. Extend jib boom and lower main boom.

c. Remove pin (6, figure 6-3) from shackle (8) and remove shackle (8) from wire rope thimble (9) and hook
(1).
d. Place duck cloth on deck.

WARNING

Leather gloves should be worn anytime personnel are handling the wire rope
as personnel injury could occur.
e. Put on leather gloves.

NOTE

Drum will automatically stop when limit switch is engaged.

f. Slowly pay out wire rope until all but (2-1/2) turns of wire rope has been removed from drum.
g. Inspect wire rope for:
(1) Evidence of pitting due to corrosion.
(2) Nominal diameter is reduced no more than 1/32 inch.
(3) Six broken wires in one rope lay length or three broken wires in one strand, lay length.
(4) Kinking, crushing, birdcaging or any other evidence of damage resulting in distortion of the rope struc-
ture.
(5) Inspect swage fittings for deterioration, cracks, wear and looseness.
h. Depress ″MOTOR OFF″ pushbutton on control panel. Refer to SIB and locate power distribution panel and
place boat crane circuit breaker in the OFF position.
i. Tag circuit breaker ″OUT-OF-SERVICE.″

WARNING

Use care when removing wire rope fixing plate (106, figure FO-14) to pre-
vent injury to personnel.
j. Loosen two screws retaining wire rope fixing plate (106, figure FO-14) to right drum flange (63).
k. Remove wire rope from hole in right drum flange (63).
l. Slowly remove wire rope from drum and pull through jib boom sheave. Clean and inspect.

WARNING

Cleaning solvent is highly toxic to eyes, skin and respiratory tract. Avoid all
contact. Skin and eye protection is required. Use only with adequate venti-
lation.

6-27
SG811-BV-MMA-010

m. Put on face shield and chemical gloves.

n. Using cleaning solvent, utility pail and wiping rags, clean drum, flanges and wire rope.
o. Remove face shield and chemical gloves.

NOTE

New cable comes with end wrapped with wire to prevent cable fraying. Cable
end must be brazed and the wire removed. The cable is now ready for use.
p. To replace the wire rope, put on leather gloves.
q. Using a brush, put a light coat of MIL-G-18458 on drum and approximately 5 feet of the wire rope.
r. Thread wire rope through boom head and wrap wire rope clockwise around the top of the drum approxi-
mately 2-1/2 turns.
s. Slide end of wire rope through opening in right drum flange (63, figure FO-14).
t. Place fixing plate (106) against right drum flange (63) so wire rope extends approximately 2 inch past fix-
ing plate (106).
u. Tighten two screws (2) through fixing plate (106) and into drum flange (63).
v. Torque two screws to 31 ft-lb.
w. Slide wire rope on drum towards flange outer most grooves closest to right side of drum where wire rope is
secured.
x. Remove ″OUT-OF-SERVICE″ tags from boat crane circuit breaker.
y. Place circuit breaker in the ″ON″ position.
z. Using a brush, put on a light coat of MIL-G-18458 lubricant on wire rope as it is being installed on drum.
aa. Slowly take in wire rope onto drum (make sure wire rope is kept taut and that it lays in drum grooves).
ab. Replace boat crane shackle onto wire rope thimble.
ac. Install shackle (8, figure 6-3) through thimble (9).
ad. Install hook (1) on shackle (8) and secure with pin (6).
ae. Install hex head bolt through shackle.
af. Check pay out limit switch for 2-1/2 wraps on drum and haul in limit switch for a set distance between hook
and boom tip.

6-4.3 Jib Boom Removal. Remove the jib boom as follows, referring to figure FO-12 or figure FO-13. If it is
necessary to remove the major components from the jib boom, perform step a, step b, and step c. The jib boom
can be separated from the main boom if required, without total disassembly.

WARNING

Before performing any maintenance action notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
Warning-continued

6-28
 SG811-BV-MMA-010

Warning - precedes
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel.

WARNING

Boat crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply may result in injury or
death to maintenance personnel.

a. At the control panel, depress ″MOTOR OFF″ pushbutton to shut down the hydraulic pump.

WARNING

Hazardous voltages are present. Ensure power is removed and tagged

″OUT-OF-SERVICE″. Failure to comply may result in injury or death to
maintenance personnel.

b. Deenergize electrical power to crane by opening circuit breaker on the 1S switchboard and tag ″OUT-OF-
SERVICE.″ Refer to SIB Volume 3 for exact location of circuit breaker.

c. Engage slew ring locking assembly, (93, figure FO-12 or figure FO-13) to the locked (lock in) position.

WARNING

Crane operations have inherent hazards that cannot be mechanically safe-

guarded. Hard hats and safety shoes are required when performing mainte-
nance as injury to personnel could occur.

WARNING

When performing the following procedures, ensure adequate hoisting equip-

ment is used as the jib boom weighs 356 pounds and jib boom cylinder
weighs 265 pounds. Injury or death to maintenance personnel could occur if
these equipments are mishandled.

d. Remove jib boom cylinder in accordance with paragraph 6-4.1.1.

e. If required, remove winch assembly in accordance with paragraph 6-4.1.3.

6-29
SG811-BV-MMA-010

NOTE

If the winch assembly is not being removed, the hydraulic lines attached to the
winch must be removed first in accordance with paragraph 6-4.1.3.
f. If required, remove boom head assembly in accordance with paragraph 6-4.1.5.
g. Using a mobile crane, support the jib boom by the four lifting eyes.
h. Remove six screws (70, figure FO-12 or figure FO-13) and washers (71) that secure two covers (69) and
remove covers (69).
i. Using a rubber mallet and wooden dowl, tap out pin (68).
j. Place the jib boom on a suitable surface.

6-4.4 Main Boom Disassembly. Disassemble the main boom as follows, referring to figure FO-12 or figure
FO-13:

WARNING

Before performing any maintenance action notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel.

WARNING

Proper equipment must be used to support the main boom cylinder during
removal. The main boom cylinder weighs 287 pounds. Failure to comply
may result in injury or death to maintenance personnel.

WARNING

Boat crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply may result in injury or
death to maintenance personnel.

a. Remove jib boom in accordance with paragraph 6-4.3.

b. Remove main boom cylinder in accordance with paragraph 6-4.4.1.
c. Remove two bushings (41) from turret end of main boom (67).
d. Remove all hydraulic piping from main boom by removing screws, clamps and upper piping supports.

6-30
 SG811-BV-MMA-010

e. Remove all electrical conduit from main boom by removing screws, clamps and conduit supports.

f. Remove two self-locking nuts (146 and 213), washers (145 and 212), from connection box (120) and main
boom (67).

g. Remove two screws (121), washers (122) and remove connection box (120) from main boom (67).

h. Remove two self-locking nuts (142, figure FO-12 or figure FO-13), washers (141), and ground strap (131)
from connection box (120) and main boom (67).

i. Remove two screws (121), washers (122) and remove connection box (120) from main boom (67).

CAUTION

Care must be taken to ensure no contamination to the system occurs. When

hydraulic lines are disconnected they must be capped immediately to pre-
vent contamination and damage to the equipment.

j. Remove hydraulic lines and remove two screws (181), washers (182) and antishock valve (183).

k. Remove hydraulic lines and remove two screws (191), washers (192) and remove antishock valve (193).

l. Remove self locking nuts (159) and washers (160).

m. Extract threaded bar (158) while holding eyelet (161).

n. When threaded bar (158) is clear of main boom, pull eyelet (161) free.

6-4.4.1 Main Boom Cylinder Removal. Remove the main boom cylinder using figure FO-12 or figure FO-13
as follows:

WARNING

Before performing any maintenance action notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel.

WARNING

Proper equipment must be used to support the main boom cylinder during
removal. The main boom cylinder weighs 287 pounds. Failure to comply
may result in injury or death to maintenance personnel.

6-31
SG811-BV-MMA-010

WARNING

Boat crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply may result in injury or
death to maintenance personnel.

a. Remove and cap two hydraulic lines from each end of the main boom.
b. Remove screws (32, figure FO-12 or figure FO-13) and washers (33) from bottom (3) and cover (22) to bleed
air from main boom cylinder (refer to figure 6-2).
c. Screw in four lifting eyes (type M10 UNI 2947) into bottom (3) and cover (22) (refer to figure 6-2).
d. Using a mobile crane, support main boom cylinder (62) to prevent movement.
e. Remove twelve screws (56), twelve washers (57), two lockwashers (55), and two spacers (99) from forward
attachment point of the main boom cylinder (53).
f. Using a wooden dowel, tap out pin (54).
g. Lower and support the end of the main boom cylinder (53).
h. Remove twelve screws (51), washers (52), two lockwashers (50), and two spacers (99) from rear attachment
point of the main boom cylinder (53) on the turret.
i. Using a wooden dowel, tap out pin (49).
j. Remove main boom cylinder (53) and set on a proper surface.

6-4.4.1.1 Main Boom Cylinder Disassembly. Disassembly of the main boom cylinder is identical to the jib
boom cylinder in paragraph 6-4.1.1.1.

6-4.4.1.2 Main Boom Cylinder Assembly. Assembly of the main boom cylinder is identical to the jib boom
cylinder in paragraph 6-4.1.1.2. When assembling apply a light coating of petroleum jelly on all O-rings. Lubri-
cate all mating surfaces with hydraulic fluid. Torque all screws and blocking ring nuts (14) to 220.69 ft-lbs (299.2
nm).

6-4.4.2 Installation of Main Boom Cylinder. Install the main boom cylinder as follows, referring to figure
FO-12 or figure FO-13.

WARNING

Proper equipment must be used to support the main boom during installa-
tion of the main boom cylinder. Failure to comply may result in injury or
death to maintenance personnel.

a. Using a mobile crane, place main boom cylinder (53) in rear bracket on turret.
b. Replace pin (49), spacers (99), lockwashers (50), washers (52), and screws (51) in rear bracket.

6-32
 SG811-BV-MMA-010

c. Place forward end of main boom cylinder (53) in forward bracket on main boom.

d. Replace pin (54), spacers (99), lockwashers (55), washers (57), and screws (56) in forward bracket.

e. Connect all hydraulic lines.

6-4.4.3 Main Boom Removal. Remove the main boom as follows, referring to figure FO-12 or figure FO-13.

WARNING

Before performing any maintenance action notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel.

WARNING

Boat crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply may result in injury or
death to maintenance personnel.

a. At the control panel, depress MOTOR OFF pushbutton to shut down the hydraulic pump.

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply may result in injury or
death to maintenance personnel.

b. Deenergize electrical power to boat crane by opening circuit breaker on the 1S switchboard and tag ″OUT-
OF-SERVICE.″ Refer to SIB Volume 3 for exact location of circuit breaker.

c. Place the slew ring locking assembly to the locked (lock in) position.

WARNING

Crane operations have inherent hazards that cannot be mechanically safe-

guarded. Hard hats and safety shoes are required when performing mainte-
nance as injury to personnel could occur.

6-33
SG811-BV-MMA-010

WARNING

When performing the following procedures, ensure adequate hoisting equip-

ment is used as the jib boom weighs 356 pounds, the jib boom cylinder
weighs 265 pounds and the main boom cylinder weighs 287 pounds. Injury
or death to maintenance personnel could occur if these equipments are mis-
handled.

CAUTION

Care must be taken to ensure no contamination to the system occurs. When

hydraulic lines are disconnected they must be capped immediately to pre-
vent contamination and damage to the equipment.
d. Remove, tag and identify six hydraulic lines and hydraulic connections on main boom (67, figure FO-12 or
figure FO-13).
e. Open junction box cover (120) and disconnect wires and remove cables.
f. Using a mobile crane, attach lifting device to lifting padeyes located on the main boom.
g. Disconnect two hydraulic lines from the main boom cylinder.
h. Remove 6 screws (56, figure FO-12 or figure FO-13) and 6 washers (57) from lockwasher (55) on both sides
of the main boom cylinder where the cylinder (53) attaches to the main boom (67).
i. Remove jib boom cylinder in accordance with paragraph 6-4.1.1.
j. Remove jib boom from main boom in accordance with paragraph 6-4.3.
k. Remove self-locking nut (136), washer (135), and ground strap (128) from main boom (67).
l. Remove six screws (39), washers (40) and two lockwashers (38) from pin (37).

WARNING

The main boom pin (37) weighs 61 pounds. Before attempting the next step,
the two man lift applies to prevent personnel injury.
m. Tap main boom pin (37) out of turret attachment point and separate the main boom (67) from the turret (9).

6-4.4.4 Main Boom Installation. Install the main boom in the reverse order of procedure listed in paragraph
6-4.4.3.

6-4.5 Operator Seat Assembly. The following paragraphs describe the removal, disassembly, reassembly, and
installation of the operator seat assembly.

6-4.5.1 Operator Seat Assembly Removal. Remove the operator seat as follows, referring to figure FO-12 or
figure FO-13 and Figure 6-6.

6-34
 SG811-BV-MMA-010

WARNING

Before performing any maintenance action notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel.

a. Depress ″MOTOR OFF″ pushbutton on control panel to shut down hydraulic pump.

b. Place the slew ring locking assembly (93, figure FO-12 or figure FO-13) to lock (LOCK IN) position.

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply may result in injury or
death to maintenance personnel.

WARNING

When removing hydraulic lines, ensure that all excess oil is cleaned up as it
is slippery and injury to personnel could occur.

c. Deenergize electrical power to crane by opening circuit breaker on the 1S switchboard, and tag ″OUT-
OFSERVICE″. Refer to SIB Volume 3 for exact location of circuit breaker.

NOTE

It takes two people to perform the following steps.

d. Using door locking tool, unlock and open turret side door (1, figure 6-6), on right side of turret (9, figure
FO-12 or figure FO-13).

e. Open cover to electric motor starter (10).

f. Tag and disconnect six cables (20) going into the electric motor starter (10).

g. Remove nut (24), flat-washer (25), and washer (23), and remove ground cable.

h. Loosen four retaining screws (14) on connection box no. 4 cover (15) and remove cover.

6-35
SG811-BV-MMA-010

Figure 6-6. Operator Seat Removal

6-36
 SG811-BV-MMA-010

i. Tag electrical leads coming into connection box no. 4 from outside operator seat assembly at terminal board.
j. Loosen retaining screws and remove electrical leads from terminal board.

NOTE

It is not necessary to totally disassemble the operator seat to remove it from the
crane. However the major components of the operator seat can be removed by
performing step k through step r.
k. Remove four screws (30) and washers (31) inside connection box no. 4 (9) and remove box from operator
seat assembly.
l. Remove electronic control unit (4) in accordance with paragraph 6-4.5.11.
m. Remove control panel assembly (28) in accordance with paragraph 6-4.5.3.
n. Remove control joysticks (29) in accordance with paragraph 6-4.5.10.
o. Remove pressure gauge (18) in accordance with paragraph 6-4.5.9.
p. Remove the ground strap (21) and six cable feed throughs (20) with cable from under seat assembly.
q. Close valve directly behind pressure gauge and disconnect pressure gauge (18) hydraulic line from connec-
tion on block of valves.
r. Install four eyebolts (2947) into eyebolt lifting holes.

WARNING

The operator seat assembly weighs 527 pounds. Proper equipment must be
used to support the operator seat assembly during removal and installation.
Failure to comply may result in injury or death to maintenance personnel.
s. Attach a four leg lifting sling to four lifting eyes.
t. Connect lifting sling to mobile crane lifting hook and take up slack.
u. Remove eight screws (34, figure FO-12 or figure FO-13) and washers (35) securing operator seat assembly
(33) to revolving turret (9).
v. Remove five screws (36) and washers (97) securing operator seat assembly (33) to the turret enclosure (85).
w. Using mobile crane, remove operator seat assembly (33) from revolving turret (9) and lower onto pallet.
x. Disconnect sling from mobile crane lifting hook.

6-4.5.2 Operator Seat Assembly Installation. Install the operator seat as follows, referring to figure FO-12 or
figure FO-13 and figure 6-6.

WARNING

Before performing any maintenance action notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment

6-37
SG811-BV-MMA-010

Warning - precedes
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel.

WARNING

For any hydraulic maintenance action, turn off electric power. This will
reduce hydraulic pressure to zero. Failure to comply may result in injury or
death to maintenance personnel.

WARNING

The operator seat assembly weighs 527 pounds. Proper equipment must be
used to support the operator seat assembly during removal and installation.
Failure to comply may result in injury or death to maintenance personnel.

a. Attach four leg lifting slings to four lifting points on operator seat assembly and connect sling to mobile crane
lifting hook.
b. Using mobile crane, lift operator seat assembly (33, figure FO-12 or figure FO-13) up and lower into posi-
tion on revolving turret (9).
c. Secure operator seat assembly (33) to revolving turret (9) with eight screws (34) and washers (35) torque at
132 ft-lbs (178.9 nm).
d. Secure operator seat (33) to turret enclosure (85) with five screws (36) and washers (97).
e. Disconnect lifting sling from four lifting eyes, and remove four eyebolts.
f. Replace electric motor starter (13, figure 6-6) in accordance with paragraph 6-4.5.15.
g. Replace electronic control unit (4) in accordance with paragraph 6-4.5.11.
h. Replace control panel assembly (28) in accordance with paragraph 6-4.5.6.
i. Replace control joysticks in accordance with paragraph 6-4.5.10.
j. Replace pressure gauge (18) in accordance with paragraph 6-4.5.9.
k. Replace six cables (20) through bottom and ground from rear of operator seat assembly (2).
l. Connect hydraulic line located on front of operator seat assembly (2) to block of valves.
m. Install electrical connection box no. 4 (9) under electric motor starter using four screws (30) and washers
(31).
n. Install all electrical leads to connection box no. 4 (9) terminal board.
o. Replace cover (15) and secure it with four screws (14) and close and lock turret side door (1) using door
locking tool.
p. Locate power distribution panel on the 1S switchboard and remove ″OUT-OF-SERVICE″ tag from circuit
breaker.

6-38
 SG811-BV-MMA-010

q. Place circuit breaker in ON position.

6-4.5.3 Removal of Control Panel. Remove the control panel as follows, refering to figure 6-7.

WARNING

Before performing any maintenance action notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel.

WARNING

For any hydraulic maintenance action, turn off electric power. This will
reduce hydraulic pressure to zero. Failure to comply may result in injury or
death to maintenance personnel.

WARNING

Hazardous voltages are present. Ensure electric power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply may result in injury or
death to maintenance personnel.

a. Deenergize electrical power to crane by opening circuit breaker on power distribution panel located on the 1S
Switchboard and tag ″OUT-OF-SERVICE.″ Refer to SIB Volume 3 for exact location of circuit breaker.

b. Locate control panel assembly (3, figure 6-7) on upper right hand side of the crane operator control station.

c. Remove 18 screws (1) and washers (2) from periphery of control panel assembly (3).

d. Pull control panel assembly (3) from the mounting position enough to gain access to rear of assembly.

e. Remove connector (12) from back of control panel assembly (3).

6-39
SG811-BV-MMA-010

Figure 6-7. Control Panel Removal

6-40
 SG811-BV-MMA-010

f. Remove nut (13) from control panel assembly ground stud.

g. Remove ground strap (15) from ground stud.

h. Remove control panel assembly (3) from the operator seat mounting position.

6-4.5.4 Control Panel Disassembly. Disassemble the control panel as follows, referring to figure 6-8.

a. Loosen fixing knob (4) on rear of box (2).

b. Remove panel (1) with gasket (3) from box (2).

c. Tag and disconnect four electrical wires from four indicator lamps (16), alternate action switches (11).

d. Remove two nuts (7), lug (15), ground wire (13), and brass washers (12). Remove screw (14), lug (15), and
ground wire (13).

e. Remove dripproof seal (17), filters/lenses (18) and pushbutton (19) and remove lamps (20).

f. Remove four screws (8), nuts (9), gasket (10) from connector (5) and remove connector from box (2).

6-4.5.5 Control Panel Assembly. Assemble the control panel in the reverse order of the procedures listed in
paragraph 6-4.5.4.

6-4.5.6 Replace Control Panel. Install the control panel in the reverse order of the procedures listed in
paragraph 6-4.5.3.

6-4.5.7 Remove and Replace Terminal Board TB1. Terminal board TB1 is located inside the operator seat con-
sole behind the control panel. Remove and replace the terminal board TB1 as follows, referring to figure 6-7.

a. Remove control panel assembly (3) in accordance with paragraph 6-4.5.4.

b. Tag and remove all wires from terminal board TB1 (11).

c. Remove two screws (16) and washers (17) and remove terminal board TB1 (11) from console.

d. Reinstall the terminal board TB1 (11) in the reverse order.

6-4.5.8 Remove, Disassemble, Assemble, and Replace the Control Panel Cover. Remove and replace the con-
trol panel cover as follows, referring to figure 6-7.

a. Remove four screws (19) and washers (23) securing hinge (45) to top of operator console.

6-41
SG811-BV-MMA-010

Figure 6-8. Control Panel Disassembly

6-42
 SG811-BV-MMA-010

b. Remove locknut (37), washer (38) and brace (32) from the bolt (42).
c. Lift cover (20) off console.
d. Remove two hinges (45) from back of cover by:
(1) Removing two screws (19) and washers (23) from inside cover (20).
(2) Reinstall in reverse order.
e. Remove handle (21) by:
(1) Removing two screws (19) and washers (23) from inside cover.
(2) Remove handle (21).
(3) Reinstall in reverse order.
f. Remove latch (24) from cover by:
(1) Removing two screws (19), nuts (25) and washers (26) from cover (20).
(2) Remove latch (24).
(3) Reinstall in reverse order.
g. Remove the latch handle (27) by:
(1) Removing control panel assembly in accordance with paragraph 6-4.5.3.
(2) Remove two screws (31) securing latch handle (27) to two spacers (30).
(3) Remove latch handle (27).
(4) Remove two nuts (28) and washers (29) from spacer inside console.
(5) Remove spacer (30, figure 6-7) from front of console.
(6) Reinstall in reverse order.
h. Reinstall the control panel cover in the reverse order.

6-4.5.9 Removal/Installation of Pressure Gauge. Remove the pressure gauge as follows, referring to figure 6-7:

WARNING

Boat crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply may result in injury or
death to maintenance personnel.

a. Depress ″MOTOR OFF″ pushbutton on control panel to shut down hydraulic pump.

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply may result in injury or
death to maintenance personnel.

6-43
SG811-BV-MMA-010

b. Deenergize electrical power to the boat crane by opening the circuit breaker on the 1S switchboard and tag
″OUT-OF-SERVICE.″ Refer to SIB Volume 3 for the exact location of circuit breaker.

c. The pressure gauge (5) is located above the control panel (3).

d. Close gauge cutoff valve (9) at rear of gauge bracket (18) above control panel and tag valve ″OUT-OF-
SERVICE.″

e. Loosen tubing connection (10) on pressure gauge (5).

f. Remove three screws (6), and washers (7) securing pressure gauge (5) to mounting bracket (18).

g. Remove pressure gauge (5) from mounting bracket (18).

h. Using a wiping rag, wipe up any spilled hydraulic fluid.

i. Install the pressure gauge in the reverse order of removal.

6-4.5.10 Remove and Replace the Control Joysticks. Remove and replace the control joysticks as follows,
referring to figure 6-9.

WARNING

Before performing any maintenance action notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel.

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE″. Failure to comply may result in injury or
death to maintenance personnel.

NOTE

There are four control joysticks on the topside of revolving turret. The following
steps are applicable to all control joysticks.

a. Deenergize electrical power to crane by opening circuit breaker on the 1S switchboard and tag ″OUT-OF-
SERVICE.” Refer to SIB Volume 3 for exact location of circuit breaker.

b. Remove 12 screws (1, figure 6-9) and washers (2) securing bottom access cover (3) to control panel (12).

6-44
 SG811-BV-MMA-010
Figure 6-9. Control Joystick Removal and Replacement
6-45
SG811-BV-MMA-010

c. From underneath, in bottom access, remove nut (10) and washer (11) securing control stick assembly (4) to
the control panel (12).
d. Remove four side bolts (5) and nuts (6) on side of control joystick (4) allowing access to electrical connec-
tion points.
e. Inside control joystick (4), remove three screws (9) securing three electrical wire connections (8).
f. Remove three electrical wires (8) from control joystick (4) terminals.
g. Remove the defective control joystick (4).
h. Remove nameplate (13) by removing four nuts (14), washers (15) and screws (16).
i. Install the control joystick in the reverse order.

6-4.5.11 Remove Electronic Control Unit. Remove the electronic control unit as follows, referring to figure 6-6.

WARNING

Before performing any maintenance action, notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel.

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply may result in injury or
death to maintenance personnel.

a. Deenergize electrical power to crane by opening circuit breaker on the 1S Switchboard and tag ″OUT-OF-
SERVICE.″ Refer to SIB Volume 3 for exact location of circuit breaker.

NOTE

Ensure turret door is accessible before attempting the following steps.

b. Using turret door key, unlock turret door by loosening door retaining fasteners.
c. Open turret door and locate ECU (4, figure 6-6) in forward section of compartment within operator seat
assembly.
d. Tag and disconnect three male connectors (7) on side of ECU (4).
e. Remove ground strap (34) from side of ECU (4).
f. Remove two ground strap nuts (32) from ground stud (33).

6-46
 SG811-BV-MMA-010

WARNING

The ECU weighs over 20 pounds. Care should be used to properly support
the ECU as personnel injury could occur.
g. Remove four hex screws (6) and washers (35) securing ECU (4) to the vibration mounts (8).
h. Remove ECU (4) from vibration mounts (8).

6-4.5.12 Electronic Control Unit Disassembly/Reassembly. Disassemble the electronic control unit as follows,
referring to figure 6-10.

a. Loosen six retaining locking screws (2) and open electronic control unit cover (1) and, if required, remove/
replace gasket (3).
b. Disconnect ground strap (4) from inside front cover (1).
c. Remove screws (5), spring washers (6), and washers (7) from top of cover (8) and remove screw (9) and
washers (10) from side of ECU.
d. Remove supply board (12), in accordance with paragraph 6-4.5.12.3.
e. Remove the control board (13), in accordance with paragraph 6-4.5.12.1.

6-4.5.12.1 Remove Control Board. Remove the control board from the ECU as follows, referring to figure
6-10. The following procedure can be used while the ECU is still within the crane.

WARNING

Before performing any maintenance action, notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury on death to maintenance personnel.

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply may result in injury or
death to maintenance personnel.

a. If the ECU is still in the crane, deenergize electrical power to crane by opening circuit breaker on the 1S
Switchboard and tag ″OUT-OF-SERVICE.″ Refer to SIB Volume 3 for exact location of circuit breaker.
b. Tag and remove wires from terminal board (25).
c. Remove connector P1 (15) from J1 on control board (13).

6-47
SG811-BV-MMA-010

d. Remove dirty box (11) in accordance with paragraph 6-4.5.12.5.

e. Remove eight nuts (23), sixteen washers (24), securing control board (13) to ECU.
f. Remove control board (13).

6-4.5.12.2 Replace Control Board. Install the control board as follows, referring to figure 6-10.

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply may result in injury or
death to maintenance personnel.

a. Place control board (13) in position inside the ECU.

b. Place 16 washers (24) and 8 nuts (23) on control board (13).
c. Replace connector P1 (15) on control board.
d. Install tagged wires to terminal board (25) and secure wires with retaining screws.
e. Reinstall dirty box in accordance with paragraph 6-4.5.12.5.

6-4.5.12.3 Remove Supply Board. Remove the supply board as follows, referring to figure 6-11. The follow-
ing procedure can be used with the ECU still inside the crane.

WARNING

Before performing any maintenance action notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel.

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply may result in injury or
death to maintenance personnel.

a. If the ECU is still inside the crane, deenergize electrical power to crane by opening circuit breaker on the 1S
Switchboard and tag ″OUT-OF-SERVICE.″ Refer to SIB Volume 3 for exact location of circuit breaker.
b. Using identification markers, tag and remove wires from terminals TB1 through TB4 (1, 2, 3, and 4) by loos-
ening retaining screws.

6-48
 SG811-BV-MMA-010

Figure 6-10. Electronic Control Unit Disassembly

6-49
6-50

SG811-BV-MMA-010
Figure 6-11. Supply Board/Transformer Removal
 SG811-BV-MMA-010

c. Remove five nuts (6) and washers (7) securing supply board (5) to standoff (8).
d. Remove supply board (5) from ECU.
e. Reinstall in the reverse order.

6-4.5.12.4 Remove and Replace Dirty Box. Remove the dirty box from the ECU as follows, referring to figure
6-10,

a. Remove 15 screws (5), spring washers (6), and washers (7).

b. Remove connector P1 (15) from J1 on control board (13).
c. Remove two leads (26) coming from the dirty box F1 (27) and F2 (28).
d. Lift dirty box (11) out of ECU.
e. Reinstall in the reverse order.

6-4.5.12.5 Disassemble/Replace Dirty Box. Disassemble the dirty box as follows, referring to figure 6-10.

a. Remove 11 screws (5), spring washers (6), and washers (7) securing cover (8) and remove cover.

CAUTION

To prevent damage to equipment, do not use soldering iron over 25 watts.

b. Remove/replace connectors J1 through J4 as follows:
(1) Tag and unsolder wires from connectors.
(2) Remove four nuts (29) and washer (30) from screw (31) and remove screw (31) from front of connector.
(3) Reinstall in reverse order.
c. Remove and replace the ground stud as follows:
(1) Remove two nuts (32), and one washer (33), from ground stud (34).
(2) Pull ground stud (34) out through the front of the dirty box (11).
(3) Reinstall in the reverse order.

CAUTION

To prevent damage to equipment, do not use soldering iron over 25 watts.

d. Remove and replace the filter board (16) assemblies as follows:
(1) Tag and unsolder wire to filter board (16).
(2) Remove six screws (17) from the top of the filter board (16) and remove the board.
(3) Reinstall in the reverse order.

CAUTION

To prevent damage to equipment, do not use soldering iron over 25 watts.

6-51
SG811-BV-MMA-010

e. Remove line filters (20) as follows:

(1) Tag and unsolder wires from both sides of filter (20).
(2) Remove nut (35) from outside of dirty box.
(3) Slide filter (20) out through inside of box.
(4) Reinstall in reverse order.

6-4.5.12.6 Remove and Replace Transformers TO47 and TO48. Remove and replace transformers TO47 and
TO48 as follows, referring to figure 6-10 and figure 6-11.

a. Remove the supply board (5) in accordance with paragraph 6-4.5.12.3.

b. Tag and remove wires from terminal board (11, figure 6-11) on top of transformer to be removed.
c. Remove four nuts (12) and washers (13) securing transformer (9) to standoff (8).
d. Reinstall in the reverse order. Ensure standoffs (8) for the supply board (5) are put onto new transformer.

6-4.5.12.7 Remove and Replace Resistors R1 through R4. Remove and replace resistors R1 through R4 as fol-
lows, referring to figure 6-12.

a. At resistor (19, 24, 25, or 26) to be removed, remove two screws (20), nuts (21) lockwashers (22) and flat-
washers (23).

CAUTION

To prevent damage to equipment, do not use soldering iron over 25 watts.

b. Turn resistor to access wires, tag and unsolder wires from resistor.

NOTE

To remove R1 or R2 it may be necessary to remove capacitor C1 (38, figure

6-10) first.
c. Reinstall in reverse order.

6-4.5.12.8 Remove and Replace Capacitor C1. Remove and replace capacitor C1 as follows, referring to figure
6-10.

WARNING

Capacitors are storage devices for electricity. Care should be used in han-
dling capacitors as electric shock or injury could occur.

a. Tag and disconnect two wires from top of capacitor (38).

b. Loosen screw (36) on band (37) securing capacitor C1 (38).

6-52
 SG811-BV-MMA-010

c. Remove capacitor C1 (38).

d. Reinstall in reverse order.

6-4.5.12.9 Remove and Replace Fuseholders F1 and F2. Remove and replace fuseholders F1 and F2 as follows,
referring to figure 6-10.

a. Tag and remove two leads from fuseholder (39) to be removed.

b. Remove two nuts (40), lockwashers (41), and washers (42) securing fuseholder (39).

NOTE

Screw is mounted from beneath mounting plate and cannot be removed unless
the entire mounting plate is removed from ECU.
c. Remove fuseholder (39).
d. Reinstall in reverse order.

6-4.5.12.10 Remove and Replace Heat Sink. Remove, disassemble, assemble and replace the heat sink and its
components as follows, referring to figure 6-12.

NOTE

To remove components from the heat sink it must first be removed from the side
of the ECU.

a. Remove two nuts (1) and washers (2 ) from heat sink (3).
b. Hold two nuts (4) and remove two screws (5) and washers (6) from side of ECU (7).
c. The heat sink can now be turned so that wires from the components on the bottom of the heat sink can be
removed.

CAUTION

To prevent damage to equipment, do not use soldering iron over 25 watts.

d. Remove transistor Q1 (8) or Q2 (9) as follows:
(1) Tag and unsolder wires attached to transistor.
(2) Remove two screws (10) nuts (11), lockwashers (12) and washers (13) securing transistor (8) to heat sink
(3).
(3) Remove transistor (8) with mica insulator (14).
(4) Reinstall in reverse order.

CAUTION

To prevent damage to equipment, do not use soldering iron over 25 watts.

6-53
SG811-BV-MMA-010

e. Remove diodes D1 through D4 as follows:

(1) Tag wire (17) and remove nut (18) and then remove wire (17) with lug and washer (16) from diode (15)
bottom.
(2) Tag and unsolder wire from diode top.
(3) Slide diode out through top of heat sink (3).
(4) Reinstall in reverse order.

6-4.5.12.11 Remove and Replace ECU Door. Remove and replace ECU door and hinges as follows, referring
to figure 6-13.

a. To remove door (1), loosen and remove two nuts (6), lockwashers (7) and flatwashers (8) from hinge studs
(2).
b. Lift door (1) away from box and remove washer (12).
c. Remove hinge from door by removing nut (9), lockwasher (10) and flat-washer (11) from hinge (2) on hinge
bolt (3).
d. Reassemble in reverse order. Use nut (4, figure 6-13) to adjust cover closure.

6-4.5.13 Electric Motor Starter Removal. Remove electric motor starter as follows, referring to figure 6-6 and
6-14.

WARNING

Before performing any maintenance action, notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel.

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply may result in injury or
death to maintenance personnel.

a. Deenergize electrical power to crane by opening circuit breaker on the 1S switchboard and tag ″OUT-OF-
SERVICE.″ Refer to SIB Volume 3 for exact location of circuit breaker.

b. Open seven door locks (36) and open container door (10), referring to figure 6-6.

c. Tag and disconnect electrical wires from TB1 (1, figure 6-14), two wires to OL1, three wires to contactor CO1
(3) and remove nut (4) and wire from ground stud.

6-54
 SG811-BV-MMA-010
Figure 6-12. Heat Sink Assembly
6-55
SG811-BV-MMA-010

Figure 6-13. ECU Door Assembly

6-56
 SG811-BV-MMA-010

Figure 6-14. Electric Motor Starter Disassembly

6-57
SG811-BV-MMA-010

WARNING

The starter weighs in excess of 50 lbs. Ensure the unit is well supported to
prevent injury to personnel.
d. Remove six bolts (5) and washers (6) holding motor starter to vibration dampeners (7).
e. Remove electric motor starter from crane.

6-4.5.14 Electric Motor Starter Disassembly. Disassemble electric motor starter as follows, referring to figure
6-14.

WARNING

Hazardous voltages exist inside electric motor starter. If the electric motor
starter is disassembled on the crane, ensure all power is removed as in
paragraph 6-4.7.1 prior to starting work as death or injury to personnel
could occur.

a. If the unit is still mounted in the crane, deenergize electrical power to crane by opening circuit breaker on 1S
switchboard and tag ″OUT-OF-SERVICE.″ Refer to SIB Volume 3 for exact location of circuit breaker.
b. Loosen door lock retaining screws (36, figure 6-6) and open container door (10).
c. Secure door in the reverse order.

6-4.5.14.1 Remove and Replace Overload Relay OL1. Remove and replace overload relay OL1 as follows,
referring to figure 6-14:

a. Tag and remove wires attached to overload relay OL1 (2).

b. Remove four screws (8) and washers (9) from overload relay OL1 base and remove overload relay from bot-
tom plate (10).
c. Reinstall in reverse order.

6-4.5.14.2 Remove and Replace Contactor CO1. Remove and replace the contactor CO1 (3) as follows, refer-
ring to figure 6-14.

a. Tag and remove wires attached to contactor CO1 (3).

b. Remove 4 screws (11) and washers (12) from contactor CO1 (3) base and remove contactor CO1 (3) from
bottom plate (10).
c. Reinstall in reverse order.

6-4.5.14.3 Remove and Replace Relays R1 and R2. Remove and replace relays R1 (13) and R2 (14) as fol-
lows, referring to figure 6-14.

6-58
 SG811-BV-MMA-010

a. Tag and remove all wires on the relay to be removed.

b. Remove screws (15), lockwashers (16) and washers (17) securing the relay to the bottom plate (10).
c. Remove the relay.
d. Reinstall the relay in the reverse order.

6-4.5.14.4 Remove and Replace Transformer TR1. Remove and replace transformer TR1 (18) as follows,
referring to figure 6-14.

a. Tag and remove wires from terminal board on top of transformer TR1 (18).
b. Remove four screws (19), lockwashers (20), and flat washers (21) securing the transformer TR1 to the bottom
plate (10).
c. Remove the transformer TR1 (18).
d. Reinstall in the reverse order.

6-4.5.14.5 Remove and Replace Fuseholder F1 through F6. Remove and replace fuseholders F1 through F6
(22, 23, 24, 25, 26, and 27) as follows, referring to figure 6-14.

a. Tag and remove all wires from fuseholder to be removed.

b. Remove two screws (28, figure 6-14), lockwashers (29) and, washers (30) securing fuseholder to bottom plate
(10).
c. Remove fuseholder.
d. Reinstall in reverse order.

6-4.5.14.6 Remove and Replace Terminal Board TB1. Remove and replace terminal board TB1 (1) as follows,
referring to figure 6-14.

a. Tag and remove all wires from terminal board TB1 (1).
b. Remove two screws (31) and washers (32).
c. Remove terminal board TB1 (1)
d. Reinstall in reverse order.

6-4.5.14.7 Remove and Replace RESET Switch. Remove and replace the RESET switch as follows, referring
to figure 6-15.

a. Tag and remove all wires from switch (1).

b. Remove three screws (2), lockwashers (3) and washers (4) from back of RESET switch.
c. Remove switch (1) and plate (6) from rear of door (5).
d. Remove bottom cover (7) from front of door (5).
e. Reinstall in reverse order.

6-59
SG811-BV-MMA-010

6-4.5.14.8 Remove and Replace BATTLE SHORT Switch. Remove and replace the BATTLE SHORT switch
as follows, referring to figure 6-15.

a. Tag and remove all wires from switch (8).

b. Remove ring nut from front of switch (8).

c. Pull switch through back of door (5).

d. Reinstall in the reverse order.

6-4.5.14.9 Remove and Replace Elecric Motor Starter Door. Remove and replace the electric motor starter door
(5) as follows, referring to figure 6-15.

a. Tag and remove all wires from battle short switch (8).

b. Tag and remove all wires from reset switch (1).

c. Remove nut (10), flat washer (11), and lockwasher (12) from hinge bolts.

d. Remove door (5) from motor starter.

e. Reinstall in reverse order.

6-4.5.15 Electric Motor Starter Installation. Install the electric motor starter as follows, referring to figure 6-15.

a. Place the electric motor starter enclosure in position in operator seat assembly.

b. Replace six washers (12) and screws (11). Torque bolts to 31.13 ft-lbs (42.2 Nm).

c. Reconnect all electrical leads and remove tags.

d. Close door (5, figure 6-15) and secure six screw locking devices.

e. Energize electrical power to crane by closing circuit breaker on the 1S switchboard and remove ″OUT-OF-
SERVICE″ tag.

6-60
 SG811-BV-MMA-010

Figure 6-15. Electric Motor Starter Door

6-61
SG811-BV-MMA-010

6-4.5.16 Remove and Replace Connection Box No. 4. Remove and replace connection box no. 4 (9) as fol-
lows, referring to figure 6-6.

a. Loosen four retaining screws (14) on connection box no. 4 cover (15) and remove cover (15).
b. Tag and remove all electrical leads coming into the box.
c. Remove four screws (30) and washers (31), inside connection box no. 4 (9) and remove box.
d. Reinstall connection box no. 4 (9) in the reverse order.

6-4.6 Disassemble/Assemble the Turret Enclosure. Disassemble and reassemble the turret enclosure (85) in
accordance with the following paragraph, referring to figure FO-12 or figure FO-13.

WARNING

Before performing any maintenance action, notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel.

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE″. Failure to comply may result in injury or
death to maintenance personnel.

WARNING

The turret enclosure and ladder weighs approximately 194 pounds. Failure
to support properly during handling may result in injury to maintenance
personnel or damage to equipment.

a. Attach lifting device to rail on turret enclosure (85).

b. Remove screw (172) and washer (173) from rail on turret enclosure (85) to back of operator seat (33).
c. Remove twelve screws (6, figure FO-12 or figure FO-13) and 12 washers (7) from revolving turret (9).
d. Remove 5 screws (36) and washers (97) from operators seat (33).
e. Lower turret enclosure (85) to deck.
f. Reinstall turret enclosure (85) in the reverse order.

6-4.7 Remove Electric Motor. Remove electric motor as follows, referring to figure 6-16.

6-62
 SG811-BV-MMA-010

a. Deenergize electrical power to crane by opening circuit breaker on the 1S switchboard and tag ″OUT-OF-
SERVICE.″ Refer to SIB Volume 3 for exact loca-tion of circuit breaker.

CAUTION

Identify and tag electrical leads as they are disconnected to prevent incor-
rect wiring connection during installation procedures.

b. Remove screws (38) and lockwashers (43) from electrical connector box cover (24) and remove cover.

c. Disconnect and tag electrical leads (27) from motor connections. Remove ground strap.

d. Remove cable from electrical connector box (21).

WARNING

Failure to support electric motor properly during handling may result in

personnel injury or damage to equipment.

e. Attach lifting device to eyebolt (4, figure 6-16) on motor.

f. Remove four screws (21) and four washers (22) between connection bell (16) and electric motor (24). (Refer
to figure FO-12 or figure FO-13).

g. Remove four screws (25) and washers (26) between revolving turret (9) and electric motor (24).

h. Lower electric motor (24) to deck and remove lifting device.

6-4.7.1 Disassemble Electric Motor. Before disassembling the motor, refer to NSTM S9086-KE-STM-000
Chapter 302. Disassemble the electric motor as follows, referring to figure 6-16.

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE″. Failure to comply may result in injury or
death to maintenance personnel.

a. Remove bracket (3) from frame (1) and shaft (11).

b. Remove screw (37, figure 6-16) and washer (43) from shutter (20) and remove shutter (20) from bearing
bracket (2).

6-63
6-64

SG811-BV-MMA-010
Figure 6-16. Electric Motor (Sheet 1 of 2)
 SG811-BV-MMA-010

Figure 6-16. Electric Motor (Sheet 2 of 2)

6-65
SG811-BV-MMA-010

c. Using a bearing puller, remove bearing back end (6) from shaft (11).
d. Remove screw (35) and washer (41) from bearing bracket (2).
e. Remove bearing bracket (2) from frame (1) and shaft (11).
f. Remove spring captive washer (17) and spring headed pin (16).
g. Using a bearing puller, remove bearing front end (5) from shaft (11).
h. Remove rotor and shaft assembly (10) from frame (1).

CAUTION

Removing the rotor assembly from the motor shaft is not recommended, as
damage to the motor shaft could occur.
i. Place the rotor assembly (10) in the hydraulic press with pump end of shaft facing up. Install fixtures on to
rotor assembly.
j. Place cylindrical fixture squarely against face of the rotor assembly (12), between rotor assembly (12) and
shaft (11).
k. Press rotor assembly (12) from shaft (11). Two to four tons of force should be required.
l. Remove rotor key (19) from shaft (11).

6-4.7.2 Clean and Inspect Electric Motor. Clean and inspect electric motor as follows, referring to figure 6-16.

WARNING

Cleaning solvents are hazardous to personal health. When use of solvent

P-D-680 is necessary, only Type III, which has a high flash point shall be
used. Use only in a well ventilated area. Use care as personnel injury or
death can result.

a. Use a stiff brush to clean the frame (1). Use P-D-680 Type III solvent as necessary.
b. Inspect front end bracket (2) for scoring. Reject if severely scored.
c. Inspect back end bracket (3) for scoring. Reject if severely scored.
d. Clean outside of motor frame (1) using a stiff bristle brush and P-D-680 Type III solvent. Do not get solvent
on windings.
e. Inspect wound stator assembly (9) leads and clean using a soft bristle brush or cloth dampened with P-D-680
Type III. If rewinding is necessary, refer to a repair facility.
f. Clean rotor assembly (12, figure 6-16) using a soft bristle brush and P-D-680 Type III solvent.
g. Wipe down shaft (11) with clean soft cloth dampened with P-D-680 Type III solvent. Inspect shaft (11) for
scoring, scratches or nicks. Replace shaft (11) if severely damaged.
h. All other motor component limits and tolerances are given in NAVSEA 0900-LP-060-2010, NAVSEA Tech-
nical Manual For Electric Motor Repair.

6-66
 SG811-BV-MMA-010

6-4.7.3 Assemble Electric Motor. Assemble the electric motor by performing the procedures in paragraph
6-4.7.1 in the reverse order.

NOTE

To prevent damage to rotor and shaft assembly (10), wrap rotor assembly in
heavy gauge paper and set complete rotor and shaft assembly into frame (1).

6-4.8 Replace Electric Motor. Install the electric motor as follows, referring to figure FO-12 or figure FO-13
and figure 6-16:

a. Attach lifting device to eyebolt (4, figure 6-16) on electric motor frame (1).
b. Move electric motor into place over connection bell (16, figure FO-12 or figure FO-13).
c. Secure electric motor (24) to revolving turret (9) using four washers (26) and screws (25).
d. Secure electric motor (24) to connection bell (16) using washers (21) and screws (22) and nuts (23).
e. Remove lifting device from eyebolt (4, figure 6-16) on electric motor frame (1).
f. Replace cable in electrical connector box (21, figure 6-16).
g. Connect and remove tags from electrical leads (27) of motor (24).
h. Secure cover (24) to connector box (21) using four screws (38).
i. Energize electrical power to crane by closing circuit breaker on the 1S Switchboard and remove ″OUT-OF-
SERVICE″ tag.

6-4.9 Slew Ring. The following paragraphs list procedures to remove, disassemble, reassemble, and install the
slew ring.

6-4.9.1 Slew Ring Removal. Remove slew ring as follows, referring to figure FO-12 or figure FO-13:

WARNING

Before performing any maintenance action notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel.

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply may result in injury or
death to maintenance personnel.

6-67
SG811-BV-MMA-010

a. Remove boat crane from pedestal in accordance with paragraph 6-3.1.

b. Place four threaded eye bolts, size 20mm x 135mm, through upper outside slew ring, 90 degrees apart. Attach
four flat washers, size 21 x 37 and four self-locking nuts, size 20mm, onto the four eye bolts.

c. Attach a four way chain with hooks to the four eye bolts on outer ring.

d. Using mobile crane connect the four way chain to lifting hook of a mobile crane.

e. Remove 36 screws (14, figure FO-12 or figure FO-13) and 36 washers (15) from bottom of pedestal (1).

f. Provide a suitable supporting stand for receiving slew ring.

g. Using mobile crane, lift slew ring vertically straight up off of pedestal and lower it over the ship’s side onto
a suitable supporting stand on the dock.

h. Remove four way chains from lifting eyes of slew ring.

6-4.9.2 Slew Ring Disassembly. Disassemble the slew ring as follows, referring to figure 6-17.

a. Provide a jig platform, with a bolt through connection template of the pedestal (1, figure FO-12 or figure
FO-13) mounting holes and hard mount the slew ring to a flat horizontal surface.

b. Use a four way chain to connect slew ring to mobile crane or other lifting device.

WARNING

Personnel must be clear of the total lifting chain swing radius. Failure to
comply may result in personnel injury or death.

c. Lift slew ring from the support stand and move it in place on jig stand.

d. Align mounting holes and secure (36 each) bolts (14, figure FO-12 or figure FO-13 and washers (15) through
the jig bottom into slew ring.

e. Provide a suitable stand for top bearing ring which allows access for inspection and measurements.

f. Using a punch, remove six pins (8, figure 6-17) from slew ring.

6-68
 SG811-BV-MMA-010
Figure 6-17. Slew Ring Assembly
6-69
SG811-BV-MMA-010

g. Remove 36 screws (10) and washers (9) from the supporting ring (2).
h. Lift the supporting ring (2) away from retaining ring (3).
i. Remove seal (14), from gear ring (1).
j. Remove upper outer wire race (5) from upper roller cage (4).
k. Remove upper roller cage (4) with bearings (7).
l. Remove inner wire race (6) from gear ring (1).
m. Remove oblique roller cage (4) with bearings (7).
n. Remove lower outer wire race (5) from retaining ring (3).
o. Lift gear ring (1) out.
p. Remove springs (12) and (11) and remove seal (14).

6-4.9.3 Assembly of Slew Ring. Assemble the slew ring in the reverse order of disassembly in paragraph
6-4.9.2.

6-4.9.4 Installation of Slew Ring. Install the slew ring as follows, referring to figure FO-12 or figure FO-13.

a. Using a mobile crane attach a four way chain to crane lifting hook and four slew ring eyebolts.
b. Lift slew ring clear of support stand and horizontally and straight over top of pedestal (1).
c. Using crane lower slew ring straight down onto the pedestal (1).
d. Align bottom ring mount holes.

e. Reinstall the (36 each) screws (14) and washers (15) and secure slew ring (10) to pedestal (1).

f. Disconnect four chains from slew ring.

g. Remove four eye bolts.

h. Install boat crane in accordance with paragraph 6-3.2

6-4.9.5 Removal of Slew Ring Locking Device. Remove the slew ring locking device as follows, referring to
figure 6-18:

WARNING

Before performing any maintenance action notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel.

6-70
 SG811-BV-MMA-010

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply may result in injury or
death to maintenance personnel.

a. Deenergize electrical power to crane by opening circuit breaker on the 1S switchboard and tag ″OUT-OF-
SERVICE.″ Refer to SIB Volume 3 for exact location of circuit breaker.

b. Remove pin (1, figure 6-18) from fixed bushing (2).

c. Place a screw driver in the slot at the end of the mobile bushing (5) and move the locking device lever (13)
towards the LOCK OUT position. Stop when the lever is directly over the mobile bushing (5).

d. Place the locking lever (13) in the lock position.

e. Remove 18 screws (3) and washers (4) from access panel (2) on bottom of pedestal assembly (1, refer to
figure FO-12 or figure FO-13).

f. Remove access panel (2).

g. Remove pin (6, figure 6-18), washer (7) and self-locking nut (8).

WARNING

The spring (4) inside the mobile bushing (5) is under high tension. Do not
remove screw driver from the slot in mobile bushing as the fixed bushing (2)
will be free to come out and injury to personnel will occur.

h. Rotate mobile bushing (5) and remove it from rotating lever pin (24).

i. Remove screw (9) from mobile bushing (5) and insert special tool as shown in figure 6-19 through the hole
where screw (9) was removed.

j. Screw the special tool into fixed bushing (2).

k. Tighten the floating nut on the special tool enough to compress spring (4) and allow removal of screwdriver
from the slots of mobile bushing (5).

l. Slowly back off the floating nut on the special tool until the spring (4) compression is released.

m. Remove special tool and allow fixed bushing (2) O-ring (3), and spring (4) to slide out of mobile bushing
(5).

6-4.9.6 Disassembly of the Slew Ring Locking Device. Disassemble the slew ring locking device as follows,
referring to figure 6-18.

6-71
SG811-BV-MMA-010

Figure 6-18. Slew Ring Locking Device

6-72
 SG811-BV-MMA-010

a. Remove nut (10, figure 6-18) from lever (12) and remove lever (12) from bushing (11).

b. Remove bushing (11) from shaft of eccentric (35).

c. Remove transmission bushing (17) and remove two oil seals (14), two spacers (16), and bearing (15) from
transmission bushing (17).

d. Remove six screws (26) and six washers (25) from cover (29).

e. Remove cover (29), spherical roller bearing (30) and oil seal (31).

f. Remove tongue (34) from eccentric (35).

g. Remove bushing (27) and oil seal (28) from eccentric (35).

h. Remove eight screws (32), washers (33), washers (38) and nuts (39) and remove locking device from crane.

i. Remove six screws (47) and six washers (46) from bottom cover (45) of slew ring locking assembly.

j. Remove spherical roller bearing (44) and oil seal (43) from eccentric (35).

k. Remove eight screws (42) and eight washers (41) from bottom of frame (37).

l. Remove toothed interlock (55) from frame (37).

m. Remove two lower sliding blocks (36) from frame (37).

n. Remove six screws (48) and separate fastening lock (49) from toothed interlock (55).

o. Remove eccentric (35) from between fastening lock (49) and toothed interlock (55).

p. Remove six screws (52) from two stop plates (53 and 54).

q. Remove stop plates (53 and 54) and six bearings (50 and 51).

r. Remove six screws (18) and six washers (19) from rotating lever pin cover (20).

s. Remove cover (20).

t. Remove oil seal (21), two ball bearings (22), spacer (23) and rotating lever pin (24).

u. Loosen adapter (60) on end of lubrication tube (58).

v. Remove lubrication tube (58), male stud coupling (59), adapter (60), and washer (61) from revolving turret.

w. Remove grease nipple (56) from male stud coupling (57).

6-4.9.7 Assembly of Slew Ring Locking Device. Assemble the slew ring locking device as follows, referring
to figure 6-18 and figure 6-19:

6-73
SG811-BV-MMA-010

Figure 6-19. Use of Special Tool

a. Tighten male stud coupling (57, figure 6-18) onto tube (58).
b. Tighten grease nipple (56) onto male stud coupling (57).
c. Replace washer (61, figure 6-18), male stud coupling (59), adapter (60) and lubrication tube (58) on revolv-
ing turret.
d. Tighten adapter (60) on male stud coupling (59).
e. Install ball bearing (22) rotating lever pin (24), spacer (23), and oil seal (21).
f. Replace rotating lever pin cover (20), and secure six washers (19), and six screws (18).
g. Torque screws to 16 ft-lbs.

6-74
 SG811-BV-MMA-010

h. Install six bearings (50) and (51), two stop plates (53) and (54).
i. Replace six screws (52) in two stop plates (53) and (54).
j. Torque screws (52) to 16 ft-lbs.
k. Position toothed interlock (55) and eccentric (35) fastening lock (49) together and secure using six screws
(48).
l. Torque screws (48) to 31 ft-lbs.
m. Place lower sliding block (36) into frame (37) and secure with washer (41) and screw (42).
n. Torque screws (42) to 16 ft-lbs.
o. Insert toothed interlock (55) into frame (37).
p. Install oil seal (43) roller bearing (44), cover (45) in frame (37) and secure with six washers (46) and screws
(47).
q. Torque screws (47) to 16 ft-lbs.
r. Insert frame (37) with eccentric (35) up through revolving turret.
s. Install eight screws (32), eight washers (33), eight washers (38) and eight nuts (39) to secure frame (37) to
revolving turret.
t. Torque screws (32) and nuts (39) to 132 ft-lbs.
u. Replace tongue (34) in eccentric (35).
v. Install oil seal (31), bearing (30) and cover (29), and secure with six washers (25) and screws (26).
w. Torque screws (26) to 16 ft-lbs.
x. Install bushing (27), oil seal (28), transmission bushing (17) and bushing (11) on eccentric (35).
y. Install spring (4), O-ring (3), and fixed bushing (2) in mobile bushing (5).
z. Insert special tool (figure 6-19) through the end of mobile bushing (5, figure 6-18) and into fixed bushing
(2) and tighten threaded bar to compress spring (4).
aa. Place a screwdriver in the slots at the end of mobile bushing (5, figure 6-18) to hold fixed bushing in place.
ab. Remove special tool and replace screw (9).
ac. Install 2 oil seals (14) bearing (15) and two spacers (16) into transmission bushing (17).
ad. Place mobile bushing (5) over transmission bushing (17).
ae. Install bearing (22), pin (24), spacer (21), and oil seal (8) into turret.
af. Install cover (20) and secure using six screws (18) and washer (19).
ag. Slip bearing (22) over pin (24).
ah. Rotate end of mobile bushing (5) over transmission bushing (17).
ai. Install pin (6), washer (7), and self locking nut (8) in transmission bushing (17).
aj. Torque pin (6) and self-locking nut (8) to 55 ft-lbs.
ak. Insert lever (12) in bushing (11) and install nut (10) on end of lever (12).
al. Torque nut (10) to 89 ft-lbs.

6-75
SG811-BV-MMA-010

am. Move handle (13) to LOCK OUT position and remove screwdriver.

an. Move handle (13) to LOCK IN position and insert pin (1).

ao. Replace access panel (2, figure FO-12 or figure FO-13) on pedestal assembly (1).

ap. Replace 18 washers (4) and 18 screws (3).

aq. Torque screws to 31 ft-lbs.

ar. Locate power distribution panel and remove ″OUT-OF-SERVICE″ tag from circuit breaker.

6-4.10 Hydraulic Motor. The following paragraphs list the procedures necessary to remove, disassemble, reas-
semble, and install the hydraulic motor.

6-4.10.1 Removal of Hydraulic Motor. Remove the hydraulic motor as follows, referring to figure FO-12 or
figure FO-13 and 6-20.

a. Depress ″MOTOR OFF″ pushbutton on control panel to shut down hydraulic power.

WARNING

Before performing any maintenance action, notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel.

WARNING

Boat crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply may result in injury or
death to maintenance personnel.

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply may result in injury or
death to maintenance personnel.

6-76
 SG811-BV-MMA-010

Figure 6-20. Hydraulic Motor, Brake, and Reduction Gear

6-77
SG811-BV-MMA-010

b. Deenergize electrical power to crane by opening circuit breaker on the 1S switchboard and tag ″OUT-OF-
SERVICE.″ Refer to SIB Volume 3 for exact location of circuit breaker.
c. Place oil pan under hydraulic lines connected to hydraulic motor (1).

CAUTION

Cap all hose connections to ensure that the hydraulic system is not contami-
nated by the introduction of foreign material.
d. Loosen hydraulic line connections at hydraulic motor (1, figure 6-20).
e. Wipe up any spilled hydraulic fluid.
f. Remove four screws (2) and four washers (3) securing hydraulic motor (1) to hydraulic brake (5).

WARNING

Failure to support hydraulic motor properly during handling may result in

personnel injury or damage to equipment.
g. Remove hydraulic motor (1) from hydraulic brake (5).

6-4.10.2 Assembly and Installation of Hydraulic Motor. Install the hydraulic motor as follows, referring to
figure FO-12 or figure FO-13 and figure 6-20.

WARNING

Failure to support hydraulic motor properly during handling may result in

personnel injury or damage to equipment.

a. Position hydraulic motor (1) on hydraulic brake (5).

b. Secure hydraulic motor (1) with four washers (3) and four screws (2) torque to 55 ft-lb.
c. Connect hydraulic lines to hydraulic motor (1).
d. At the 1S switchboard remove ″OUT-OF-SERVICE″ tag from circuit breaker.
e. Place circuit breaker in the ON position.

6-4.11 Hydraulic Brake. The following paragraphs describe the removal, disassembly, reassembly and installa-
tion of the hydraulic brake.

6-4.11.1 Hydraulic Brake Removal. Remove hydraulic brake as follows referring to figure FO-12 or figure
FO-13 and figure 6-20.

6-78
 SG811-BV-MMA-010

WARNING

Before performing any maintenance action, notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel.

WARNING

Boat crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply may result in injury or
death to maintenance personnel.

a. Depress ″MOTOR OFF″ pushbutton on control panel to shut down hydraulic power.

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply may result in injury or
death to maintenance personnel.
b. Deenergize electrical power to crane by opening circuit breaker on the 1S switchboard and tag ″OUT-OF-
SERVICE.″ Refer to SIB volume 3 for exact location of circuit breaker.
c. Place oil pan under hydraulic lines connected to hydraulic brake (5) and hydraulic motor (1).

CAUTION

Cap all hose connections to ensure that the hydraulic system is not contami-
nated by the introduction of foreign material.
d. Remove hydraulic lines from valve block assembly, (42 figure FO-12 or figure FO-13), through tee on pilot
valve and through tee on forward side of pilot valve.
e. Remove hydraulic line from valve block (42) to valve tee.
f. Remove hydraulic line for hydraulic connection from hydraulic motor (1, figure 6-20) to sump cover. Remove
hydraulic line from brake assembly (5).
g. Remove hydraulic line from hydraulic brake (5, figure 6-20) to hydraulic union on side of sump.
h. Remove hydraulic line from motor (1) to the tee connection under valve block.
i. Wipe up any spilled hydraulic fluid.
j. Remove eight screws (6) from the brake (5).

6-79
SG811-BV-MMA-010

WARNING

Failure to support hydraulic brake properly during handling may result in

personnel injury or damage to equipment.

k. Remove hydraulic brake assembly (5) with hydraulic motor from reduction gear (8).

l. To remove hydraulic motor (1) from brake assembly (5), refer to paragraph 6-4.10.

6-4.11.2 Disassembly of Hydraulic Brake. Disassemble the hydraulic brake as follows, referring to figure 6-21.

a. Remove four magnetic plugs (10) from braking casing (9).

b. Remove four steel plugs (20) from brake cover (2).

c. Remove four screws (1) and four washers (27) to separate the hydraulic motor from brake cover (2).

d. Remove eight screws (22) from brake cover (2).

e. Separate brake cover (2) from braking casing (9).

f. Remove coupling joint (19) and expansion ring (21) from brake shaft (16).

g. Using retaining ring pliers, remove retaining ring (3) from brake cover (2).

h. Remove brake shaft (16) from brake cover (2).

i. Remove two O-rings (6 and 7) and backing ring (8) from piston brake (23).

j. Remove two brake springs (11) from piston brake (23).

k. Remove piston brake (23) from brake casing (9).

l. Remove O-ring (7) and bcking rings (8) from spacer (26).

m. Remove spacer (26) from brake casing (9).

n. Remove O-ring (24) and backing rings (25) from brake casing (9).

o. Remove six sintered disks (12) and seven steel disks (13) from brake casing (9).

p. Remove O-ring (17) from brake cover (2).

q. Remove slip bushing (14) from lower end of brake shaft (16).

r. Using retaining ring pliers, remove retaining ring (15, figure 6-21) from lower end of brake shaft (16).

s. Using retaining ring pliers, remove two retaining rings (18 and 5) and bearing (4) from brake shaft (16).

6-80
 SG811-BV-MMA-010

Figure 6-21. Hydraulic Brake Disassembly

6-4.11.3 Assembly of Hydraulic Brake. Reassemble the hydraulic brake as follows, referring to figure 6-21.

a. Place bearing (4) on brake shaft (16).

b. Using retaining ring pliers, replace retaining rings (18 and 5) on brake shaft (16).
c. Replace expansion ring (21) and coupling joint (19).
d. Install new O-ring (17) in brake cover (2).
e. Place shaft assembly in brake cover (2).
f. Using retaining ring pliers, replace retaining ring (3) on brake cover (2).

6-81
SG811-BV-MMA-010

g. Using retaining ring pliers, replace retaining ring (15) on lower end of brake shaft (16).
h. Place six sintered disks (12) and seven steel disks (13) in braking casing (9).
i. Replace two backing rings (8 and 25), spacer (26), and two new O-rings (7 and 24).
j. Replace piston brake (23) and two brake springs (11).
k. Replace backing ring (8) and install two new O-rings (6 and 7).
l. Position brake cover (2) on braking casing (9).
m. Replace eight screws (22) in brake cover (2).
n. Torque eight screws (22) to 7 ft-lbs.
o. Replace four washers (27) and four screws (1) in brake cover (2).
p. Torque four screws (1) to 31 ft-lbs.
q. Replace four steel plugs (20) in brake cover (2) and tighten.
r. Replace magnetic plug (10) in braking casing (9) and tighten.

6-4.11.4 Installation of Hydraulic Brake. Install the hydraulic brake as follows, referring to figure 6-20.

WARNING

Failure to support hydraulic brake properly during handling may result in

personnel injury or damage to equipment.

a. Position hydraulic brake (5) on reduction gear (8) located on the pedestal.
b. Replace eight hexhead capscrews (6).
c. Torque hexhead capscrews to 55 ft-lbs.
d. Replace hydraulic motor (1, figure 6-20) on hydraulic brake (5), refer to paragraph 6-4.10.2.
e. Install hydraulic line from motor to the tee-connection under valve block.
f. Install hydraulic line from hydraulic brake to hydraulic union on side of sump.
g. Install hydraulic line for hydraulic connection from hydraulic motor to sump cover. Install hydraulic line from
brake assembly.
h. Install hydraulic line from valve block to valve tee.
i. Install hydraulic lines from valve block assembly through tee on pilot valve and through tee on forward side
of pilot valve.
j. Refill hydraulic motor and brake with hydraulic oil.
k. At the 1S Switchboard panel remove ″OUT-OF-SERVICE″ tag from circuit breaker.
l. Place circuit breaker in the ON position.

6-82
 SG811-BV-MMA-010

6-4.12 Reduction Gear. The following paragraphs describe the removal, disassembly, reassembly, and installa-
tion of the reduction gear.

6-4.12.1 Removal of Reduction Gear. Remove the reduction gear as follows, referring to figure 6-20.

WARNING

Before performing any maintenance action, notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel.

WARNING

Boat crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply may result in injury or
death to maintenance personnel.

a. Depress ″MOTOR OFF″ pushbutton on control panel to shut down hydraulic power.

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE″. Failure to comply may result in injury or
death to maintenance personnel.
b. Deenergize electrical power to crane by opening circuit breaker on the 1S switchboard and tag ″OUT-OF-
SERVICE.″ Refer to SIB Volume 3 for exact location of circuit breaker.
c. Remove hydraulic motor in accordance with paragraph 6-4.10.1.

CAUTION

Cap all hose connections to ensure that the hydraulic system is not contami-
nated by the introduction of foreign material.
d. Disconnect hydraulic lines to the hydraulic brake.
e. Place oil drain pan under drain valve (9) on reduction gear (refer to figure 6-20).
f. Open drain vlave (9) on reduction gear.
g. Wipe up any spilled hydraulic fluid.
h. Close handle on drain valve (9) and replace drain plug (16) in reduction gear (8).

6-83
SG811-BV-MMA-010

WARNING

Crane operations have inherent hazards that cannot be mechanically safe-

guarded. Hard hats and safety shoes are required when performing mainte-
nance as injury or death to personnel could occur.

WARNING

The hydraulic brake and reduction gear weight is 440 lbs (200 kg). Failure
to support properly during handling may result in personnel injury or dam-
age to equipment.
i. Insert eyebolt (M*, UNI 2497) in screw hole on reduction gear.
j. Attach lifting hook of lifting device to eyebolt and take up slack.
k. Remove 13 screws (10) and washers (11) securing hydraulic brake and reduction gear (5 and 8) to revolv-
ing turret.
l. Remove hydraulic brake (5) and reduction gear (8) from revolving turret.
m. Remove hydraulic brake (5) from reduction gear (8) in accordance with paragraph 6.4.11.1.

6-4.12.2 Disassembly of Reduction Gear. Disassemble the reduction gear as follows, referring to figure 6-22.

NOTE

Disassembly is started from the brake end of the reduction gear.

a. Remove O-ring (19) from top of toothed planetary ring (18).

b. Remove eight screws (20) holding toothed planetary gear (18) to connector spacer (17).
c. Remove flange (54), O-ring (19), shim (36) and spacer (57).
d. Using retaining ring pliers, remove retaining ring (23) from central pinion gear (37).
e. Remove screw (56), washer (55), slew ring (53), needle (52), planetary gear (51), and pin (21) from three
places on flange (54).
f. Remove eight screws (16) from connector spacer (17) holding toothed planetary ring (15) to output support
(5).
g. Remove spring pins (35) from connector spacer (17).
h. Using retaining ring pliers, remove retaining ring (34) from central pinion gear (33).
i. Remove central pinion gear (33).
j. Remove toothed planetary gear (15) and O-ring (14).
k. Remove screw (49), washer (48), slew ring (47), planetary gear (44), needle (45) and pin (46) from three
places on flange (13).

6-84
 SG811-BV-MMA-010

l. Remove flange (13), spacer (50) and shim (32).

m. Remove spacer (12) and O-ring (14).

n. Remove toothed planetary ring (11) and O-ring (10).

o. Remove three screws (61) and spring pins (60) from planetary gear support (39).

p. Remove planetary gear support (39) and central pinion (30).

q. Remove pin (9), spring pin (59), needle (41), slew ring (40), and planetary gear (38). Remove spring pins
(58) from flange (42).

r. Remove spring pins (31) from output support (5).

s. Using a spanner wrench, remove ring nut (8) on interior end of output shaft (24).

t. Remove bearing (26, figure 6-22) from output shaft (24).

u. Remove six screws (3), seal support (2) and gasket (4) from output support (5).

v. Remove output shaft (24), shim (28) and spacer (43).

w. Remove special key (7), bearing (25) and oil seal (1) from output shaft (24).

6-4.12.3 Assembly of Reduction Gear. Reassemble the reduction gear as follows, refer to figure 6-22.

NOTE

Coat all O-rings with petroleum jelly prior to their installation in the following
steps.

a. Insert output shaft (24) in seal support (2) and gasket (4).

b. Install oil seal (1), bearing (25) and special key (7) on output shaft (24).

c. Install six screws (3) attaching seal support (2) and gasket (4) to the output support (5).

d. Torque six screws (3) to 61 ft-lbs.

e. Install bearing (26) on interior end of output shaft (24).

f. Using a spanner wrench, install ring nut (8) on output shaft (24).

g. Install spacer (43) and shim (28) at end of output shaft (24).

6-85
SG811-BV-MMA-010

Figure 6-22. Reduction Gear

6-86
 SG811-BV-MMA-010

h. Install central pinion (30) in flange (42).

i. Install pin (9), spring pin (59), needle (41), slew ring (40), spring pin (58), and planetary gear (38) three
places on flange (42).
j. Install planetary gear support (39) over three planetary gear assemblies and mate with flange (42).
k. Install three screws (61) and three spring pins (60) in planetary gear support (39).
l. Torque three screws (61) to 31 ft-lbs.
m. Install O-ring (10) and toothed planetary ring (11).
n. Install O-ring (14) and spacer (12).
o. Install pin (46), needle (45), planetary gear (44) and slew ring (47) with washer (48), screw (49) three places
on flange (13) and tighten.
p. Torque three screws to 31 ft-lbs.
q. Install assembled toothed planetary gear (15) assembly on central pinion gear (33).
r. Install O-ring (14) and toothed planetary gear (15) and O-ring (14).
s. Install spacer (50), shim (32), central pinion gear (33).
t. Using retaining ring pliers, install retaining ring (34).
u. Install connector spacer (17, figure 6-22), spring pins (35) and eight screws (16).
v. Torque eight screws (16) to 31 ft-lbs.
w. Install pin (21), needle (52), planetary gear (51), slew ring (53), washer (55) and screw (56) three places on
flange (54).
x. Torque three screws (56) to 31 ft-lbs.
y. Install planetary gear assembly on central pinion (37).
z. Install O-ring (19), spacer (57), shim (36) and toothed planetary gear (18).
aa. Install central pinion gear (37) and using retaining ring pliers, install retaining ring (23) on pinion gear (37).

6-4.12.4 Installation of Reduction Gear. Install the reduction gear as follows, referring to figure FO-12 or figure
FO-13 and figure 6-20.

a. Install hydraulic brake on reduction gear in accordance with paragraph 6-4.11.

b. Insert eyebolt in screw hole of hydraulic brake.
c. Connect lifting hook of lifting device to eyebolt, lift hydraulic brake (5) and reduction gear (8) (refer to figure
6-20) up and lower into mounting position and align mounting holes.
d. Install 13 washers (11) and screws (10).
e. Tighten mounting screws.
f. Torque mounting screws to 54 ft-lb.
g. Disconnect lifting hook and remove eyebolt from hydraulic brake (5).
h. Install hydraulic brake lines.

6-87
SG811-BV-MMA-010

i. Install hydraulic motor in accordance with paragraph 6-4.10.2.

j. Remove plug (16) to replace hydraulic oil.

k. Refill reduction gear unit with oil. (MIL-L-2105 Mobilube SHC 75W-90).

l. Replace plug (16) and tighten.

m. At 1S switchboard remove ″OUT-OF-SERVICE″ tag from circuit breaker.

n. Place circuit breaker in the ON position.

6-4.13 Hydraulic Pump. The following paragraphs describe the procedures necessary to remove and install the
hydraulic pump.

6-4.13.1 Removal of Hydraulic Pump. Remove the hydraulic pump as follows, referring to figure FO-12 or
figure FO-13.

WARNING

Before performing any maintenance action, notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel.

WARNING

Boat crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply may result in injury or
death to maintenance personnel.

a. Depress ″MOTOR OFF″ pushbutton on control panel to shut down hydraulic power.

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply may result in injury or
death to maintenance personnel.

b. Deenergize electrical power to crane by opening circuit breaker on the 1S switchboard and tag ″OUT-OF-
SERVICE.″ Refer to SIB Volume 3 for exact location of circuit breaker.

6-88
 SG811-BV-MMA-010

WARNING

The turret enclosure and ladder weighs approximately 194 pounds. Failure
to support turret enclosure properly during handling may result in person-
nel injury or damage to equipment.
c. Attach lifting device to rail on turret enclosure (85).
d. Remove screw (172) and washer (173) from rail on turret enclosure (85) to back of operator seat (33).
e. Remove 12 screws (6) and washers (7) from turret enclosure (85) and revolving turret (9).
f. Remove hydraulic motor in accordance with paragraph 6.4.1.10.
g. Lower turret enclosure (85) to deck.
h. Reach through connection bell (16) and loosen setscrew (100) to joint (17).
i. Remove four screws (18) and washers (19) securing hydraulic pump (20) to connection bell (16).

WARNING

Hydraulic pump weight is 33 pounds. Failure to support hydraulic pump

properly during handling may result in personnel injury or damage to
equipment.
j. Remove connection bell (16, figure FO-12 or figure FO-13) from hydraulic pump (20).
k. Position oil drain pan under hydraulic lines on hydraulic pump (20).

CAUTION

Cap all hose connections to ensure that the hydraulic system is not contami-
nated by the introduction of foreign material.
l. Disconnect three hydraulic lines from hydraulic pump (20).
m. Remove hydraulic line from suction filter (46) to hand pump (207).
n. Wipe up any spilled hydraulic fluid.

6-4.13.2 Installation of Hydraulic Pump. Install the hydraulic pump as follows, referring to figure FO-12 or
figure FO-13 and table 6-2.

WARNING

Hydraulic pump weight is 33 pounds. Failure to support hydraulic pump

properly during handling may result in personnel injury or damage to
equipment.

6-89
SG811-BV-MMA-010

a. Position hydraulic pump (20) on end of connection bell (16).

b. Secure hydraulic pump with four screws (18) and washers (19), torque to 132 ft-lbs.
c. Reach through connection bell (16) and tighten setscrew (100).
d. Connect hydraulic line from suction filter (46) to hand pump (207) and tighten connections.
e. Connect three hydraulic lines to hydraulic pump (20) and tighten connections.
f. Attach lifting device to rail on turret enclosure (85).
g. Move turret enclosure (85) into place over electric motor (24).

h. Secure turret enclosure (85) to revolving turret (9) using washers (7) and screws (6), torque to 31.13 ft-lbs.

i. Secure rail on turret enclosure (85) to back of operator seat (33) using washer (173) and screw (172), torque
to 31.13 ft-lbs.

j. At power distribution panel on the 1S switchboard remove ″OUT-OF-SERVICE″ tag from circuit breaker.

k. Place circuit breaker in the ON position.

6-4.14 Access Panel. The following paragraphs list the procedures necessary to remove, and install the access
panel.

6-4.14.1 Removal of Access Panel. Remove the access panel as follows, referring to figure FO-12 or figure
FO-13.

a. Remove 18 bolts (3) and 18 washers (4) that secure access panel (2) to pedestal (1).

b. Remove access panel (2) from pedestal (1).

6-4.14.2 Installation of Access Panel. Install the access panel as follows, referring to figure FO-12 or figure
FO-13. Hold access panel (2) in-place and secure the access panel with 18 bolts (3) and 18 washers (4).

6-4.15 Filters, Valves, Gauges, and Hand Pump. The following corrective maintenance paragraphs provide the
procedures required to perform corrective maintenance on associated boat crane components.

WARNING

Before performing any maintenance action, notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel.

6-4.15.1 Removal/Installation of High Pressure Filter Assembly. Refer to figure 6-23.

6-90
 SG811-BV-MMA-010

WARNING

Boat crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply may result in injury or
death to maintenance personnel.

a. Depress ″MOTOR OFF″ pushbutton on control panel to shut down hydraulic power.
b. Deenergize power to the Boat Crane by opening circuit breaker on the 1S switchboard. Refer to SIB Volume
3 for exact location of circuit breaker.
c. Place a container under the filter housing (1) to contain hydraulic oil leakage during removal procedures.

Figure 6-23. High Pressure Hydraulic Filter

d. Remove turret enclosure in accordance with paragraph 6-4.6.

e. Remove two hydraulic pipe connections (2) to filter assembly.

6-91
SG811-BV-MMA-010

f. Remove one screw (3) from top of filter assembly holding filter assembly in place on turret.

g. Install high pressure filter assembly in the reverse order.

NOTE

After installing the filter, venting the system is not required.

6-4.15.2 Removal, Replacement and Installation of High Pressure Filter Assembly. Refer to figure 6-24.

WARNING

Boat crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply may result in injury or
death to maintenance personnel.

a. Depress ″MOTOR OFF″ pushbutton on control panel to shut down hydraulic power.

NOTE

Accomplish monthly or when differential pressure indicator has been activated.

Ensure all tag out procedures are in accordance with current shipboard instruc-
tions.

b. Deenergize power to the boat crane by opening circuit breaker on the 1S switchboard and tag ″OUT-OF-
SERVICE.″ Refer to SIB Volume 3 for exact location of circuit breakers.

c. Place a container under filter housing (8). Secure applicable hydraulic isolation valves.

d. Loosen hydraulic filter housing (8) and drain hydraulic fluid.

e. Remove filter housing (8) and attached O-ring (7) from filter head (4) and discard O-ring (5).

f. Clean, repair or replace high pressure filter element (6).

WARNING

Avoid prolonged contact with, or inhalation of, cleaning solvents. Avoid use
near heat or open flame and provide adequate ventilation. Wear safety
goggles and rubber gloves while cleaning parts to prevent personnel injury
or death.

g. Clean filter housing (8) with solvent and wipe dry with a lint-free cloth.

6-92
 SG811-BV-MMA-010

Figure 6-24. High Pressure Hydraulic Filter Assembly

6-93
SG811-BV-MMA-010

h. Install new O-ring (7) on filter head (4) and new O-rings (5) on filter element (6).

i. Fill filter housing (8) half full with hydraulic fluid.

j. Install filter housing (8) to filter head (6). Ensure O-ring (7) seats properly between filter housing (8) and fil-
ter head (4).

k. Torque filter housing (8) to 28 ft-lbs.

l. Remove excess hydraulic fluid.

m. Remove ″OUT-OF-SERVICE″ tag, energize circuit, open applicable isolation valves.

NOTE

After replacing the filter, it is not required to vent the system.

n. Wipe filter housing (8, figure 6-24) dry and inspect for leaks; if none, remove container.

o. Reset the filter indicator (1) by pushing the button on the top of the filter.

NOTE

Comply with own ship/station procedures for handling and disposal of hazard-
ous materials/waste identified in the tools, parts, material, test equipment section.
For general shipboard disposal procedures follow: Deposit waste in applicable
container as listed in NSTM S9086-T8-STM-000/CH-593 R2, Chapter 593 Pol-
lution Control. Store in accordance with Chapter 670. Mark or tag container with
the specific contents and any information on the contaminants. This information
must also be provided on DD form 1348-1.

6-4.15.3 Removal/Installation of Low Pressure (LP) Filter Assembly. Refer to figure 6-25.

WARNING

Boat crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply may result in person-
nel injury or death.

a. Depress ″MOTOR OFF″ pushbutton on control panel to shut down hydraulic power.

b. Deenergize power to the Boat Crane by opening circuit breaker on the 1S Switchboard. Refer to SIB Volume
3 for exact location of circuit breaker.

6-94
 SG811-BV-MMA-010

Figure 6-25. Low Pressure Hydraulic Filter

6-95
SG811-BV-MMA-010

c. Place a drip pan under LP filter.

d. Open drain plug (6) and drain hydraulic oil from LP filter assembly.
e. Close valve between the filter and sump.
f. Disconnect hydraulic line connection on both sides of LP assembly.
g. On side of LP filter assembly, remove screw (194) washer (196) and nut (197) securing LP assembly to tur-
ret (refer to figure FO-12 or figure FO-13).
h. Reinstall in reverse order.

6-4.15.4 Removal/Installation of Differential Pressure Gauge. Refer to figure 6-25.

a. On outside body of LP filter assembly, disconnect two hydraulic connections (11) on top and bottom of dif-
ferential pressure gauge (12).
b. Remove differential pressure gauge (12).
c. Install differential pressure gauge by positioning gauge in correct location and tightening both hydraulic con-
nections (11).

6-4.15.5 Removal/Installation of Low Pressure Filter Element. Refer to figure 6-25.

WARNING

Boat crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply may result in person-
nel injury or death.

NOTE

Ensure all tagout procedures are in accordance with current shipboard instruc-
tions.

NOTE

Accomplish monthly or when differential pressure indicator is in the red zone.

a. Depress ″MOTOR OFF″ pushbutton on control panel to shut down hydraulic power.
b. Deenergize power to the boat crane by opening circuit breaker on the 1S switchboard and tag ″OUT-OF-
SERVICE.″ Refer to SIB Volume 3 for exact location of circuit breaker.
c. Place a container under filter body (1).
d. Remove drain plug (6), usit-ring (5) and drain hydraulic oil into container.
e. Unscrew filter cover (4) and remove attached O-ring (3) from filter body (1) and discard O-ring (3).

6-96
 SG811-BV-MMA-010

f. Remove cartridge (7) and discard filter element (7).

WARNING

Avoid prolonged contact with, or inhalation of, cleaning solvents. Avoid use
near heat or open flame and provide adequate ventilation. Wear safety
goggles and rubber gloves while cleaning parts to prevent personnel injury.

g. Clean filter body (1) with solvent and wipe dry with a lint free cloth.

h. Install new usit-ring (5) and drain plug (6).

i. Fill hydraulic filter with hydraulic fluid until half full.

j. Install new O-ring (3, figure 6-25) and cartridge (7).

k. Install filter cover (4).

l. Remove excess oil.

m. Remove ″OUT-OF-SERVICE″ tag.

n. Wipe filter assembly dry and inspect for leaks; if none, remove container.

o. Filter differential pressure indicator (12) will reset automatically with new filter installed.

NOTE

Comply with own ship/station procedures for handling and disposal of hazard-
ous materials/waste identified in the tools, parts, material, test equipment section.
For general shipboard disposal procedures follow: Deposit waste in applicable
container as listed in the NSTM S9086-T8-STM-000/CH-593 R2, Chapter 593
Pollution Control. Store in accordance with Chapter 670. Mark or tag container
with the specific contents and any information on the contaminants. This infor-
mation must also be provided on DD form 1348-1.

6-4.15.6 Repair of Low Pressure Filter Assembly. Refer to figure 6-25.

WARNING

Boat crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply will result in personnel
injury or death.

6-97
SG811-BV-MMA-010

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply will result in personnel
death or injury.

a. Depress MOTOR OFF pushbutton on control panel to shut down hydraulic power.
b. Deenergize power to the boat crane by opening circuit breaker on the 1S switchboard and tag ″OUT-OF-
SERVICE.″ Refer to SIB Volume 3 for exact location of circuit breaker.
c. Remove filter in accordance with paragraph 6-4.15.5.
d. Place a container under filter assembly.
e. Remove filter cover (4) and attached O-ring (3) from filter body (1) and discard O-ring (3).
f. Remove top spring (9, figure 6-25) and O-ring from bypass assembly (10).
g. Remove nut (8) securing insert, inside bypass assembly (10).
h. Remove insert (2) from bypass assembly (10).
i. Remove bypass assembly (10) and element (7).
j. Remove nut (13) on bottom of bypass assembly (10).
k. Install new element (7) in bypass assembly (10).
l. Replace nut (13) on bottom of bypass assembly (10).
m. Place insert (2) in bypass assembly (10).
n. Replace nut (8) and tighten.
o. Install new O-ring (3) in top of filter body (1) and replace top spring (9).
q. Replace filter cover (4) on filter body (1) and torque to 28 ft-lbs.
r. Remove ″OUT-OF-SERVICE″ tag, energize circuit and open applicable valves.
s. Wipe filter body dry and inspect for leaks; if none, remove container.

NOTE

Comply with own ship/station procedures for handling and disposal of hazard-
ous materials/waste identified in the tools, parts, material, test equipment section.
For general shipboard disposal procedures follow: Deposit waste in applicable
container as listed in the NSTM S9086-T8-STM-000/CH-593 R2, Chapter 593
Pollution Control. Store in accordance with Chapter 670. Mark or tag container
with the specific contents and any information on the contaminants. This infor-
mation must also be provided on DD form 1348-1.

6-4.15.7 Removal/Installation of Submersible Suction Filter. Refer to figure 6-26.

6-98
 SG811-BV-MMA-010

Figure 6-26. Submersible Suction Filter

6-99
SG811-BV-MMA-010

WARNING

Boat crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply will result in personnel
injury or death.

a. Depress ″MOTOR OFF″ pushbutton on control panel to shut down hydraulic power.

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply may result in personnel
death or injury.
b. Deenergize power to the boat crane by opening circuit breaker on power distribution panel located on the 1S
switchboard and tag ″OUT-OF-SERVICE.″ Refer to SIB Volume 3 for exact location of circuit breaker.
c. Locate submersible suction filter (1, figure 6-26) on the port side of the revolving turret beside the ladder (2).
d. Remove cap from drain valve (4).
e. Connect clean hydraulic drain hose (3) that will mate with drain valve (4) located within the pedestal (5).
f. Provide suitable container that will hold oil and drain sump.
g. Place drain pan under submersible suction filter.
h. Loosen hydraulic line connections (8) on top and side of submersible suction filter.
i. Remove four screws (6) and washers (7) securing submersible suction filter to the sump.
j. Remove submersible suction filter housing from the sump.
k. Replace submersible suction filter housing (1) in sump.

NOTE

If element needs to be replaced, utilize procedure listed in paragraph 6-4.15.8.

Installation procedures are as follows:
l. Replace four washers (7) and screws (6) in submersible suction filter (1) and torque to 16 ft-lb.
m. Reconnect hydraulic lines to top and side of submersible filter and tighten.
n. Close sump drain valve (4) and remove drain hose (3).
o. Remove hydraulic main filter cap and replace hydraulic oil through main hydraulic filter cap.
p. Refill hydraulic fluid, ensuring no more than 30 gallons or 110 liters are replaced.
q. Observe sight glass while refilling hydraulic fluid.
r. Remove ″OUT-OF-SERVICE″ tag from the 1S switchboard, place circuit breaker in the on position.

6-100
 SG811-BV-MMA-010

6-4.15.8 Repair of Submersible Suction Filter Element. Refer to figure 6-27.

a. Remove submersible suction filter in accordance with paragraph 6-4.15.7.

b. Loosen and remove stud (1) from nut (2).

c. Remove cover (3) and stud (1) from filter body (4).

d. Remove O-ring (12, figure 6-27) from filter body (4).

e. Remove cartridge assembly (5) from filter body (4).

f. Remove O-ring (6) from cartridge assembly (5).

g. Remove O-ring (7) from bottom of cartridge assembly (5).

h. Remove O-ring (8) from valve body (9).

i. Remove seal ring (10) from stud (1).

j. Remove element (11) from cartridge assembly (5).

k. Install new element (11) in cartridge assembly (5).

l. Install new seal ring (10) on stud (1).

m. Install new O-ring (8) on valve body (9).

n. Install new O-ring (7) on cartridge assembly (5).

o. Install new cartridge assembly (5) in body (4).

p. Install new O-ring (12) on body (4).

q. Install new O-ring (6) on cartridge assembly (5).

r. Put stud (1) through hole in cover (3).

s. Install stud (1) through cartridge assembly (5) and tighten nut (2) in valve body (9).

6-4.15.9 Removal/Installation of Valve Block. Refer to figure 6-28.

WARNING

Before performing any maintenance action, notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel.

6-101
SG811-BV-MMA-010

WARNING

Boat crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply will result in personnel
injury or death.

NOTE

The following procedures are to be used to remove/install all the servo valves on
the valve block.

a. Depress ″MOTOR OFF″ pushbutton on control panel to shut down hydraulic power.

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply will result in personnel
injury or death.

b. Deenergize power to the boat crane by opening circuit breaker on the 1S switchboard and tag ″OUT-OF-
SERVICE.″ Refer to SIB Volume 3 for exact location of circuit breaker.

c. Locate valve block (42, figure FO-12 or figure FO-13) on center front of crane under operator seat.

d. Remove cover (11, figure 6-28) by removing four screws (12) and washers (13) that secure it to the crane.

e. Remove electrical connector (1) from pilot relief valve (2).

f. Close valve wheel (4) on pilot relief valve (2).

g. Identify, tag and disconnect hydraulic lines (14) to valve block (3).

h. Disconnect and tag the electrical connections (5) from each servo valve (6) on the front of valve block (3).

i. Remove four bolts (44, figure FO-12 or figure FO-13) and four washers (43) from the underside of valve
block (42), securing valve block (42) to the revolving turret. Remove valve block (42) from valve plate.

NOTE

If valve block is to be replaced, remove all servo valves in accordance with

paragraph 6-4.15.10.

j. Position valve block (42) on valve plate.

k. Install four bolts (44) and four washers (43) on the underside of the valve plate and tighten.

l. Connect the four electrical connections (5, figure 6-28), to each servo valve (6).

6-102
 SG811-BV-MMA-010

Figure 6-27. Submersible Suction Filter Assembly

6-103
SG811-BV-MMA-010

Figure 6-28. Valve Block

6-104
 SG811-BV-MMA-010

m. Connect the hydraulic lines to the valve block (3) and tighten.
n. Connect electrical connector (1) to pilot relief valve (2).
o. Open the valve wheel (4) located on the pilot relief valve (2).
p. Remove ″OUT-OF-SERVICE″ tag from circuit breaker.
q. Perform operational testing in accordance with chapter 2.

6-4.15.10 Removal/Installation of Servo Valve. Refer to figure 6-28.

WARNING

Boat crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply will result in personnel
injury or death.

a. Depress ″MOTOR OFF″ pushbutton on control panel to shut down hydraulic power.

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply will result in personnel
injury or death.
b. Deenergize power to the boat crane by opening circuit breaker on the 1S switchboard and tag ″OUT-OF-
SERVICE.″ Refer to SIB Volume 3 for exact location of circuit breaker.
c. Remove electrical connector (5) from side of defective servo valve (6).
d. Remove four screws (9) and washers (10) securing servo valve (6) to valve block (3).
e. Remove defective valve.
f. Repair/replace servo valve in accordance with NSTM 0948-LP-012-5000, Technical Manual for Standard
Navy Valves.
g. To install servo valve, utilize the reverse order of the preceding steps.

6-4.15.11 Removal/Installation of Ball Valves. Utilize the following procedure to remove and install the fol-
lowing ball valves. These valves are of the same form, fit and function. Refer to figure 6-29.

a. Inlet LP filter sampling valve.

b. Outlet LP filter sampling valve.
c. Inlet HP filter sample valve.
d. Outlet HP filter sample valve.

6-105
SG811-BV-MMA-010

e. Double control valve (two).

f. Overcenter valve (two).

g. Reduction gear drain valve.

Figure 6-29. Ball Valves

h. Hydraulic motor valve (two).

6-106
 SG811-BV-MMA-010

WARNING

Boat crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply will result in personnel
injury or death.

a. Depress MOTOR OFF pushbutton on control panel (figure 2-1) to shut down hydraulic power.

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply will result in personnel
injury or death.
b. Deenergize power to the boat crane by opening circuit breaker on the 1S switchboard and tag ″OUT-OF-
SERVICE.″ Refer to SIB Volume 3 for exact location of circuit breaker.
c. Locate defective valve.

d. Place drain pan under the valve.

e. Loosen hydraulic connections on the defective valve.
f. Remove the valve from the hydraulic line.
g. Repair/replace valve in accordance with NSTM 0948-LP-012-5000, Technical Manual for Standard Navy
Valves.
h. To install, position valve in hydraulic line and tighten connections.
i. Remove ″OUT-OF-SERVICE″ tag from circuit breaker. Place circuit breaker in the ON position.

j. Perform operational testing in accordance with chapter 2.

6-4.15.12 Removal/Installation of Pilot Operated Relief Valve. Refer to figure 6-28.

WARNING

Boat crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply will result in personnel
injury or death.

a. Depress ″MOTOR OFF″ pushbutton on control panel to shut down hydraulic power.

6-107
SG811-BV-MMA-010

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply will result in personnel
injury or death.
b. Deenergize electrical power to the boat crane by opening circuit breaker on the 1S switchboard and tag
″OUT-OF-SERVICE.″ Refer to SIB Volume 3 for exact location of the circuit breaker.
c. Locate pilot relief valve (2) on forward, port side of boat crane on valve block (3).
d. Place a drain pan under the hydraulic connection between valve (2, figure 6-28) and hydraulic line (14).
e. Loosen and remove hydraulic connection on the valve (2).
f. Loosen the four bolts (7) securing valve (2) to the valve block (3).
g. Remove the pilot relief valve (2) from valve block (3).
h. Repair/replace valve in accordance with NSTM 0948-LP-012-5000, Technical Manual for Standard Navy
Valves.
i. To install, position valve (2) on valve block (3) and tighten bolts.
j. Connect and tighten hydraulic line connection to valve (2).
k. Remove ″OUT-OF-SERVICE″ tag from circuit breaker. Place circuit breaker in the ON position.
l. Perform operational testing in accordance with chapter 2.

6-4.15.13 Removal/Installation of the Antishock Valve. Remove the antishock valve as follows, referring to
figure FO-12 or figure FO-13.

a. Remove two connections from the side of the antishock valve (183).
b. Remove the two screws (181) and washers (182) securing the antishock valve (183) to the main boom.
c. Reinstall the antishock valve in the reverse order.

6-4.15.14 Removal/Installation of the Hand Pump. Remove and install the hand pump as follows, referring to
figure 6-30.

WARNING

Boat crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply will result in personnel
injury or death.

a. Depress ″MOTOR OFF″ pushbutton on control panel (figure 2-1) to shut down hydraulic power.

6-108
 SG811-BV-MMA-010

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply may result in personnel
injury or death.

Figure 6-30. Hand Pump

b. Deenergize electrical power to the boat crane by opening circuit breaker on the 1S switchboard and tag
″OUT-OF-SERVICE.″ Refer to SIB Volume 3 for exact location of circuit breaker.

c. Locate the hand pump (1) on the port side of the boat crane between the ladder (2) and submersible suction
filter (3, figure 6-30).

6-109
SG811-BV-MMA-010

d. Place a drain pan under the hand pump (1).

e. Disconnect two hydraulic lines on the hand pump (1).

f. Wipe any spilled hydraulic fluid.

g. Remove four screws and washers securing hand pump (1) to mounting plate and remove hand pump (1).

h. Installation of the hand pump is the reverse order of the preceding disassembly procedures.

i. Remove ″OUT-OF-SERVICE″ tag from circuit breaker. Place circuit breaker in the ON position.

j. Perform operational testing in accordance with chapter 2.

6-4.15.15 Removal/Installation of Temperature Gauge. Remove and install the temperature gauge as follows,
referring to figure 6-31:

a. Locate temperature gauge (1) on oil sump (2).

b. Connect drain hose (3) to drain valve (4) and drain sump, refer to figure 6-26.

c. Unscrew temperature gauge (1) from hydraulic connection.

d. Reinstall temperature gauge.

e. Close sump drain valve (4) and remove hose (3), refer to figure 6-26.

f. Fill sump.

6-4.15.16 Removal/Installation of Sight Liquid Level Indicator. Remove and install the sight level indicator as
follows, referring to figure 6-32.

WARNING

Boat crane operation requires hydraulic fluid under high pressure. Prior to
performing any maintenance action, turn off electrical power. This will
reduce hydraulic pressure to zero. Failure to comply may result in injury or
death to maintenance personnel.

a. Depress ″MOTOR OFF″ pushbutton on control panel (figure 2-1) to shut down hydraulic power.

b. Deenergize electrical power to crane by opening circuit breaker on the 1S switchboard and tag ″OUT-OF-
SERVICE.″ Refer to SIB Volume 3 for exact location of circuit breaker.

6-110
 SG811-BV-MMA-010

Figure 6-31. Temperature Gauge

6-111
SG811-BV-MMA-010

Figure 6-32. Liquid Level Indicator

6-112
 SG811-BV-MMA-010

c. Connect drain hose (3) to sump drain valve (4) and drain sump, refer to figure 6-26.

d. Place a drain pan under the sight glass indicator.

e. To remove the liquid level sight glass indicator:

(1) Close the top valve (1, figure 6-32) at the top of sight glass indicator.
(2) Open the bottom two valves (2 and 3) and drain the hydraulic fluid from the sight glass indicator.
(3) Remove four protecting rods by removing the cotter pin (4) from lower retaining nut (5), and raising rod
(6) up through upper holding bracket (7).
(4) Loosen the two nuts (8) at the top and bottom of the sight glass indicator.
(5) Lift up on the sight glass (9) and remove sight glass from the bracket.

f. The following steps are applicable to remove the top and bottom valves associated with the liquid level sight
glass indicator.
(1) Drain the hydraulic fluid below the level of the valve to be removed. Reduce level of hydraulic fluid by
transferring hydraulic fluid from sump by use of drain valve located in the pedestal. Utilize procedure
6-4.15.7 and figure 6-26.
(2) Once hydraulic fluid level in sump is below valve to be removed, unscrew and remove the specific valve
from the sump.

g. To remove sight glass drain valve (3) perform the following:

(1) Close the bottom sight glass indicator valve (2).
(2) Unscrew and remove the sight glass drain valve (3).

h. Install the sight glass components in the reverse order.

6-4.16 Remove and Replace Control Joystick ID Plate. Remove and replace the control joystick ID plate as
follows, referring to figure 6-33.

a. Remove two screws (1) and washers (2) securing each ID plate (3) to the control panel (4).

b. Remove the ID plate (3).

c. Reinstall the ID plate in the reverse order.

6-4.17 Remove and Replace the Oil Sump Cover. Remove and replace the oil sump cover as follows, referring
to figure FO-12 or figure FO-13.

6-113
SG811-BV-MMA-010

Figure 6-33. Control Stick ID Plate Replacement.

6-114
 SG811-BV-MMA-010

a. Remove five hydraulic connections to the cover.

b. Remove 12 screws (95) and washers (96) securing the cover (94) to the sump.
c. Remove the cover (94).
d. Remove the cap (218) by unscrewing.
e. Remove six screws (125) and washers (126) that secure the oil load plug (124) to the sump cover (94).
f. Remove the O-ring (102) from the cover (94).
g. Replace in reverse order.

6-4.18.1 Slew Limit Relay Box Removal. (MHC 52, 55, 58 & 59) Remove the Slew limit relay box as fol-
lows, referring to figure 6-34.

WARNING

Before performing any maintenance action, notify supervisory personnel.

Shipboard tagout procedures must be followed when tagging equipment
″OUT-OF-SERVICE″ to conduct maintenance actions. Failure to tag equip-
ment may result in injury or death to maintenance personnel.

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to tag equipment may result in injury
or death to maintenance personnel.

a. Deenergize electrical power to the crane by opening the circuit breaker on the power distribution panel located
in the UCHS compartment and tag ″OUT-OF-SERVICE.″ Refer to SIB Volume 3 for the exact location of the
circuit breaker.
b. Using the turret side door key, unlock the turret side door.
c. The slew limit relay box is located in the forward section of the compartment under the electronic control unit.
d. Remove four self-locking nuts (15) securing the box to the bottom of the compartment.
e. Remove the ground wire.
f. Remove the relay box (1) from four stud bolts (14).
g. Loosen four retainer locking screws (13), turn the four clamps (12) and remove the cover (11).
h. Tag and disconnect four cables from the box.

6-4.18.2 Slew Limit Relay Box Disassembly/Reassembly. (MHC 52, 55, 58 & 59) Disassemble/reassemble the
slew limit relay box as follows, referring to figure 6-34:

6-115
SG811-BV-MMA-010

a. Loosen four retainer locking screws (13), turn the four clamps (12) and remove the cover (11).

b. To remove two relays:

(1) Tag and disconnect 12 wires from two relays (3).
(2) Remove eight bolts (5), eight nuts (7), and eight washers (6).
(3) Remove the two relays (3).

c. Reassemble the slew limit relay box by reversing this procedure.

6-4.18.3 Slew Limit Relay Box Installation. (MHC 52, 55, 58 & 59) Install the slew limit relay box as follows,
referring to figure 6-34.

WARNING

Hazardous voltages are present. Ensure electrical power is removed and

tagged ″OUT-OF-SERVICE.″ Failure to comply may result in injury or
death to maintenance personnel.

a. Place the slew limit relay box (1) close to its location and open the cover (11).

b. Connect four cables to the terminal board (4).

c. Replace the cover (11), place the four clamps (12) on the cover flanges and tighten four locking screws (13).

d. Place the slew limit relay box (1) on the four stud bolts (14) and tighten the four self-locking nuts (15).

e. Install a grounding wire.

6-116
 SG811-BV-MMA-010

Figure 6-34. Slew Limit Relay Box (Sheet 1 of 2) (MHC 52, 55, 58, & 59)

6-117
SG811-BV-MMA-010

Figure 6-34. Slew Limit Relay Box (Sheet 2 of 2) (MHC 52, 55, 58 & 59)

6-118
 SG811-BV-MMA-010

Figure FO-12. Boat Crane Exploded View

6-119 / (6-120 Blank)

6-120
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

Figure FO-13. Boat Crane Exploded View

6-121 / (6-122 Blank)

6-122
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

Figure FO-14. Winch Assembly Exploded View

6-123 / (6-124 Blank)

6-124
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

CHAPTER 7

PARTS LIST

7-1. INTRODUCTION.
This chapter contains the illustrated parts lists with information applicable to the boat crane. It lists and
describes the parts necessary for equipment support and is used for requisitioning, identifying parts and illustrat-
ing disassembly and assembly relationships.

7-1.1 Subassemblies and Components. The parts list consists of a breakdown of the complete unit into subas-
semblies and detailed parts. Each component that can be separately identified is listed, regardless of whether or
not a particular component is provisioned as a spare or authorized to be used by a repair activity.

7-1.2 Abbreviations. Each abbreviation used in this parts list is in accordance with MIL-STD-12, Abbreviations
for use on Drawings and Specifications, Standards and Technical Documents.

7-2. LIST OF MAJOR COMPONENTS.

Table 7-1 lists each major component of the Pellegrini Boat Crane. This table includes each assembly and
subassembly represented by separate illustrated parts list.

7-3. LIST OF MANUFACTURERS.

Table 7-2 lists manufacturers supplying items for the boat crane as identified in the parts list (see paragraph
7-4). Tabulated data includes the manufacturer’s name, address and code identification. The code identification is
the Commercial and Government Entity (CAGE).

7-4. PARTS LIST.

7-4.1 Format. Component parts list (table 7-3 through table 7-27) are presented in 5 column format.

7-4.2 Figure and Item Number. In this column, item numbers are assigned in numerical order and are essen-
tially in disassembly sequence. Item numbers relate directly to numbers displayed on the respective parts break-
down illustration.

7-4.3 Description. This column lists the item nomenclature along with those modifiers necessary to identify the
item. Military identification numbers are provided when available. In the absence of a military number, physical
characteristics are listed (material, grade, series, dimensions, specifications, etc).

7-4.4 Quantity. This column lists the total number of each part required per assembly or subassembly. This
number may not necessarily be the number of items used in the end item or system. Only one set of components
is listed where the components of two assemblies are the same (identical left and right hand assemblies). The
letters AR (as required) are used to identify bulk items.

7-4.5 Commercial and Government Entity. This column lists the original manufacturer’s CAGE. Common
hardware items such as screws, washers and O-rings are identified by military number where available.

7-1
SG811-BV-MMA-010

7-4.6 Manufacturer’s Part Number. This column lists the original manufacturer’s assigned part number. Part
numbers for common hardware items are supplied where available.

7-4.7 Parts List Figures. Figure 7-1 through figure 7-23 and FO-12, FO-13, FO-14 and FO-15 are the figures
to be used in conjunction with parts list table.

Table 7-1. List of Major Components

QUANTITY NOMENCLATURE FIGURE NO.
1 Boat Crane FO-12 or FO-13
1 Winch FO-14
1 Main Boom Cylinder 7-1
1 Jib Boom Cylinder 7-2
1 Boom Head 7-3
1 Control Panel 7-4
1 Electronic Control Unit 7-5
1 Control Board 7-6
1 Power Supply 7-7
1 Dirty Box 7-8
1 Electric Motor Starter 7-9
1 Electric Motor 7-10
1 Revolving Turret FO-12 or FO-13
1 Slew Ring 6-17
2 Hydraulic Motor (Turret) 7-11
1 Hydraulic Brake 7-12
1 Reduction Gear 7-13
1 Hydraulic Pump 7-14
1 Pedestal FO-12 or FO-13
1 Access Panel FO-12 or FO-13
1 Operator Seat FO-12 or FO-13, 7-15
1 Slew Ring Locking 7-16
1 Control Joytick 6-9
1 Connection Box 7-17
1 Hydraulic Filter High Pressure 7-18
1 Hydraulic Filter Low Pressure 7-19
1 Submersible Suction Filter 7-20
1 Hydraulic System Diagram 7-21 or 7-22
1 Slew Limit Relay Box 7-23

Table 7-2. List of Manufacturers

MANUFACTURER ADDRESS CAGE
Marine Equipment Pellegrini (MEP) Via E Torricelli A4867
37135 Verona Italy
Penny and Giles Data Records LTD Airfield Road K1474
Christchurch Dorset BH23
UK
Datron Inc. Tech Systems Div Precise Power Sys- 401 Watertown Rd 20019
tems Operation Thomaston CT, 06787-1922
Phone 203-283-5801

7-2
 SG811-BV-MMA-010

Table 7-2. List of Manufacturers - Continued

MANUFACTURER ADDRESS CAGE

Whittet-Higgins Co 33 Higginson Ave 79568
Central Falls RI, 02863
Phone 401-728-0700
SKF Industries Inc 1100 1ST Ave 52676
King of Prussia PA, 19406-1312
Phone 215-265-1900
Hagglunds Dension Corp 1220 Dublin Rd 9F512
Columbus OH, 43216
Fairey Arlon LTD Cranford Lane K7516
Heston Hounslon Middx
TW5 9NQ UK
Danfoss Fluid Power Inc 1201 Pelzer Hy 8Z296
Easley SC, 29640-4852
Phone 803-855-2884
Heilmeier Weinlein Neumarkter Strasse 26 D0637
8000 Muenchen
80 Germany
Moog Inc. Seneca St at Jamison Rd 94697
East Aurora NY, 14052
Phone 716-652-2000
Minor Rubber Co Inc. 49 Ackerman St 76385
Bloomfield NJ, 07003-4201
Hoesch Rothe ERDESchmiedag AG Tremoniastrasse 5-11 D8856
Postfach 311
4600 Dortmund 1 Germany
Ghisalba SPA VIA Tevere, 15 A2515
10090 Cascine Vica-Rivoli Italy
Nadella Cuscinetti S.P.A. V. Melette, 16 A3280
20128 Milano, Italy
Veam Division of Litton System Inc. 100 New Wood Road C2107
Watertow, Ct 06795
Weskler Instrument Freeport NY 64467
Eugene Ernest Products Co. South Main Street 16199
P.O. Box 427
Farmingdale, NJ 07727
EATON Corporation (Cutler Hammer Products) 4265 North 30th Street 27192
Milwaukee, WI 53216
INA Bearing Co. P.O. Box 241328 27737
4301-h Stewart Andrew Blvd
Cheraw, SC 29520
Timkin Co. 1835 Dueber Ave SW 60038
Canton, OH 44706
Unimax Switch Co Molly Millars Lane K6910
Workingham Berks Rg11
2WB, UK
CAST Componenti Automazioni Standardizzate Strada Del Salino 7 A5277
Torino SRL 10133 Torino Italy

7-3
SG811-BV-MMA-010

Table 7-2. List of Manufacturers - Continued

MANUFACTURER ADDRESS CAGE

Spirol Intl Corp 30 Rock Ave P.O. Box 179 00287
Danielson, CT 06239-0179
Phone 203-774-8571
Thompson Electronic Supplies 182 E Long St 1F026
Columbus, OH 43215-1819
Phone 614-228-6191
Fag Bearings Corp 911 Hope St 43991
Stamford, CT 06097
Phone 203-353-6848
J P Semiconductors, Inc Arcadia, CA 52107
Military Specifications Promulgated By Military 81349

Table 7-3. Boat Crane Assembly Parts List

FIG & ITEM MFG. PART
NO. DESCRIPTION QTY CAGE NO.
FO-12 or Boat Crane Assembly 1 A4867 21490080
FO-13
1 Pedestal 1 A4867 21490081
2 Panel, Access 1 A4867 21490082
3 Screw, M10x25, ASTM A193, Gr. B8M UNI5739 14
4 Washer, 10.5x21, ASTM A240, 316L UNI6592 14
5 Buffer, Rubber 2 A4867 50106005
6 Screw, M10x20, ASTM A193, Gr. B8M UNI5739 12
7 Washer, 10.5x21, ASTM A240, 316L UNI6592 12
8 Lever, Hand Pump, ASTM A276, 316L 1 A4867 21490098
9 Turret, Revolving 1 A4867 21490086
10 Ring, Slew 1 D8856 842.12.
0905.000.
34.1303
11 Screw, M16x110, ASTM A193, Gr. B7 UNI5737 36
12 Washer, 17x30, ASTM A240, 316L UNI6592 72
13 Nut, Self locking, M16, ASTM A194, GR. 7 UNI7473 36
14 Screw, M16x40, ASTM A193, Gr. B7 UNI6592 36
15 Washer, 17x30, ASTM A240, 316L UNI6592 36
16 Bell, Connection 1 A4867 21490089
17 Joint 1 A4867 21490090
18 Screw, M10x30, ASTM A193, Gr. B8M UNI5739 4
19 Washer, 10.5x21, ASTM A240, 316L UNI5739 4
20 Pump, Hydraulic 1 A4867 21490091
21 Screw, M18x70, ASTM A193, Gr. B8M UNI5737 4
22 Washer, 19x34, ASTM A240, 316L UNI6592 8
23 Nut, Self-locking, M18, ASTM A194, Gr. 8M UNI7473 4
24 Motor, Electric, 15 HP, 135 kg 1 20019 251803-01
25 Screw, M18x60, ASTM A193, Gr. B8M UNI5735 4
26 Washer, 19x34, ASTM A240, 316L UNI6592 4
27 Gear, Reduction 1 A4867 11490094
28 Brake, Hydraulic 1 A4867 11490023

7-4
 SG811-BV-MMA-010

Table 7-3. Boat Crane Assembly Parts List - Continued

FIG & ITEM MFG. PART

NO. DESCRIPTION QTY CAGE NO.
29 Motor, Hydraulic 1 9F512 MF05-0203IN
30 Screw, M12x50, ASTM A193, Gr. B8M UNI5739 13
31 Washer, 13x24, ASTM A240, 316L UNI6592 13
32 Nut, Self-Locking, M8, ASTM A194, Gr. 8M 1 A4867 50080608
33 Seat, Operator 1 A4867 11490097
34 Screw, M16x40, ASTM A193, Gr. D8M UNI5739 8
35 Washer, 17x30, ASTM A240, 316L UNI6592 8
36 Screw, M10x20, ASTM A193, Gr. B8M UNI5739 4
37 Pin, Main Boom, ASTM A240, 316L 27.7 1 A4867 21490107
38 Lockwasher, ASTM A276, 316L 2 A4867 21490078
39 Screw, M12x50, ASTM A193, Gr. B8M UNI5739 12
40 Washer, 13x24, ASTM A240, 316L UNI6592 12
41 Bushing, Bronze Dwg. No. 149048 3 A4867 21490048
42 Valves, Block of 1 A4867 11490797
43 Screw, M12x40, ASTM A, 193 Gr. B8M UNI5739 4
44 Washer, 13x24, ASTM A, 193 Gr. B8M UNI6592 4
45 Not Used -
46 Filter, Submersible Suction 1 K7516 ATX 1-120 R1
47 Screw, M8x40, ASTM A193, Gr. B8M UNI5739 4
48 Washer, 8.4x17, ASTM A240, 316L UNI6592 4
49 Pin, ASTM 276, XM19 1 A4867 21490115
50 Lockwasher, ASTM A276, 316L 2 A4867 21490106
51 Screw, M12x40, ASTM A, 193 Gr. B8M UNI5739 12
52 Washer, 13x24, ASTM A240, 316L UNI6592 12
53 Main Cylinder 1 A4867 11490111
54 Pin, ASTM 276, XM19 1 A4867 21490121
55 Lockwasher, ASTM A276, 316L 3 A4867 21490106
56 Screw, M12x40, ASTM A193, Gr. B8M UNI5739 12
57 Washer, 13x24, ASTM A240, 316L UNI6592 12
58 Pin, ASTM 276, XM19 1 A4867 21490121
59 Lockwasher, ASTM A276, 316L 2 A4867 21490106
60 Screw, M12x40, ASTM A193, Gr. B8M UNI5739 12
61 Washer, 13x24, ASTM A240, 316L UNI6592 12
62 Jib Cylinder 1 A4867 11490117
63 Pin, ASTM 276, XM19 1 A4867 21490119
64 Lockwasher, ASTM A276, 316L 2 A4867 21490106
65 Screw, M12x40, ASTM 193, Gr. B8M UNI5739 12
66 Washer, 13x24, ASTM A240, 316L UNI6592 12
67 Main Boom 1 A4867 21490100
68 Pin Jib Boom, ASTM 276, XM19 1 A4867 21490109
69 Lockwasher, ASTM A276, 316L 3 A4867 21490342
70 Screw, M12x40, ASTM A, 193 Gr. B8M UNI5739 12
71 Washer, 13x24, ASTM A240, 316L UNI6592 12
72 Bushing, Bronze ASTM B271, 955 3 A4867 21490110
73 Winch Assembly 1 A4867 11490122
74 Screw, M12x60, ASTM A193, Gr. B8M UNI5739 6

7-5
SG811-BV-MMA-010

Table 7-3. Boat Crane Assembly Parts List - Continued

FIG & ITEM MFG. PART

NO. DESCRIPTION QTY CAGE NO.
75 Washer, 13x24, ASTM A240, 316L UNI6592 12
76 Nut, Self-Locking, M12, ASTM A194, Gr. 8M UNI7473 6
77 Jib Boom 1 A4867 21490101
78 Boom Head Assembly 1 A4867 11490102
79 Shackle 5/8″, Steel 1 A4867 21490808
80 Hook 1 A4867 54001270
81 Wire Rope, Dia. 1/2″ LG. 100 Ft., ASTM A276, 305 MIL-W- 1 A4867 53001221
18242
82 Screw, M20x70, ASTM A193, Gr. B8M UNI5739 20
83 Washer, 21x37, ASTM A240, 316L UNI6592 40
84 Nut, Self locking, M20, ASTM A194, Gr. 8M UNI7413 20
85 Turret Enclosure and Ladder 1 A4867 21490186
86 Pinion, ASTM A304, Gr. 9840 2 A4867 21490093
87 Lockwasher, ASTM A240, 316L 1 A4867 21490293
88 Screw, M10x30, ASTM A193, Gr. B8M UNI5739 2
89 Washer, 10.5x21, ASTM A240, 316L UNI6592 2
90 Screw, M12x50, ASTM A193, Gr. B8M UNI5739 6
91 Washer, 13x24, ASTM A240, 316L UNI6592 12
92 Nut, Self-locking, M12, ASTM A194 Gr. 8M UNI7473 6
93 Slew Ring, Locking 1 A4867 11490264
94 Cover, ASTM A240, 316L 1 A4867 21490087
95 Screw, M10x25, ASTM A193, Gr. B8M UNI5759 12
96 Stat-O-Seal NAS 1523C-7R SS NAS1523 12 A4867 50034004
97 Washer, 10.5x21, ASTM A, 240 316L UNI6592 4
98 Grease Nipple, M10 UNI7663 4
99 Spacer, ASTM A276, 316L 8 A4867 21490413
100 Screw, M10x22, ASTM A193, Gr. B8M UNI5923 1
101 Screw, M10x10, ASTM A193, Gr. B8M UNI5923 1
102 O-Ring, Lg. 1050 Nitrile - 70 MIL-R-83248-1 1 A4867 50103284
103 Wall-Mounting Receptacle 2 A4867 11490458
104 Screw, M4x16, ASTM A193, Gr. B8M UNI5739 8
105 Washer, 4.3x9, ASTM A240, 316L UNI6592 16
106 Nut, Self-locking, M4, ASTM A194 Gr. 8M UNI7473 8
107 Screw, M8x25, ASTM A193, Gr. B8M UNI5739 4
108 Washer, 8.4x17, ASTM A240, 316L UNI6592 3
109 O-Ring, 237 Nitrile-70 MIL-R-83248-1 1 A4867 50102237
110 Flange, ASTM A276, 316L 0.7 KG 1 A4867 21490555
111 Gasket, Silicon Rubber 1 A4867 21490556
112 Cable, W12 1 A4867 11490126
113 Flexible Unit 1 A4867 11490126
114 Cover, ASTM A240, 316L 1 A4867 21490557
115 Screw, M8x16, ASTM A193, Gr. B8M UNI5739 18
116 Washer, 8.4x17, ASTM A240, 316L UNI6592 18
117 Valve, Ball, 0.3KG RIVA VSB130 1 A4867 50110102
118 Nipple, 1/2″ BSP, ASTM A276, 316L 0.15KG Cast NGI 1/2″ 1 A4867 58100828
119 Plug, 1/2″ BSP 1 A4867 50020587

7-6
 SG811-BV-MMA-010

Table 7-3. Boat Crane Assembly Parts List - Continued

FIG & ITEM MFG. PART

NO. DESCRIPTION QTY CAGE NO.
120 Connecting Box 2 A4867 21490520
121 Screw, M6x20, ASTM A193, Gr. B8M UNI5739 8
122 Washer, 6.4x12.5, ASTM A240, 316L UNI6592 8
123 Oil Level 1 A4867 56913341
124 Oil Load Plug 1 A4867 11490458
125 Screw, M5x20, ASTM 193 UNI5739 6
126 Washer, 5.3x10, ASTM A240, 316L UNI6592 6
127 Cable, Ground, W 26/8 1 A4867 21490784
128 Cable, Ground, W26/13 1 A4867 21490781
129 Cable, Ground, W26/12 1 A4867 21490780
130 Cable, Ground, W26/11 1 A4867 21490769
131 Cable, Ground, W26/10 1 A4867 21490767
132 Cable, Ground, W26/2 1 A4867 21490768
133 Cable, Ground, W26/9 1 A4867 21490767
134 Cable, Ground, W26/1 1 A4867 21490782
135 Washer, 8.4x17, ASTM A240, 316L UNI6592 2
136 Nut, Self Locking, M6, ASTM A194, Gr. 8M UNI7473 2
137 Washer, 9.4x17, ASTM A240, 316L UNI6592 2
138 Nut, Self Locking, M6, ASTM A194, Gr. 8M UNI7473 2
139 Washer, 8.4x17, ASTM A240, 316L UNI6592 2
140 Nut, Self Locking, M6, ASTM A194, Gr. 8M UNI7473 2
141 Washer, 5.3x10, ASTM A240, 316L UNI6592 2
142 Nut, Self Locking, M5, ASTM A194, Gr. 8M UNI7473 2
143 Washer, 8.4x17, ASTM A240, 316L UNI6592 2
144 Nut, Self Locking, M6, ASTM A194, Gr. 8M UNI7473 2
145 Washer, 5.3x10, ASTM A240, 316L UNI6592 2
146 Nut, Self Locking, M5, ASTM A194, Gr. 8M UNI7473 2
147 Washer, 8.4x17, ASTM A240, 316L UNI 6592 2
148 Nut, Self Locking, M6, ASTM A194, Gr. 8M UNI7473 2
149 Earth Terminal, OT58PB-H10 1 A4867 21490027
150 Ground Cable, W.26/1 1 A4867 21490782
151 Washer, 8.4x17, ASTM A240, 316L UNI6592 1
152 Nut, Self Locking, M6, ASTM A194, Gr. 8M UNI7473 1
153 Nut, Self Locking, M8, ASTM A194, Gr. 8N UNI7473 1
154 Nut, M8, ASTM A194, Gr. 8M UNI5588 1
155 Screw, M8x50, ASTM A193, Gr, B8M UNI5739 1
156 Washer, 8.4x17, ASTM A240, 316L UNI6592 2
157 Limit Switch, Cutler Hammer 2 27192 6984H4753
157A Proximity Switch, 0.5 inch sensing distance (MHC 52, 55, 58, 2 MIL-S-24711
59) DC-0, 5-NONC
158 Threaded Bar, ASTM A276, 316L 1 A4867 21490561
159 Nut, Self Locking, M30, ASTM A194 Gr. 8M UNI7473 2
160 Washer, 31x56, ASTM A240, 316L UNI6592 2
161 Eyelet, ASTM A276, 316L 1 A4867 21490560
162 Screw, M612, ASTM A193, Gr. B8M UNI5739 4
163 Screw, M4x16, ASTM A193, Gr. B8M UNI5739 8

7-7
SG811-BV-MMA-010

Table 7-3. Boat Crane Assembly Parts List - Continued

FIG & ITEM MFG. PART

NO. DESCRIPTION QTY CAGE NO.
164 Cam, ASTM A276, 316L 4 A4867 21490804
164A Cam, ASTM A240, 316L (MHC 52, 55, 58, & 59)
165 Cams Fixing Plate, ASTM A240, 316L 1 A4867 21490805
165A Cam Sensing Plate, MIL-S-22698, Steel (MHC 52, 55, 58, 59)
166 Cams Support, ASTM A240, 316L 1 A4867 21490806
167 Engaging Lever 1 A4867 11490264
168 Screw, M5x45, ASTM A193, Gr. B8M UNI5931 2
169 Screw, M5x45, ASTM A193, Gr. B8M UNI5931 2
170 Shims, (for Mechanical Stop) 1 A4867 21490235
171 Washer, Copper UNI5649/1 1
172 Screw, M10x45, ASTM A193, Gr. B8M UNI5737 1
173 Washer, 10.5x21, ASTM A240, 316L UNI6592 1
174 Bracket, ASTM A240, 316L 4 A4867 50002206
175 Screw, M10.5x21, ASTM A193, Gr. B8M UNI5793 4
176 Washer, 10.5x21, ASTM A240, 316L UNI6592 4
177 Nut, Self Locking, M8, ASTM A194 Gr, 8M UNI7473 2
178 Washer, 8.4x17, ASTM A240, 316L UNI6592 4
179 Screw, M8x70, ASTM A193, Gr. B8M UNI5737 2
180 Overcenter Valve 1 HK30VP-11-250 Dwg. No. 149130 1 A4867 50001210
181 Screw, M10x50, ASTM A193, Gr. B8M UNI5737 2
182 Washer, 10.5x21, ASTM A240, 316L UNI6592 2
183 Antishock Valve 1.1 KG Dwg. No. 149130 1H23-F6W-405 1 A4867 56913010
184 Bracket, ASTM A240 316L 1 A4867 21490814
185 Hydraulic Filter, High Pressure 1 K7516 SH175A-2635-
EZ101
186 Screw, M8x20, ASTM A193, Gr. B8M UNI5739 1
187 Washer, 8.4x17, ASTM A240, 316L UNI6592 1
188 Screw, M10x35, ASTM A193, Gr. B8M UNI5739 2
189 Washer, 10.5x21, ASTM A240, 316L UNI6592 2
190 Nut, Self Locking, M10, ASTM A194, Gr. 8M UNI7473 2
191 Screw, M10x50, ASTM A193, Gr. B8M UNI5737 2
192 Washer, 10.5x21, ASTM A240, 316L UNI6592 2
193 Antishock Valve 11123-F6W-40S 1 A4867 56913010
194 Screw, M8x90, ASTM A193, Gr. B8M UNI5737 1
195 In Line Filter, Low Pressure 1 K7516 GA-1-90-R1
196 Washer, 8.4x17, ASTM A240, 316L UNI6592 1
197 Self Locking Nut, M8, ASTM A194 Gr. 8M 1
198 Washer, 10.5x21, ASTM A240, 316L UNI6592 2
199 Nut, Self Locking, M10, ASTM A194, Gr. 8M UNI7473 2
200 Support Valve, ASTM A240, 316L 1 A4867 21490815
201 Washer, 13x24, ASTM A240, 316L UNI6592 2
202 Screw, M12x30, ASTM A193, Gr. B8M 2
203 Overcenter Valve, 1HK30VP-11-250 1 A4867 56913006
204 Screw, M10x130, ASTM A193, Gr. B8M UNI5737 2
205 Screw, M6x65, ASTM A193, Gr. B8M UNI5931 3
206 Label Plate Support, ASTM A240, 316L 1 A4867 21490820

7-8
 SG811-BV-MMA-010

Table 7-3. Boat Crane Assembly Parts List - Continued

FIG & ITEM MFG. PART

NO. DESCRIPTION QTY CAGE NO.
207 Hand Pump, Dwg. No. 149458 1 A4867 56913345
208 Self Locking Nut, M10, ASTM A194, Gr. 8M 3
209 Washer, 10.5x21, ASTM A240, 316L UNI6592 3
210 Thermometer 02KG 1 64467 E-3-18-02
211 Stowage Stand, ASTM A240, 316L 1 A4867 21490228
212 Washer, 8.4x17, ASTM A240, 316L 1 A4867 50080704
213 Nut, Self Locking, M6, ASTM A194, Gr. 8M 1
214 Washer, 8.4x17, ASTM A240, 316L UNI6592 1
215 Control Panel 1 A4867 11490098
216 Pin 1 A4867 50080627
217 Spring Pin 1 A4867 50080643

Table 7-4. Winch Assembly Parts List

FIG & ITEM MFG. PART
NO. DESCRIPTION QTY CAGE NO.
FO-14 Winch Assembly 1 A4867 21490122
1 Sight Window, Screwed Ends, Brass EEP 540 Size 3/4″ NPT 2 A4867 50020580
2 Screw, M10x20, ASTM A193, Gr. B8M UNI5931 4
3 Spring Pin, ø8x45 Steel, UNI6873 4
4 Enclosure Flange, ASTM A276, 316L 1 A4867 21490386
5 O-Ring, 161 Nitrile - 70 1 A4867 50102161
6 Screw, M8x60, ASTM A193, Gr. B8M UNI5931 10
7 Reduction Box, ASTM A297, 316L 1 A4867 21490387
8 Bearing, Taper Roller 1 52676 SKF 30210
9 Bevel Gear, ASTM A519, Gr. 3115 1 A4867 21490388
10 Screw, M8x20, ASTM A193, Gr. B8M UNI5931 6
11 Bearing, Taper Roller 1 52676 SKF 30207
12 Screw, M8x10, ASTM A193, Gr. B8M UNI5923 3
13 Tongue B, 16x10x30, ASTM A, 304 Gr. UNI6604 2
14 Shaft, ASTM A519, Gr. 3115 1 A4867 21490390
15 Cover, ASTM A276, 316L 0.72 1 A4867 21490391
16 O-Ring, 147 Nitrile - 70 1 A4867 50102147
17 Ring, WR58 Steel 1 A4867 50101638
18 O-Ring, 161 Nitrile - 70 1 A4867 50102161
19 Screw, M6x18, ASTM A193, Gr. B8M UNI5933 3
20 Hydraulic Motor 1 9F512 MF0502031
21 Bearing, Taper Roller 1 52676 SKF 32207
22 Bearing, Taper Roller 1 52676 SKF 30207
23 Self Locking Ring Nut, M35x1.5, ASTM A194, Gr. 8M 1 A4867 50037012
24 Bearing, Ball 1 52676 SKF 16014
25 O-Ring, 155 Nitrile - 70 1 A4867 50102155
26 O-Ring, 156 Nitrile - 70 1 A4867 50102156
27 Retaining Ring, øI 55 Steel, UNI7437 1
28 Retaining Ring, øE 70 Steel, UNI7435 1
29 Clutch, One Way, BWX 133392 1 A4867 51004052

7-9
SG811-BV-MMA-010

Table 7-4. Winch Assembly Parts List - Continued

FIG & ITEM MFG. PART

NO. DESCRIPTION QTY CAGE NO.
30 Screw, M8x70, ASTM A193, Gr. B7 UNI5931 6
31 O-Ring, 155 Nitrile - 70 1 A4867 501012155
32 Backing Ring, 8-154 PTFE 1 A4867 50110079
33 O-Ring, 154 Nitrile - 70 1 A4867 50102154
34 Ring, BR81 Steel 2 A4867 50101559
35 Spring, OD.80 ID.41 TH.3 Steel 0.09 KG 2 A4867 50020928
36 O-Ring, 150 Nitrile - 70 1 A4867 50102150
37 Backing Ring, 8-150 PTF3 1 A4867 50110080
38 Steel Disk, FO16 Steel 3 A4867 50110081
39 Bronze Disk, EO14 Bronze 0.03 KG 2 A4867 50110078
40 Bearing, Ball 1 52676 SKF 16005
41 Bearing, Needle Roller, HK3012 1 27737 HK3012
42 O-Ring, 154 Nitrile - 70 1 A4867 50102154
43 Screw, M10x35, ASTM A193, Gr. B8M UNI5931 4
44 Tongue 1 A4867 N/A
45 Motor Fixing Flange, ASTM A276, 316L 1 A4867 21490397
46 Braking Piston, ASTM A276, 316L 1 A4867 21490398
47 Sleeve, ASTM A519, Gr. 3115 1 A4867 21490399
48 Braking Casing, ASTM A276, 316L 1 A4867 21490400
49 Transmission Shaft, ASTM A519, Gr. 3115 1 A4867 21490401
50 Brake Enclosure Flange, ASTM A276, 316L 1 A4867 21490402
51 Screw, M8x50, ASTM A193, Gr. B8M UNI5931 3
52 Bevel Pinion, ASTM A519, Gr. 3115 1 A4867 21490403
53 Spacer Ring, ASTM A276, 316L 2 A4867 21490404
54 Screw, M14x30, ASTM A193, Gr. B8M UNI5739 4
55 Screw, M10x50, ASTM A193, Gr. B7 UNI5931 8
56 Screw, M8x20, ASTM A193, Gr. B8M UNI5931 4
57 Screw, M10x20, ASTM A193, Gr. B8M UNI5933 8
58 Lebus Half Shell, ASTM A276, Ti 2 A4867 21490405
59 Spring Pin, ø10x40 Steel UNI6873 4
60 O-Ring, 170 Nitrile - 70 4 A4867 50102170
61 Toothed Planetary Ring, ASTM A519, Gr. 3115 4 A4867 21490406
62 Flange, ASTM A304, Gr. 4140 4 A4867 21490529
63 Right Drum Flange, 23.5 K 1 A4867 21490408
64 Sprocket, 3/8″x7/32″ Z=46, ASTM A240, 316L 0.3 KG 1 A4867 21490392
65 Screw, M6xl5, ASTM A193, Gr. B8M UNI5739 6
66 Retaining Ring, ø195 Steel, UNI7437 1
67 Screw, M10x20, ASTM A193, Gr. B7 UNI5739 10
68 Bearing, Ball 1 52676 SKF 6012
69 Spacer, ASTM A519, Gr. 1030 1 A4867 21490563
70 Oil Seal, BASL 65x85x10 NBR 1 A4867 50094210
71 Pinion, ASTM A304, Gr. 4320 1 A4867 21490409
72 Pinion, ASTM A304, Gr. 4320 1 A4867 21490410
73 Antirotation Flange, ASTM A519, Gr. 3115 1 A4867 21490411
74 Screw, M10x80, ASTM A193, Gr. B7 UNI5931 8
75 Frame, ASTM A24, 0 XM 19 35.5 1 A4867 21490124

7-10
 SG811-BV-MMA-010

Table 7-4. Winch Assembly Parts List - Continued

FIG & ITEM MFG. PART

NO. DESCRIPTION QTY CAGE NO.
76 Coupling Joint, ASTM A519, Gr. 3115 1 A4867 21490389
77 Spacer, ASTM A276, 316L 7 A4867 21490412
78 Flange, ASTM A304, Gr. 4140 1 A4867 21490212
79 Spring Pin, ø10X30 Steel, UNI6873 4
80 Toothed Planetary Ring, ASTM A519 Gr. 3115 1 A4867 21490414
81 Retaining Ring, øE 65 Steel, UNI7435 1
82 Retaining Ring, ø1 100 Steel, UNI7437 1
83 Ball Bearing 1 52676 SKF 6013
84 Oil Seal, BASL 70x90x10 NBR 1 A4867 50094300
85 Left Drum Flange 1 A4867 21490415
86 Load Bearing Flange, ASTM A304 Gr. 1040 1 A4867 21490416
87 Planetary Gear Support, ASTM A339-55 1 A4867 21490526
88 Shimming ETACETAL 1 A4867 21490393
89 Spacer, ASTM A304, Gr. 1040 1 A4867 21490375
90 Spring Pin, ø10x35 Steel, DIN6325 3 A4867 50021465
91 Screw, M10x30, CL8.8 UNI5931 3
92 Planetary Gear, ASTM A304, Gr. 4320 0.4 3 A4867 21490377
93 Needle, Steel 207 A3280 ø4x39.8 BR
94 Slew Ring, ASTM A304, Gr. 1070 6 A4867 21490528
95 Pin, ASTM A304, Gr. 4320 3 A4867 21490527
96 Spring Pin, ø3x14 Steel, DIN1481 3 A4867 50021043
97 Spring Pin, ø3x10 Steel, DIN1481 6 A4867 21490393
98 Shimming, Etacetal 1 A4867 21490393
99 Spacer, ASTM A304, Gr. 1040 1 A4867 21490375
100 Planetary Gear, ASTM A519, Gr. 3115 3 A4867 21490376
101 Needle, Steel 306 A3280 ø3.5x23 BR
102 Pin, ASTM A304, Gr. 4320 3 A4867 21490310
103 Slew Ring, ASTM A304, Gr. 1070 3 A3280 CP 3047
104 Washer, ASTM A304, Gr. 12L14 3 A4867 21490214
105 Screw, M8x20, Cl. 8.8, UNI5933 3
106 Plate Fixing Wire Rope, ASTM A240, 316L UNI5931 2
107 Screw, M8x25, ASTM A193, Gr. B8M UNI5931 2
108 Chain Enclosure 1 A4867 21490569
109 Sprocket, 3/8″x7/32″ Z=26 0.24 KG 1 A4867 21490567
110 Screw, M4x6, ASTM A193, Gr. B8M UNI5927 1
111 Chain, 3/8″ Lg, 628.65, ASTM A240, 304 1 A4867 50309904
112 Washer 4 A4867 50080706
113 Screw 4 A4867 50002103
114 Gear Limit Switch 2 A4867 55000101
115 Washer, 10.5x21, ASTM A240, 316L UNI 6592 2
116 Screw, M10x15, ASTM A193, Gr. B8M UNI 5931 2
117 Limit Switch Support, ASTM A240, 316L 0.7 KG 1 A4867 21490565
118 Shimming PTFE 1 A4867 21490566
119 Plug with Gasket 1/4″ Gas Brass 1 A4867 80020582
120 Plug with Gasket 3/4″ Gas Brass 1 A4867 50020583

7-11
SG811-BV-MMA-010

Table 7-5. Main Boom Cylinder Assembly Parts List

FIG & ITEM MFG. PART
NO. DESCRIPTION QTY CAGE NO.
7-1 Main Boom Cylinder Assembly 1 A4867 21490111
1 Retaining Ring, Steel ø1 90 Steel UNI7437 4
2 Spherical Joint, SKF GE 60 CS-2Z, SST PTFE 1.1 KG 2 A4867 51004525
3 Bottom, ASTM A276, 316L 15.5 1 A4867 21490112
4 Screw, M10x35, ASTM A193, Gr. B8M UNI5931 1
5 Schnorr Washer, 10 50 Cr V4 ASTM A304 Gr. 6150 1 A4867 50110005
6 Back Braking System, ASTM A304, Gr. 1040 0.25KG 1 A4867 21490113
7 Braking Bushing, XANTAL-B 1 A4867 21490114
8 Screw, M14x105, ASTM A193, Gr. B7 UNI5931 16
9 Backing Ring, BKF248 2 A4867 50110018
10 Circlip, B055 Steel, UNI7433 1
11 Screw, M6x8, ASTM A193, Gr. B8M UNI5927 1
12 O-Ring, 248 Nitrile-70 MIL-R-83248-1 2 A4867 50102248
13 Gasket, AE 1000 PTFE + BRZ 2 A4867 50110035
14 Blocking Ring Nut, ASTM A276, 316L 2 A4867 21490125
15 Gasket, DEM 1000 PTFE + BRZ Nitrile 1 A4867 50110036
16 O-Ring, 834 Nitrile 70 MIL-R-83248-1 1 A4867 50102834
17 Front Braking System, ASTM A519, Gr. 1030 1 A4867 21490127
18 Rod Piston, ASTM A276, 316L 1 A4867 21490129
19 Pipe, ASTM A276, 316L 1 A4867 21490452
20 O-Ring, 238 Nitrile 70 MIL-R-83248-1 1 A4867 50102238
21 Backing Ring, BKF 238 PTFE 1 A4867 50110017
22 Cover, ASTM A276, 316L 1 A4867 21490436
23 Gasket, SIM 0700 PTFE + BRZ Nitrile 70 2 A4867 50110037
24 Screw, M14x125, ASTM A193, Gr. B7 UNI5931 16
25 Cover Guide, XANTAL-B 1.4 KG 1 A4867 21490437
26 Gasket, R 0700 PTFE + BRZ Nitrile 70 1 A4867 50110038
27 Front Connection, ASTM A276, 316 1 A4867 21490438
28 Piston, ASTM A276, 316 1 A4867 21490439
29 Front Feed Block, ASTM A240, 316 1KG 1 A4867 21490118
30 Overcenter Valve, LHK30VP-11-250 HAWE 4KG 2 A4867 50003169
31 Screw, M8x90, UNI5931 8
32 Screw, M6x10, ASTM A193, Gr. B8M UNI5931 2
33 Washer, PRO6 Copper UNI5649/1 2
34 Backing Ring, BKF834 PTFE 2 A4867 50110004
35 Identification Plate 1 A4867 50110533
36 O-Ring, 112 Nitrile 2 A4867 50102112
37 Back Feeding Block, ASTM A240, 316L 1 A4867 21490450

7-12
 SG811-BV-MMA-010
Figure 7-1. Main Boom Cylinder Parts Location
7-13
SG811-BV-MMA-010

Table 7-6. Jib Boom Cylinder Assembly Parts List

FIG & ITEM MFG. PART
NO. DESCRIPTION QTY CAGE NO.
7-2 Jib Boom Cylinder 1 A4867 21490117
1 Retaining Ring, øI 90 Steel, UNI7437 4
2 SPHERICAL Joint 2 52676 SKF GE 60
CS-2Z
3 Bottom, ASTM A276, 316L 1 A4867 21490120
4 Screw, M10x35, ASTM A193, Gr. B8M UNI5931 1
5 SCHNORR, Washer, 10, ASTM A304, Gr. 6150 1 A4867 50110005
6 Back Braking System, C40 0.25 KG, ASTM A304, Gr. 1040 1 A4867 21490113
7 Braking Bushing, Xantal-B 0.1 KG 1 A4867 21490114
8 Screw, M14x105, ASTM A193, Gr. B7 UNI5931 14
9 Backing Ring, BKF 246 PTF3 2 A4867 50110014
10 Circlip, B055 Steel, UNI7433 1 A4867 50110021
11 Screw, H6x8, ASTM A193, Gr. B8M UNI5927 1
12 O-Ring, 246 Nitrile -70 MIL-R-83248-1 2 A4867 20102246
13 Gasket, AE 0950 PTFE + Brz 2 A4867 50110031
14 Blocking Ring Nut, ASTM A236, 316L 2 A4867 21490442
15 Gasket, DEM0950 PTFE - Brz Nitrile -70 1 A4867 50110032
16 O-Ring, 834 Nitrile -70 MIL-R-83248-1 1 A4867 50102834
17 Front Braking System, Xantal-B 1 A4867 21490127
18 Rod Piston, ASTM A276, 316L 1 A4867 21490444
19 Pipe, ASTM A276, 316L 31.5 1 A4867 21490445
20 Backing Ring, BKF 237, PTFE 1 A4867 50110016
21 O-Ring, 237 Nitrile -70 MIL-R-83248-1 1
22 Cover, ASTM A276, 316L 1 A4867 21490446
23 Gasket, SIM 0650 PTFE + Brz Nitrile -70 2 A4867 50110033
24 Screw, M14x125, ASTM A193, Gr. B7 UNI5931 14
25 Cover Guide, Xantal-B 1 A4867 21490447
26 Gasket, R 0650 PTFE + Brz Nitrile -70 1 A4867 50110034
27 Front Connection, ASTM A276, 316L 13KG 1 A4867 21490438
28 Piston, ASTM A276, 316L 2KG 1 A4867 21490449
29 Front Feeding Block, ASTM A276, 316L 1 A4867 21490450
30 Overcenter Valve Hawe, LHK30VP-11-250 2 A4867 56913030
31 Screw, M8x90, ASTM A193, Gr. B8M UNI5931 8
32 Screw, M6x10, ASTM A/93 GR. B8M UNI 5931 4 A4867 50110024
33 Washer, RR 06 Copper UNI5649/1 2
34 Backing Ring, BKF 834 PTFE 2
35 Not Used
36 O-Ring, 112 Nitrile -70 MIL-R-83248-1 2
37 Back Feeding Block, ASTM A276, 316L 1 A4867 21490450

7-14
 SG811-BV-MMA-010
Figure 7-2. Jib Boom Cylinder Parts Location
7-15
SG811-BV-MMA-010

Table 7-7. Boom Head Assembly Parts List

FIG & ITEM MFG. PART
NO. DESCRIPTION QTY CAGE NO.
7-3 Boom Head Assembly 1 A4867 11490102
1 Boom Head 1 A4867 21490292
2 Boom Head Support 1 A4867 21490291
3 Ring Nut, Bronze 1 A4867 21490290
4 Pin, ASTM A276, XM19 1 A4867 21490104
5 Sheave, Nylatron GSM 1 A4867 21490103
6 Lock Washer, ASTM A2240, 316L 1 A4867 21490046
7 Screw, M12x40, ASTM A193, Gr. B8M UNI5739 1
8 Washer, 13x24, ASTM A240, 316L UN16592 1
9 Semi-Ring, ASTM A240, 316L 2 A4867 21490289
10 Screw, M12x25, ASTM A193 Gr, B8M UNI5739 18
11 Washer, 13x24, ASTM A240, 316L UNI6592 18
12 Ball Bearing, SKF 62208-2RS1 2 52676 62208-2RS1
13 Spacer, ASTM A276, 316L 2 A4867 21490288
14 Oil Seal, SN 50728, NBR 2 A4867 50093686
15 Screw, M10x25, ASTM A193, Gr. B8M UNI5733 12
16 Cover, ASTM A240, 316L 2 A4867 21490286
17 Nut, M10, ASTM A194, Gr. 8M, UNI5588 8
18 Washer, 10.5x21, ASTM A240, 316L UNI6592 16
19 Screw, M10x60, ASTM A193, Gr. B8M UNI5737 8
20 Ring, ASTM A240, 316L 2 A4867 21490285
21 Thickness, Nylatron GSM 2 A4867 21490294
22 Screw, M10x15, ASTM A193, Gr. B8M UNI5723 2
23 O-Ring, 872 MIL-R-83248-1 Nitrile-70 21 A4867 50102872
24 Bearing, Taper Roller Bearing 2 60038 JP12049A-
JL12010
25 Sealing Washer, 3/4″ 2 A4867 50104012
26 Plug, BSP 3/4″, ASTM A194, Gr. 8M 2 A4867 50020550
27 Roller, Nylatron GSM 1 A4867 21490282
28 Bracket 1 A4867 21490276
29 Spring Split Pin, Steel 1 A4867 21490187
30 Pin, ASTM A276, 316L 1 A4867 21490279
31 Washer, ASTM A240, 316L 2 A4867 21490283
32 Screw, M12x35, ASTM A193, Gr. B8M UNI5739 2
33 Pin, ASTM A276, 316L 1 A4867 21490278
34 Washer, ASTM A240, 316L 2 A4867 21490283
35 Screw, M12x30, ASTM A193, Gr. B8M UNI5739 2
36 Pin, ASTM A276, 316L 1 A4867 21490277
37 Bearing, Ball 2 52676 SKF 60062RS1
38 Spacer, ASTM A276, 316L 2 A4867 21490280
39 Oil Seal, SM 38557, NBR 2 A4867 50092970
40 Retaining Ring, φI55 Steel, UN17437 2
41 Bushing, Bronze 2 A4867 21490281
42 Grease Nipple, M10, Steel UNI7663 1
43 Pin 1 A4867 2140546
44 Spring Split Pin 1 A4867 21490190
45 Washer, 6.4x12.5, ASTM A240, 316L UNI6592 4

7-16
 SG811-BV-MMA-010

Table 7-7. Boom Head Assembly Parts List - Continued

FIG & ITEM MFG. PART

NO. DESCRIPTION QTY CAGE NO.
46 Screw, M6x15, ASTM A193, Gr. B8M UNI5739
47 Screw, M6x20, ASTM A193, Gr. B8M UNI5739 3
48 Chain, ASTM A276, 316L 1 A4867 21490199
49 Label Plate 1 A4867 50110567
50 Label Plate 1 A4867 50110573
51 Identification Plate 4 A4867 50110533
52 Grease Nipple, M10, Steel UNI7663 1

7-17
7-18

SG811-BV-MMA-010
Figure 7-3. Boom Head Assembly Parts Location
 SG811-BV-MMA-010

Table 7-8. Control Panel Assembly Parts List

FIG & ITEM MFG. PART
NO. DESCRIPTION QTY CAGE NO.
7-4 Control Panel Assembly, 017TZD01 1 A4867 11490098
1 4SPDT Alternate Action Switch Unimax 1 K6910 9H11253-
584051690726
2 Indicator Lamp Unimax 4 K6910 9H16253-
58405160726
3 4SPDT Momentary Action Switch Unimax 2 K6910 9H11253-
584051686726
4 Fixing Knob, MLTA 1 A4867 01700F04
5 Connector, Veam 1 C2107 MS3102AZ8-
121P
6 Peralluman Panel, MLTA 1 A4867 01700D03
7 Rubber Strip, CATI 1 A4867 TC58
8 Inox Box, AISI316 MLTA 1 A4867 01700D02
9 Identification Label, MLTA 1 A4867 01700F03
10 Yellow/Green Wire, CEI 2--22 II N07V-K 2.5 mmg AR A4867 55018595
11 Screw, M4x8, ASTM A193, Gr. B8M, UNI6107 1
12 Nut, 5.3, ASTM A193, Gr. B8M, UNI5588 3
13 Washer, 5.3x10, ASTM A193, Gr. B8M, UNI6592 1
14 Identification Label, MLTA 017T0F02 14 A4867 55018214
15 Nut, M4, ASTM A194, Gr. 8M, UNI5588 4
16 Earth Terminal, MLTA 1 A4867 21490027
17 Washer, 3.2x6, ASTM A193, Gr. B8M UNI6592 5
18 Gasket, Veam 1 C2107 16958
19 Screw, M4x10, ASTM A193, Gr. B8M UNI6107 4
20 2 SPDT Alternate Action Switch Unimax 1 K6910 9H1125358-
4051688726
21 Drip Proof Seal 8 K6910 9.902
22 RFI Shielding 8 K6910 9H-368
23 Green Lamp Filter 4 K6910 9H-368
24 Red Lamp Filter 8 K6910 9H-41
25 Yellow Lamp Filter 10 K6910 9H-44
26 Blue Lamp Filter 2 K6910 9H-47
27 Lamp, 527/345, 6V-40mA 1 A4867 55018900
28 Mode Record Label, MLTA 01700F01 1 A4867 55018212
29 Blue Low Smoke Wire, CEI 20-22 II N07V-K 0.5mmg AR A4867 55018590

7-19
SG811-BV-MMA-010

Figure 7-4. Control Panel Assembly Parts Location (Sheet 1 of 3)

7-20
 SG811-BV-MMA-010

Figure 7-4. Control Panel Assembly Parts Location (Sheet 2 of 3)

7-21
SG811-BV-MMA-010

Figure 7-4. Control Panel Assembly Parts Location (Sheet 3 of 3)

Table 7-9. Electronic Control Unit Parts List
FIG & ITEM MFG. PART
NO. DESCRIPTION QTY CAGE NO.
7-5 Electronic Control Unit Assembly, 21KG, MLTA 016S1D01 1 A4867 11490099
1 Identification Label, MLTA P/N 01700F03 1 A4867 55019005
2 Silicon Conductive Gasket, S.I.R.I. 31192-C6 1 A4867 55019006
3 Supply Board Identification Label, MLTA P/N 016N0F02 1 A4867 55019007
4 Vibration-Dampener, O.M.L. AVAU 705 A 99.49-031/B 4 A4867 55019008
5 Dirty Box, MLTA P/N 018F 1 A4867 55019010
6 Control Board CST 103 M.L.T.S. P/N 016M/3 1 A4867 55019011
7 Power Resistor Dalge WH25-33-5 1 A4867 55019026
8 Diode, Thomson BYX 62600 4 A4867 55019027
9 Power Transistor, Thomson BUV 23 2 A4867 55019028
10 Heat Sink, MLTA P/N H003 1 A4867 55019013
11 Electrolytic Capacitor, Itelcond ARX 15000UF 63V 1 A4867 55019015
12 Shock Proof Fuse Carrier, Ghisalba NF16 2 A2515 55019016
13 Service Transformer, MLTA T053 1 A4867 55019017
14 Supply Board, CST 102 MLTA P/N 016V/1 1 A4867 55019018

7-22
 SG811-BV-MMA-010

Table 7-9. Electronic Control Unit Parts List - Continued

FIG & ITEM MFG. PART

NO. DESCRIPTION QTY CAGE NO.
15 Power Transformer, MLTA T052 1 A4867 55019019
16 Identification Label, MLTA 5 A4867 55019096
17 Inox, Screw, M3x10, ASTM A193, Gr. B8M UNI6107 8
18 Power Resistor, Dalge WH25-68-5 1 A4867 55019021
19 Power Resistor, Dalge WH25-220-5 1 A4867 55019024
20 Insulated Kit, T03 Elmi 2 A4867 LC3-P-08298L
21 Thermal Interface Materials, Chomerics WW-10-0808-1678 1 A4867 55019025
22 Nut, M4, Vitor, UNI5588 12
23 Screw, M4x16, ASTM A193, Gr. B8M UNI6107 19
24 Bottom Plate 1 A2515 8.512.047
25 Washer, 4.3x9, ASTM A240, 316L UNI6592 46
26 Screw, M3x16, ASTM A193, Gr. B8M UNI6107 8
27 Washer, 3.2x6, ASTM A240, 316L UNI6592 32
28 Nut, M3, ASTM A194, Gr. 8M UNI5588 16
29 Fuse, 500V, 4Amp 2 A2515 NF16
30 Wire, NAV-13 A075 MMI QFRT 1x1mmg AR A4867 55018595
31 Yellow/Green Cable, Lg 250 CEI 20-22 II H07V-K 2 A4867 55018590
32 Screw, M10x20, ASTM A193, Gr. B8M UNI5727 4
33 Washer, 10.5x21, ASTM A240, 316L UNI6592 4
34 Screw, M5x20, ASTM A193, Gr. B8M UNI5727 4
35 Washer, 5.3x10, ASTM A240, 316L UNI6592 16
36 Self Locking Nut, M5, ASTM A194, Gr. 8M UNI7473 8
37 Screw, M4x40, ASTM A193, Gr. B8M UNI6107 5
38 Self Locking Nut, M4, ASTM A194, Gr. 8M UNI7473-6S 15
39 Spacer, M3 H=10 EKMI LC3-P-082982 8 A4867 55019054
40 Clamp, Itelcond ZAF 50/I 1 A4867 55019051
41 Screw, M4x25, ASTM A193, Gr. B8M UNI6107 4
42 Label Plate 1 A4867 50110557
43 Label Plate 1 A4867 50110556
44 Captive Screw, M6 4 A4867 55018550
45 Box, with Cover 1 A2515 8216091
46 Screw Pin 2 A4867 55018554
47 Screw Hinge 2 A4867 55018552
48 Washer, 6.4x12.5, ASTM A240, 316L UNI6592 2
49 Nut, M6, ASTM A194, Gr. 8M UNI5588 2
50 Washer, 4.1x7.6, ASTM A240, 316L UNI1751 2
51 Nut, M4, ASTM A194, GR. 8M UNI5588 2
52 Washer, 4.3x9, ASTM A240, 316L UNI6592 2
53 Washer, 6.1x11.8, ASTM A240, 316L UNI1751 2

7-23
SG811-BV-MMA-010

Figure 7-5. Electronic Control Unit Parts Location (Sheet 1 of 3)

7-24
 SG811-BV-MMA-010

Figure 7-5. Electronic Control Unit Parts Location (Sheet 2 of 3)

7-25
SG811-BV-MMA-010

Figure 7-5. Electronic Control Unit Parts Location (Sheet 3 of 3)

7-26
 SG811-BV-MMA-010

Table 7-10. Control Board Assembly Parts List

FIG & ITEM MFG. PART
NO. DESCRIPTION QTY CAGE NO.
7-6 Control Board 1 A4867 016M1201
1 Stamped Terminal Strip, TP6, TP4, TP5, TP5 4 A4867 M/AW 111/20
2 Ceramic Capacitor, 0.1uf, 50v. X7R-C40, C35, C36, C42 4 A4867 RPE131X7R10
4K50
3 Film Resistor, 100Kohm, 1%, 1/4 w R48, R37, R40, R45, R50, 8 A4867 LR1-100000
R51, R53 R38
4 Film Resistor, 25Kohm, 1%, 1/4 w R34 1 A4867 LR1-25000
5 Film Resistor, 2.2Kohm, 1%, 1/4 w R46, R47 2 A4867 LR1-2200
6 Film Resistor, 39Kohm, 1%, 1/4 w R55 1 A4867 LR1-39000
7 Diode LED, D16, D15, D29, D30 D31 5 A4867 LR3160-DG
8 Polyester Capacitor, 2.2uf 63v X7R C38 1 A4867 R.60-2.2uf K63
9 Film Resistor, 1K5ohm, 1% 1/4 w, R36, R54 2 A4867 LR1-1500
10 Diode, D46, D20, D21, D22, D23 D24, D25, D34, D37, D38, 12 A4867 1N4007
D39 D40
11 Film Resistor, 390 ohm, 5%, 1/2 w R1 1 A4867 LR5-390
12 Film Resistor, 1mohm, 1% 1/4 w, R39 1 A4867 LR1-1000000
13 Film Resistor, 1kohm, 1% 1/4 w, R56 1 A4867 LR1-10000
14 Polyester Capacitor, 1uf 63v ±10%, C34 1 A4867 R.60-1MF K63
15 Film Resistor, 150 ohm, 1%, 1/4 w R31 1 A4867 LR1-150
16 Film Resistor, 3.9kohm, 1% 1/4 w R41, R42, R59, R64, R65 5 A4867 LR1-3900
17 Diode Zener, 2V7, 400 mw D50 1 1F026 BZX552V7
18 Relay 4 Contactor RL 9 1 A4867 DS4E-S-DC
24V
19 Relay 2 Contactor RL2, RL1, RL5, RL6 4 A4867 DS2E-F-DC
24V
20 Electrolytic Capacitor 10uf-50v, C5 1 A4867 10uf-50v
21 Diode Zener, 15v, 1w, D3 1 A4867 ZBY-15V
22 Operational Amplifier, Linear U8 1 A4867 LM239
23 Film Resistor 150 ohm, 5%, 1/2 w R33 1 A4867 LR5-150
24 Connector 25 Pin SK1 1 A4867 DN25S
25 Connector DB 15 Pins PH1 1 A4867 DN15S
26 Optoisolator, U7 1 A4867 1LQ1
27 Board 1 A4867 CST 103

7-27
SG811-BV-MMA-010

Figure 7-6. Control Board (Part of ECU)

7-28
 SG811-BV-MMA-010

Table 7-11. Power Supply (Part of ECU) Parts List

FIG & ITEM MFG. PART
NO. DESCRIPTION QTY CAGE NO.
7-7 Power Supply 1 A4867 016V0201
1 Connector, TB1, TB2, TB3, TB4 4 A4867 MKDS 3/9
2 Film Resistor, 3.9Kohm, 1% 1/4w R5 1 A4867 LR1-3900
3 Quick Acting Fuse 3A, F1, F2 2 A4867 RVF-3-250V
4 Quick Acting Fuse 5A, F5, F4 2 A4867 RVF-5-250V
5 Diode LED, D7 1 A4867 LR 3160-DG
6 Quick Acting Fuse 1A, F6 1 A4867 RVF-1-250V
7 Diode Zener, 13V, 400mw D3 1 1F026 BZX55C13
8 Diode Zener, 5VI, 400mw D2 1 1F026 BZX555V1
9 Film Resistor, R3, 4K7, 5% 1/2 w 1 A4867 LRS-4700
10 Film Resistor, 27 kohm, R4 1% 1/4 w 1 A4867 LRS-27000
11 Ceramic Capacitor, 2.2uf, 100v, X7R, C6, C7, C8 3 A4867 RPE114X7R
226J100

7-29
SG811-BV-MMA-010

Figure 7-7. Power Supply (Part of ECU)

7-30
 SG811-BV-MMA-010

Table 7-12. Dirty Box Assembly Parts List

FIG & ITEM MFG PART
NO. DESCRIPTION QTY CAGE NO.
7-8 Dirty Box Assembly, MLTA SRL 1 A4867 018F1F01
1 Identification Label, MLTA 1 A4867 P/N01700F3
2 Screw, M4x16, ASTM A193, GR. B8M UNI6107 8
3 Washer, 4.3x9, ASTM A240, 316L UNI6592 11
4 Screw, M4x11, ASTM A193, G12, B8M UNI6107 4
5 Blue Low Smoke Wire, CEI 20-22 II H07V-K-0.5mmg AR
6 Deform Nut, M4, 0.7 Special Insert 26 A4867 M4 TCS
7 Dirty Connector Panel, MLTA 1 A4867 018G1102
8 Connector, Veam 1 C2107 MS3102A207P
9 Connector, Veam 1 C2107 MS3102A18-
19P
10 Sub D Connector Ceep DN25P2 (CT25) 1 A4867 DN25P2
11 Screw, M3x10, ASTM A193, GR. B8M UNI6107 12
12 Washer, 3.2x6, ASTM A240, 316L UNI6592 40
13 Spacer, M3x20, ELMI 12 A4867 CH7-M3 20
MF
14 Nut, M3, ASTM A194, GR.8M UNI5588 12
15 I/O Filter Board, MLTA 1 A4867 018M1201
16 I/O Filter Board MLTA 1 A4867 018C1201
17 Dirty box, MLTA 1 A4867 018F1101
18 Self Locking Nut, M3, ASTM A194, GR.8M UNI7473 16
19 Screw, M3x16, ASTM A193, GR.B8M UNI6107 16
20 Earth Terminal, MLTA 1 A4867 00890D01
21 Nut, M5, ASTM A194, GR.8M 2 A4867 UNI5588
22 Connector, Veam 1 52107 MS3102A32-
22P
23 Connector, Veam 1 52107 MS3102A-14S
24 LC Filter Siemens B85313-AC1 30 A4867 B85313-AC1
25 Wire, NAV-13 A075 MMI QFRT 1x1mmg AR A4867 NAV-13

7-31
SG811-BV-MMA-010

Figure 7-8. Dirty Box (Part of ECU) (Sheet 1 of 2)

7-32
 SG811-BV-MMA-010

Figure 7-8. Dirty Box (Part of ECU) (Sheet 2 of 2)

7-33
SG811-BV-MMA-010

Table 7-13. Electric Motor Starter Parts List

FIG & ITEM MFG. PART
NO. DESCRIPTION QTY CAGE NO.
7-9 Electric Motor Starter, 45 KG MLTA 1 A4867 11490211
1 Container Inox Amagnetic 1 A2515 8.512.048
2 Bottom Plate Inox 1 A2515 8.512.047
3 Shock Proof Contactor N50-3-22-115/60 1 A2515 4.11.387
4 Overload Aux Relay, RTD-NOL Tar. 20A 1 A2515 4.311.274
5 Relays NR-22 115/60 2 A2515 4.117.200
6 Service Transformer, T40CMM 440/115-60 Hz 1 A2515 4.411.761
7 Fuse Holder, 6A NF16 6 A2515 4.165.106
8 Fuse, 5SA1 2 A2515 4.162.161
9 Fuse, 5SA2 4 A2515 4.162.161
10 Terminal Board, MM-184A 1 A2515 8.096.082
11 Bracket-18TB, MMI 1 A2515 8.096.072
12 Switch, MMI 098USLS2 1 A2515 8.512.040
13 Label ″Battle Short″ Off-On 1 A4867 55018216
14 Running Contactor, 1 A2515 4.221.167
15 Stuffing Tube, 3/4x18x14 2 A2515 4.821.134
16 Stuffing Tube, 3/4x20x16 3 A2515 4.821.1352
17 Label Plate 1 A4867 50110547
18 Screw, M10x20, UNI6107 6
19 Wire AR A4867 55019002
20 Screw, M6x16, UNI6107 16
21 Screw, M6x20, UNI6107 4
22 Screw, M4x16, UNI6107 12
23 Screw, M4x8, UNI6107 3
24 Screw, M6x40, UNI6107 7
25 Washer, 10.5x21, UNI6592 6
26 Washer, 6.4x12.5, UNI6592 27
27 Washer, 4.3x9, UNI6592 15
28 Label Plate 1 A4867 50110556
29 Label Plate 1 A4867 50110557
30 Label Plate 1 A4867 50110533

7-34
 SG811-BV-MMA-010

Figure 7-9. Electric Motor Starter Parts Location (Sheet 1 of 3)

7-35
SG811-BV-MMA-010

Figure 7-9. Electric Motor Starter Parts Location (Sheet 2 of 3)

7-36
 SG811-BV-MMA-010

Figure 7-9. Electric Motor Starter Parts Location (Sheet 3 of 3)

7-37
SG811-BV-MMA-010

Table 7-14. Electric Motor Assembly Parts List

FIG & ITEM MFG. PART
NO. DESCRIPTION QTY CAGE NO.
7-10 Electric Motor 1 20019 2149008
1 Frame and Wound Stator Assy, MIL-M-17060 1 20019 2016005-38
2 Bracket, Bearing Alum QQ-A-601 1 20019 20260013-15
3 Bracket, Bearing Alum QQ-A-601 1 22019 20260014-3
4 Eyebolt, 1/2-13 SST QQ-S-763 1 20019 11000026-4
5 Ball Bearing Assy, FF-B-171 1 43991 K52-0050
6 Ball Bearing Assy, FF-B0171 1 43991 K52-0006/
3609
7 Coil Winding Copper, J-W-1177 1 20019 MC3686
8 Connector, WT Assy MIL-M-17060 1 20019 15000046
9 Wound Stator Assy, MIL-M-17060 1 20019 20360054
10 Rotor And Shaft Assy 1 20019 21060060
11 Shaft Monel, QQ-N-286 1 20019 21160069
12 Rotor Assy, MIL-M-017060 1 20019 21460015
13 Fan Alum, QQ-A-601 1 20019 22200038-15
14 Lock Nut, SST FF-B-171 1 79568 BH-06-SS
K59-0071
15 Key Woodruff, 807 SST 316 QQ-S0763 1 81349 K75-0029
16 Spring Washer, Steel AISI 1075 1 20019 11700003-5
17 Roll Pin, Steel 5/6x1/4 MBK 1 00287 AISI1075-95
18 Shrink Ring, SST QQ-S-763 1 20019 11400001-398
19 Key, SQ. 25x2.50 Steel B1113 1 20019 25000359-215
20 Shutter Alum, QQ-A6-1 1 20019 23360016-4
21 Terminal Box, Alum QQ-A-601 1 20019 23000030-4
22 O-Ring, Neoprene MIL-G-1149 2 76385 K70-0114
23 Not Used
24 Cover, Terminal Box Alum, QQ-A-250 1 20019 23100020-178
25 Gasket, Saddle Rubber MIL-R-6855 1 20019 23200021-32
26 Gasket, Cover Rubber MIL-R-6855 1 20019 23200020-13
27 Terminal Lugs Assy, MIL-T-7928 3 81349 MS25036-157
28 Instruction Plate, VPI MIL-P-15024 1 20019 10100134
29 Name Plate, SST MIL-P-15024 1 20019 10100037
30 Rotation Plate, SST MIL-P-15024 1 20019 10100061
31 Lubrication Plate, SST MIL-P-15024 1 20019 10100060
32 Key, 3/8 SQ 3-1/2 1 20019 25000359-343
33 Set Screw, 1/2-12x3/8 LG Soc HD SST FF-S-200 1 20019 SPP64-0250
34 Not Used
35 Screw, 3/8-16x1-1/4 LG Hex HD SST FF-S-85 16 20019 SPP62-0309
36 Screw, 1/4-20x3/4 LG Hex Hd SST FF-S-85 4 20019 SPP59-0105
37 Screw, 10-32x3/4 LG Pan HD FF-S-92 6 20019 SPP59-0106
38 Screw, 10-32x3/4 LG Pan HD FF-S-107 4 20019 SPP59-0106
39 Drive Screw, 4x1/4 LG Pan HD FF-S-107 8 20019 SPP70-0001
40 Not Used
41 Lock Washer, 3/8 SST FF-W-84 16 20019 SPP51-0057
42 Lock Washer, 3/8 FF-W-84 SST 4 20019 SPP51-0055
43 Lock Washer, #10 SST FF-W-84 10 20019 SPP51-0054

7-38
 SG811-BV-MMA-010
Figure 7-10. Electric Motor Parts Location (Sheet 1 of 2)
7-39
SG811-BV-MMA-010

Figure 7-10. Electric Motor Parts Location (Sheet 2 of 2)

Table 7-15. Slew Ring Assembly Parts List

FIG & ITEM MFG. PART
NO. DESCRIPTION QTY CAGE NO.
6-17 Slew Ring Assembly 1 A4867 21490084
1 Gear Ring, AL ZN Mg CU 0.5 1 D8856 842.12.0905.
000.0194
2 Supporting Ring, AL ZN Mg CU 0.5 1 D8856 843.12.0905.
000.0294
3 Retaining Ring, AL ZN Mg CU 0.5 1 D8856 842.12.0905.
000.0394
4 Oblique Roller, Cage Segment Plastic 68 D8856 742.12.0905.
000.0494
5 Race Wire Outer, SST 2 D8856 842.12.0905.
000.0594
6 Race Wire Inner, SST 1 D8856 842.12.0905.
000.0694
7 Cylindrical Roller, SST 332 D8856 842.12.0905.
000.0794

7-40
 SG811-BV-MMA-010

Table 7-15. Slew Ring Assembly Parts List - Continued

FIG & ITEM MFG. PART

NO. DESCRIPTION QTY CAGE NO.
8 Dowel Pin, SST 6 D8856 842.12.0905.
000.0894
9 Locking Washer, SST 36 D8856 842.12.0905.
000.0994
10 Socket Head Cap Screw, SST 36 D8856 842.12.0905.
000.1094
11 Radial Seal, NBR 1 D8856 842.12.0905.
000.1194
12 Tension Spring, SST 1 D8856 842.12.0905.
000.1294
13 Tension Spring, SST 1 D8856 842.12.0905.
000.1394
14 Radial Seal, NBR 1 D8856 842.12.0905.
000.1494
15 Threaded Insert, SST 36 D8856 842.12.0905.
000.1494
16 Threaded Insert, SST 36 D8856 842.12.0905.
000.1694
17 Threaded Pin, Plastic 2 D8856 842.12.0905.
000.1974
18 Grease Nipple M10x1 2 A4867 50020060

Table 7-16. Hydraulic Motor Assembly Parts List

FIG & ITEM MFG. PART
NO. DESCRIPTION QTY CAGE NO.
7-11 Hydraulic Motor Denison 4 9F512 MF05-02031N
1 Motor Body 1 9F512 035-28527
2 End Cap 1 9F512 035-28596
3 Screw, S.H.C. 5/16 - 18x2 3/4″ 4 9F512 35814300
4 Screw, S.H.C. 5/16 - 18x1/2″ 1 9F512 358-14086
5 Barrel Bearing 1 9F512 035-14413
6 Port Block 1 9F512 035-28532
7 Screw, S.H.C. 5/16-18x1 1/4″ 4 9F512 0358-14180
8 Seal Retainer 1 9F512 035-12691
9 Screw, S.H.C. 1/4-20x5/8″ 4 9F512 358-12100
10 O-Ring, 70-62305-(ARP-227) 1 9F512 671-00227
11 Shaft Seal, 67x291 1 9F512 620-50291
12 External Snap Ring, Eaton No. 698-R 1 9F512 356-11305
13 Ball Bearing, MRC-305-RDB (Matched part) 1 9F512 230-07305
14 & 15 Spacers, 1 Set (035-14916 & 14417) 1 9F512 S15-99891
16 Lock Nut, No. 5 1 9F513 341-10005
17 Lock Nut, WO-5 1 9F512 350-01005
18 Motor Shaft 1 9F512 035-14422
19 Shaft Key, 3/16″x1 1/4″ 1 9F512 035-19578
20 O-Ring, 70-6230-16 (ARP-238) 1 9F512 671-00238
21 O-Ring, 70-6230-17 (ARP-239) 2 9F512 671-00239

7-41
SG811-BV-MMA-010

Table 7-16. Hydraulic Motor Assembly Parts List - Continued

FIG & ITEM MFG. PART

NO. DESCRIPTION QTY CAGE NO.
22 Port Plate 1 9F512 035-27678
23 Dowel Pin, 1/8″x3/8″ 1 9F512 324-20806
24 Cylinder Barrel 1 9F512 035-14409
25 Screw, S.H.C. 10-24x1 1/2″ 7 9F512 035-10200
26 P & S Assembly (7 pistons, 7 shoes & 035-27362 retainer) 1 9F512 S15-12316
27 Ball, Steel 7/16″ dia. 1 9F512 201-14001
28 Spring Retainer 1 9F512 035-12690
29 Pin, 1/16x1/4″ 1 9F512 325-04040
30 Spring Socket 1 9F512 035-19271
31 Hold Down Spring 1 9F512 035-22136
32 Cam Plate 1 9F512 035-12687
33 O-Ring, 70-6230-8 (ARP-30) 1 9F512 671-00230
34 Plug, AN-913-2D Sq. Hd. Pipe, 1/4″ NPT 1 9F512 488-13024

7-42
 SG811-BV-MMA-010

Figure 7-11. Hydraulic Motor Parts (Turret)

7-43
SG811-BV-MMA-010

Table 7-17. Hydraulic Brake Assembly Parts List

FIG & ITEM MFG. PART
NO. DESCRIPTION QTY CAGE NO.
7-12 Hydraulic Brake Assembly 2 A4867 21490023
1 Screw, M10x35, AISI 316L UNI5739 4
2 Brake Cover, AISI 316L 2 A4867 21490495
3 Retaining Ring, Steel UNI7437 1
4 Bearing 1 A4867 51000444
5 Retaining Ring, Steel UNI7435 1 A4867 50200060
6 O-Ring, Nitrile-70 MIL-R-83248 TY-1, CL-1 (75±5 Hardness) 1 A4867 50102047
7 O-Ring, Nitrile-70 (MIL-R-83248 TY-1, CL-1 (75±5 Hardness) 2 A4867 50102156
8 Backing Ring, Parbak NBR 2 A4867 50110052
9 Braking Casing, AISI 316L 1 A4867 21490494
10 Magnetic Plug, 1/4″ Gas Steel 4 A4867 50020582
11 Spring, For Brake 55SICR6 4 A4867 21490493
12 Sintered Disk, 3.5″ 6 A4867 50110054
13 Disk Steel, 3.5 7 A4867 50110053
14 Slip Bushing Bronze 1 A4867 21490492
15 Retaining Ring, Steel UNI7437 1
16 Brake Shaft, 18NICRMO, 6 16CRNI 4 1 A4867 50102155
17 O-Ring, Nitrile-70 MIL-R-83248 TY-1, CL-1 (75±5 Hardness) 1 A4867 50102154
18 Retaining Ring, Steel, UNI7435 4
19 Coupling, Joint, 16NICR 1 A4867 21490497
20 Magnetic Plug, 1/4″ Gas Steel 4 A4867 50020582
21 Expansion Plug, φ45 Steel 1 A4867 50020581
22 Screw, M6x60, AISI, 316L UNI5931 8
23 Piston Brake, 16NICR 1 A4867 21490490
24 O-Ring, Nitrile-70 MIL-R083248 TY-1, CL-1 (75±5 Hardness) 1 A4867 50102238
25 Backing Ring, Parbak NBR 1 A4867 50110051
26 Spacer Brake, AQ 42 1 A4867 21490491
27 Washer, 10.5x21, AISI, 316L UNI6592 4

7-44
 SG811-BV-MMA-010

Figure 7-12. Hydraulic Brake Parts Location

7-45
SG811-BV-MMA-010

Table 7-18. Reduction Gear Assembly Parts List

FIG & ITEM MFG. PART
NO. DESCRIPTION QTY CAGE NO.
7-13 Reduction Gear Assembly 1 A4867 11490094
1 Oil Seal, SM 8511012 Nitrile-70 ASTM D735-58T SB715B 1 A4867 50094641
E1E3F1
2 Seal Support, ASTM A276, 316L 1 A4867 21490470
3 Screw, M6x14, ASTM A193, GR B8M UNI5931 6
4 Gasket 1 A4867 21490471
5 Output, Support, ASTM A276, 316L 1 A4867 21490472
6 Plug, 3/8″, BSP, ASTM A276, 316L Cast 312403 1 A4867 50020584
7 Special Key, ASTM A304, Gr 1040 1 A4867 21490473
8 Ring Nut, Steel 1 52676 SKF KM 15
9 Pin, ASTM A304, GR 4320 3 A4867 21490474
10 O-Ring, 170 MIL-R-83248-1 Nitrile-70 2 A4867 50102170
11 Toothed Planetary Ring, ASTM A519 GR 3115 1 A4867 21490475
12 Spacer, ASTM A276, 316L 1 A4867 21490476
13 Flange, ASTM A304, Gr 4140 1 A4867 21490487
14 O-Ring, 170 Nitrile-70 MIL-R-83248-1 2 A4867 80102170
15 Toothed Planetary Ring, ASTM A519 Gr. 3115 1 A4867 21490478
16 Screw, M10x120, ASTM A193, Gr B8 UNI5931 8
17 Connection Spacer, ASTM A276, 316L 1 A4867 21490479
18 Toothed Planetary Ring, ASTM A519, Gr. 3115 1 A4867 21490480
19 O-Ring, 162 MIL-R-83248-1 Nitrile-70 2 A4867 50102162
20 Screw, M8x35, ASTM A193, Gr. B8M UNI5931 8
21 Pin, ASTM A304, Gr. 4320 3 A4867 21490481
22 Plug 1 A4867 50110568
23 Retaining Ring, φE40 Steel UNI7435 1
24 Output Shaft, ASTM A304, Gr. 9840 1 A4867 21490482
25 Taper Roller Bearing 1 52676 SKF 32215
26 Taper Roller Bearing 1 52676 SKF 32015X
27 Inlet Extension, ASTM A276, 316L 1 A4867 21490166
28 Shimming Eracetal 1 A4867 21490483
29 Plug, 3/8″, BSP Cast 312403 ASTM A276 316L 4 A4867 50020584
30 Central Pinion, ASTM A304, Gr. 4320 1 A4867 21490484
31 Spring Pin, φ10x60 Steel DIN 1481 4 A4867 50021531
32 Shimming Eracetal 1 A4867 21490483
33 Central Pinion, ASTM A30, 4 Gr. 4320 1 A4867 21490488
34 Retaining Ring, φE40 Steel UNI7435 1
35 Spring Pin, φ10x50 Steel 4 A4867 50021530
36 Shimming Eracetal 1 A4867 21490483
37 Central Pinion, ASTM A304, Gr. 4320 1 A4867 21490486
38 Planetary Gear, ASTM A304, Gr. 4320 3 A4867 21490530
39 Planetary Gear Support, ASTM A339-55 1 A4867 21490531
40 Slew Ring, ASTM A304, Gr. 1070 6 A4867 21490532
41 Needle Nadella, 4x39.8 BR Steel 84 A4867 51003760
42 Flange, ASTM A304, Gr 4140 1 A4867 21490533
43 Spacer, ASTM A304, Gr 1040 1 A4867 21490534
44 Planetary Gear, ASTM A519, Gr. 3115 3 A4867 21490540
45 Needle Nadella, 3/5x17.8, Br Steel 90 A4867 51003743

7-46
 SG811-BV-MMA-010

Table 7-18. Reduction Gear Assembly Parts List - Continued

FIG & ITEM MFG. PART

NO. DESCRIPTION QTY CAGE NO.
46 Pin, ASTM A304, Gr. 4320 3 A4867 21490536
47 Slew Ring, ASTM A304, Gr. 1070 3 A4867 21490537
48 Washer, ASTM A304, Gr. 12L 14 3 A4867 21490538
49 Screw, M8x20, UNI 3740 CL 8.8 UNI5933 3
50 Spacer, ASTM A304, Gr 1040 1 A4867 21490539
51 Planetary Gear, ASTM A 304, Gr. 4320 3 A4867 21490541
52 Needle Nadella, 2x13.8 BR Steel 114 A4867 51003715
53 Slew Ring Nadella, CP 1932, ASTM A304, Gr. 1070 3 A4867 50097501
54 Flange, ASTM A304, Gr. 4140 1 A4867 21490542
55 Washer, ASTM A304, Gr 12L 14 3 A4867 21480538
56 Screw, M8x20, CL 8.8 UNI5933 3
57 Spacer, ASTM A304, Gr. 1040 1 A4867 21490539
58 Spring Pin, φ3x10, Steel, DIN1481 6 A4867 50021503
59 Spring Pin, φ3x10, Steel, DIN1481 3 A4867 50021503
60 Dowel Pin, φ10x35, Steel, DIN6325 3 A4867 50021465
61 Screw, M10x30, CL 8.8 UNI5931 3
62 Sight Window Screwed Ends Brass EEP 540 Size 1″ NDT 4 16199 50020579
63 Sight Window Screwed Ends Brass EEP 540 Size 3/4″ NPT 1 16199 50020580
64 Oil Level Monitor, GTSF3 G 1 A4867 56923011
65 Adapter 1 A4867 21490165
66 Stud Standpipe Adapter, with Seal, ASTM A276, 316L CAST 1 A4867 58100742
111107
67 Male Stud Coupling, ASTM A276, 316L CAST 110507/S 1 A4867 58100741
68 Ball Valve, CAST VSP 120 1 A4867 50110201
69 Identification Plate 1 A4867 50110534
70 Label Plate 1 A4867 50110573
71 Label Plate 1 A4867 50110566
72 Plug 1 A4867 50110568

7-47
SG811-BV-MMA-010

Figure 7-13. Reduction Gear Parts Location

7-48
 SG811-BV-MMA-010

Table 7-19. Hydraulic Pump Assembly Parts List

FIG & ITEM MFG PART
NO. DESCRIPTION QTY CAGE NO.
7-14 Hydraulic Pump Denison 1 9F512 21490091
1 Shaft 1 9F512 035-14422
2 Seal Retainer 1 9F512 035-12691
3 Snap Ring 1 9F512 356-11305
4 Bearing 2 9F512 230-07305
5 Port Block 1 9F512 035-27862
6 O-Ring 1 9F512 671-00238
7 Port Plate RH 1 9F512 035-27678
8 Piston & Shoe Assembly 1 9F512 S15-12316
9 Bearing 1 9F512 035-27085
10 End Cap 1 9F512 035-27101
11 Screw Socket Head Cap (10-32x5/8) 14 9F512 309-09100
12 Rollpin (1/16x1/4) 1 9F512 325-04040
13 Spring Retainer 1 9F512 035-12690
14 Compression Spring 1 9F512 035-22136
15 Cylinder Barrel 1 9F512 035-14409
16 Dowel Pin (1/8x3/8) 1 9F512 324-20806
17 Screw, Socket Head Cap (5/16-18x1-1/4) 4 9F512 358-14180
18 O-Ring, 70-6230-5 1 9F512 617-00227
19 Screw, Socket Head Cap (1/4-20x5/8) 4 9F512 308-12100
20 Shaft Seal 1 9F512 620-50291
21 Name Plate 1 9F512 035-20613
22 Plug, AN 814-4 1 9F512 488-14040
23 O-Ring, 70-6290-4 1 9F512 671-00904
24 Screw, Socket Head Cap (10-24x1-1/2) 1 9F512 358-10200
25 O-Ring, 70-914-4 2 9F512 671-000
26 Trunnions 3 9F512 035-27091
27 Screw, Socket Head Cap (10-24x1/2) 8 9F512 358-10080
28 Hanger, Spacer 2 9F512 035-27089
29 Screw, Socket Head Cap (8-32x3/8) 4 9F512 358-08060
30 Indicator Link 1 9F512 035-27155
31 Cotter Pin (1/6x1) 1 9F512 322-02320
32 Indicator Plate 1 9F512 035-27098
33 Screw, Round Head Machine (6-32x1/4) 3 9F512 310-06040
34 Indicator Shaft 1 9F512 035-27097
35 Indicator 1 9F512 035-27099
36 Pin/Drive (1/16x5/8) (6-32x1/4) 1 9F512 323-10410
37 O-Ring, 70-6227-5 1 9F512 671-00010
38 Hanger, Housing 1 9F512 035-27088
39 Name Plate 1 9F512 035-28230
40 Hanger 1 9F512 035-27083
41 Gasket, End Cap 1 9F512 035-27100
42 Screw, Socket Head Cap (5/16-18x1-1/2) 2 9F512 358-14200
43 Screw, Socket head Cap (5/16-18x1-1/4) 2 9F512 358-14180
44 Barrel Stop 2 9F512 035-27090
45 Plug, AN814-8 1 9F512 488-14080
46 O-Ring, 70-6290 2 9F512 671-00908

7-49
SG811-BV-MMA-010

Table 7-19. Hydraulic Pump Assembly Parts List - Continued

FIG & ITEM MFG PART

NO. DESCRIPTION QTY CAGE NO.
47 Dowel Pin, (3/16x1/2) 3 9F512 324-21208
48 Needle, Bearing B98 2 9F512 230-82012
49 Shaft Key 1 9F512 035-19578
50 Screw, Drive (2-3-1/16) 10 9F512 320-10203
51 Plunger 1 9F512 320-10203
52 Ball (7/16) 1 9F512 201-14001
53 Index Plate 1 9F512 035-27864
54 Creep Plate 1 9F512 035-27863
55 Screw, Socket Head Cap (1/4-20x1) 1 9F512 358-12160
56 Spacer, Sub Assy 1 9F512 S15-99891
57 Lockwasher, W-05 1 9F512 350-01005
58 Locknut, N-05 1 9F512 341-10005
59 Screw, Socket Head Cap (1/4-20x1-3/4) 2 9F512 358-12220
60 Screw, Socket Head Cap (1/4-20x1-1/4) 2 9F512 358-12180
Compensator Cap Assy. (Items 61 through 75) 1 9F512 S15-14874
61 Nut, Stop 5/16-24 1 9F512 331-13000
62 Handwheel 1 9F512 035-27112
63 Control Screw 1 9F512 035-27111
64 Control Handle 1 9F512 035-27109
65 Compensator Cap 1 9F512 035-27114
66 Control Stop 1 9F512 035-27110
67 O-Ring, 70-6227-5 1 9F512 671-00010
68 O-Ring, 70-6227-6 1 9F512 671-00011
69 Compensator Spool and Sleeve Assy 1 9F512 S15-12562
70 Adjusting Screw 1 9F512 035-27149
71 Locknut 1 9F512 035-10188
72 Compensator Nut 1 9F512 035-27108
73 O-Ring, 70-6227-9 1 9F512 671-00111
74 Spring Guide 1 9F512 035-27106
75 Compensator Spring 1 9F512 035-28313
76 Piston Housing 1 9F512 035-45231
77 O-Ring, 70-6227-13 1 9F512 671-00115
78 Piston, Control 1 9F512 035-45233
79 Bearing, Needle #614 YV 2 9F512 230-40614
80 Pin, Dowel (1/4x7/8) 2 9F512 324-21614
81 Screw, Socket Head Cap (1/4-20x1-1/4) 2 9F512 358-12180
82 Gasket, Vellumoid 2 9F512 035-27105
Minimum Volume Stop Assy. (Items 83 through 88) 1 9F512 S15-12563
83 Tonque 1 9F512 035-42034
84 Spring, Compression 1 9F512 035-29739
85 Stem 1 9F512 035-42035
86 O-Ring, 70-6227-12 1 9F512 671-00012
87 Cap, Stop 1 9F512 035-27104
88 Nut, Stop (5/16-24) 1 9F512 331-13000
Not Shown Tubing (for LH Pump) 1 9F512 035-28695
Not Shown Tubing (for RH Pump) 1 9F512 035-29395

7-50
 SG811-BV-MMA-010

Table 7-19. Hydraulic Pump Assembly Parts List - Continued

FIG & ITEM MFG PART

NO. DESCRIPTION QTY CAGE NO.
Not Shown Fitting 1 9F512 493-10401
Not Shown Fitting, 45° elbow (for RH Pump) 1 9F512 495-10000
Not Shown Fitting, 45° elbow (for LH Pump) 2 9F512 495-10000

7-51
SG811-BV-MMA-010

Figure 7-14. Hydraulic Pump Parts Location (Sheet 1 of 3)

7-52
 SG811-BV-MMA-010

Figure 7-14. Hydraulic Pump Parts Location (Sheet 2 of 3)

7-53
7-54

SG811-BV-MMA-010
Figure 7-14. Hydraulic Pump Parts Location (Sheet 3 of 3)
 SG811-BV-MMA-010

Table 7-20. Operator Seat Assembly Parts List

FIG & ITEM MFG. PART
NO. DESCRIPTION QTY CAGE NO.
7-15 Operator Seat 1 A4867 149097
1 Operator Seat 1 A4867 21490108
2 Washer, 6.4x12.5, ASTM A240, 316L UNI6592 2
3 Control Joysticks Support 1 A4867 21490234
4 Door 1 A4867 21490194
5 Washer, 8.4x17, ASTM A240, 316L UNI6592 6
6 Self Locking Nut, M6, ASTM A194, Gr. B8 UNI7473 2
7 Cover, ASTM A240, 316L 2 A4867 21490193
8 Washer, 8.4x17, ASTM A240, 316L UNI6592 4
9 Self Locking, Nut M8, ASTM A194, Gr. B8 UNI7473 2
10 Washer, 6.4x12.5, ASTM A240, 316L UNI6592 2
11 Washer, 6.4x12.5, ASTM A240, UNI6592 16
12 Self Locking Nut, M8, ASTM A194, Gr. B8 2 A4867 50080608
13 Pipe 1 A4867 21490189
14 End Threaded Bar, 0.11KG 1 A4867 21490152
15 Lever 1 A4867 21490146
16 Action Lever 1 A4867 21490144
17 Thickness 2 A4867 21490145
18 Door Lock, Stainless Steel Code 1000-V134-V-136-V180 5 A4867 50120000
19 Clamp, PTFE 0.1KG Type C4 φ22 2 A4867 50110095
20 Fork, M6X24, Steel, UNI1676 2
21 Hinge, ASTM A240, 316L, 0.75KG Code 1039-V11 3 A4867 50120100
22 Screw, M6x30, ASTM A193, Gr. BE 2 A4867 50002106
23 Connecting Box Code, GW44009 1 A4867 55800310
24 Electric Motor Starter 1 A4867 55998800
25 Electronic Control Unit BC Assy 1 A4867 55998810
26 Metallic Cable Suspension 4 A4867 11490099
27 Seat Belts 1 A4867 50110096
28 Screw, M8x16, UNI5739, ASTM A193, Gr. B8M 3
29 Washer, 8.4x17, ASTM A240, 316L UNI6592 3
30 Self Locking Nut, M8, ASTM A194, Gr. B8 UNI7473 6
31 Screw, M6x40, ASTM A193, Gr. B8 UNI5931 4
32 Washer, 6.4x12.5, ASTM A240, 316L UNI6592 4
33 Self Locking Nut, M6, ASTM A194, Gr. B8 UNI7473 16
34 Screw, M6x25, ASTM A193, Gr. B8M UNI5739 2
35 Screw, M10x30, ASTM A193, Gr. B8M UNI5739 6
36 Washer, 10.5x21, ASTM A240, 316L UNI6592 6
37 Screw, M6x20, ASTM A193, Gr. B8M UNI5739 16
38 Washer, 6.4x12.5, ASTM A240, 316L UNI6592 32
39 Screw, M8x65, ASTM A193, Gr. B8M UNI5739 2
40 Screw, M8x20, ASTM A193, Gr. B8M UNI5931 4
41 Screw, M6x20, ASTM A193, Gr. B8M UNI5931 6
42 Screw, M5x15, ASTM A193, Gr. B8M UNI5839 12
43 Washer, 5.3x10, ASTM A240, 316L UNI6592 12
44 Screw, M6X70, ASTM A193, Gr. B8M UNI5739 16
45 Screw, 10x45, ASTM A193, Gr. B8M UNI5739 1
46 Washer, 10.5x21, ASTM A240, 316L UNI6592 3

7-55
SG811-BV-MMA-010

Table 7-20. Operator Seat Assembly Parts List - Continued

FIG & ITEM MFG. PART

NO. DESCRIPTION QTY CAGE NO.
47 Seal, Lg. 4000 1 A4867 50110097
48 Screw, M5x20, ASTM A193, Gr. B8M UNI5739 18
49 Control Joytick 4 A4867 21490184
50 Rubber Buffer, Rubber 3 A4867 50106006
51 Screw, M10x20, ASTM A193, Gr. B8M UNI5739 2
52 Key Support, ASTM A276, 316L 1 A4867 21490192
53 Control Panel Assy 1 A4867 55998816
54 Chain, LG=600, ASTM A276, 316L 1 A4867 50309990
55 Chain, LG=240, ASTM A276, 316L 1 A4867 50309990
56 Hollow Key Code, 1004-02 1 A4867 50120200
57 Self Locking Nut, M6, ASTM A194, Gr. B8 UNI7473 3
58 Self Locking Nut, M6, ASTM A194, Gr. B8 UNI7473 1
59 Self Locking Nut, M6, ASTM A194, Gr. B8 UNI7473 2
60 Self Locking Nut, M6, ASTM A194, Gr. B8 UNI7473 4
61 Self Locking Nut, M6, ASTM A194, Gr. B8 UNI7473 16
62 Self Locking Nut, 146, ASTM A194, Gr. B8 UNI7473 2
63 Self Locking Nut, M6, ASTM A194, Gr. B8 UNI7473 2
64 Screw, M6x25, ASTM A193, Gr. B8M 1 A4867 50002206
65 Screw, 10x30, ASTM A193, Gr. B8M 3 A4867 50002206
66 Washer, 10.5x21, ASTM A240, 316L 2 A4867 50080705
67 Pressure Gauge 1 A4867 11490176
68 Screw, M5x20, ASTM A193, Gr. B8M UNI5739 3
69 Washer, 5.3x10, ASTM A240, 316L UNI6592 6
70 Self Locking Nut, M5, ASTM A240, 316L UNI7473 3
71 Identification Plate 1 A4867 50110533
72 Label Plate 1 A4867 50110551
73 Label Plate 1 A4867 50110550
74 Label Plate 1 A4867 50110549
75 Label Plate 1 A4867 50110548
76 Label Plate 1 A4867 50110546
77 Label Plate 2 A4867 50110545
78 Label Plate 1 A4867 50110547
79 Label Plate 1 A4867 50110593
80 Label Plate 1 A4867 50110540
81 Label Plate 1 A4867 50110539
82 Label Plate 1 A4867 50110592
83 Label Plate 1 A4867 50110577
84 Label Plate 1 A4867 50110555
85 Label Plate 1 A4867 50110588
86 Label Plate 1 A4867 50110576
87 Label Plate 1 A4867 50110585
88 Label Plate 1 A4867 50110563
89 Label Plate 1 A4867 50110560
90 Label Plate 1 A4867 50110591
91 Screw, M8x16, ASTM A193, 316L UNI5739 4
92 Washer, 8.4x17, ASTM A240, 316L UNI6592 4

7-56
 SG811-BV-MMA-010

Figure 7-15. Operator Seat Assembly Parts Location (Sheet 1 of 5)

7-57
SG811-BV-MMA-010

Figure 7-15. Operator Seat Assembly Parts Location (Sheet 2 of 5)

7-58
 SG811-BV-MMA-010

Figure 7-15. Operator Seat Assembly Parts Location (Sheet 3 of 5)

7-59
SG811-BV-MMA-010

Figure 7-15. Operator Seat Assembly Parts Location (Sheet 4 of 5)

7-60
 SG811-BV-MMA-010

Figure 7-15. Operator Seat Assembly Parts Location (Sheet 5 of 5)

7-61
SG811-BV-MMA-010

Table 7-21. Slew Ring Locking Assembly Parts List

FIG & ITEM MFG PART
NO. DESCRIPTION QTY CAGE NO.
7-16 Slew Ring, Locking Assembly 1 A4867 11490264
1 Spring Pin, φ10x55, Steel 1 A4867 50021295
2 Fixed Bushing, ASTM A276, 316L 1 A4867 21490261
3 O-Ring, 832 MIL-R-83248-1 Nitrile-70 1 A4867 50102832
4 Spring, ASTM A304, Gr. 9255 1 A4867 21490550
5 Mobile Bushing 1 A4867 21490261
6 Pin, ASTM A193, Gr. B8M 1 A4867 21490259
7 Washer, 13x24, ASTM A240, 316L UNI6592 1
8 Self Locking Nut, M12, ASTM A194, Gr. 8M UNI7473 1
9 Screw, M12x12, ASTM A193, Gr. B8M UNI5923 1
10 Self Locking Nut, M30, ASTM A194, Gr. 8M UNI7473 1
11 Bushing, ASTM A276, 316L 1 A4867 2140249
12 Lever, ASTM A276, 316L 1 A4867 21490254
13 Engaging Lever, ASTM A276, 316L 1 A4867 21490255
14 Oil Seal, SM 20357 ASTM D 735-58T SB715B E1 E3 F1 2 A4867 50091190
Nitrile-70
15 Ball Bearing, 1 52676 SKF
622022RS1
16 Spacer, ASTM A276, 316L 2 A4867 21490263
17 Transmission Bushing 1 A4867 21490250
18 Screw, M8x25, ASTM A193, Gr. B8M UNI5739 6
19 Washer, 8.4x17, ASTM A240, 316L UNI6592 6
20 Cover, ASTM A240, 316L 6 A4867 21490274
21 Oil Seal, SMIM 406010 1 A4867 50093120
22 Bearing 2 52676 SKF 6008-
2RS1
23 Spacer, ASTM A276, 316L 1 A4867 21490258
24 Rotating Lever Pin, ASTM A276, 316L 1 A4867 21490260
25 Washer, 8.4x17, ASTM A240, 316L UNI6592 6
26 Screw, M8x25, ASTM A193, Gr. B8M UNI5739 6
27 Bushing, Bronze 1 A4867 21490275
28 Oil Seal, SMIM 5580/10 Nitrile-70 ASTM D 735-58T SB7158 1 A4867 50093920
E1 E3 F1
29 Cover, ASTM A240, 316L 1 A4867 21490270
30 Spherical Roller Bearing 1 52676 SKF 22211 CC
31 Oil Seal, SM 8010010 ASTM D 735-58T Nitrile-70 SB715B 1 A4867 50094550
E1 E3 F1
32 Screw, M12, ASTM A193, Gr. B8M UNI5739 6
33 Washer, 13x24, ASTM A240, 316L UNI6592 8
34 Tongue, B, 16x10x45, ASTM A304, Gr. 1040 UNI6604 1
35 Eccentric, ASTM A304, Gr. 1840 1 A4867 21490265
36 Lower Sliding Block, ASTM A240, XM19 2 A4867 21490272
37 Frame 1 A4867 21490269
38 Washer, 13x24, ASTM A240, 316L UNI6592 8
39 Self Locking Nut, M12, ASTM A194, Gr. 8M UNI7473 8
40 Dowel Pin, φ10x24, Steel, UNI1707 2
41 Washer, 8.4x17, ASTM A240, 316L UNI6592 1

7-62
 SG811-BV-MMA-010

Table 7-21. Slew Ring Locking Assembly Parts List - Continued

FIG & ITEM MFG PART

NO. DESCRIPTION QTY CAGE NO.
42 Screw, M8x20, ASTM A193, Gr. B8M UNI5739 1
43 Oil Seal, SM 8010010 Nitrile-70 ASTM D735-58T SB715B E1 1 A4867 50094550
E3 F1
44 Spherical Roller Bearing 1 52676 SKF 22211 CC
45 Cover, ASTM A240 316L 1 A4867 21490271
46 Washer, 8.4x17, ASTM A240, 316L UNI6592 6
47 Screw, M8x25, ASTM A193, Gr. B8M UNI5739 6
48 Screw, M10x30, ASTM A193, Gr. B8M 6
49 Lock Fastening, ASTM A304, Gr. 9840 1 A4867 21490273
50 Bearing, BF 5015/0115 4 27737 51003012
51 Bearing, BF 7035/0114 3 27737 51003012
52 Screw, M5x12, ASTM A193, Gr. B8M UNI5933 6
53 Stop Plate, ASTM A240, 316L 2 A4867 21490303
54 Stop Plate, ASTM A240, 316L 2 A4867 21490309
55 Toothed Interlock, ASTM A304, Gr. 9840 8 A4867 21490268
56 Grease Nipple, M10, Steel UNI7663 1
57 Male Stud Coupling, ASTM A276, 316L CAST 110506 1 A5277 58100743
58 Tube, ASTM A276, 316L 1 A4867 21490725
59 Male Stud Coupling, ASTM A276, 316L CAST 110506 1 A5277 58100743
60 Adapter, ASTM A276, 316L 1 A4867 21490242
61 Washer, Copper, UNI5679/1 1 A4867 21490202

7-63
SG811-BV-MMA-010

Figure 7-16. Slew Ring Locking Assembly Parts Location

7-64
 SG811-BV-MMA-010

Table 7-22. Connection Box Assembly Parts List

FIG & ITEM MFG PART
NO. DESCRIPTION QTY CAGE NO.
7-17 Connection Box Assy 1 A4867 21490520
1 Connection Box with Cover 1 A4867 53800300
2 Earth Terminal 1 A4867 21490027
3 Stuffing Tube, Size 3/4″x20/16 1 A4867 50106003
4 Liquid Silicon Gasket 1 A4867 50098075

Figure 7-17. Connection Box Assembly Parts Location

Table 7-23. High Pressure Hydraulic Filter Parts List

FIG & ITEM MFG PART
NO. DESCRIPTION QTY CAGE NO.
7-18 Filter SH100 Series 1 K7516 SH174A-2N35
JZ121

7-65
SG811-BV-MMA-010

Table 7-23. High Pressure Hydraulic Filter Parts List - Continued

FIG & ITEM MFG PART

NO. DESCRIPTION QTY CAGE NO.
1 Bypass Valve 1 K7516 2L35-1S
2 Seal Ring, Nitrile BUNA/N 1 K7516 FF2104/908/70
3 Seal Ring, Nitrile BUNA/N 1 K7516 FF2104/014/70
4 Filter Head Assembly, Stainless Steel Type 316 1 K7516 FF4022
5 Seal Ring, Nitrile BUNA/N 1 K7516 FF2104/116/70
6 Filter Element 1 K7516 170-Z-121 A
7 Seal Ring, Nitrile, BUNA-N 1 K7516 FF2104/145/80
8 Filter Bowl 1 K7516 FF3611
9 Back-up Ring 1 K7516 FF3791

7-66
 SG811-BV-MMA-010

Figure 7-18. High Pressure Hydraulic Filter Parts Location

7-67
SG811-BV-MMA-010

Table 7-24. Low Pressure Hydraulic Filter Parts List

FIG & ITEM MFG PART
NO. DESCRIPTION QTY CAGE NO.
7-19 Filter Assembly 1 K7516 GA-90-SAE16-
TXW3-CC3-B-
22-V
1 Cover 1 K7516 5842130
2 Top Spring 1 K7516 48371201
3 Insert Assembly 1 K7516 11030000
4 Housing 1 K7516 5841411
5 Plug 1 K7516 6840101
6 Cover, O-ring 1 K7516 SOR-66
7 (Not Shown) Insert, O-ring 1 K7516 SOR-64
8 Bypass Seal (old o-ring) 1 K7516 SOR-61
8 Bypass Seal (new gasket) 1 K7516 31415021
9 Element O-Ring (Not Shown) 1 K7516 SOR-4
10 Indicator 1 K7516 0376–V
11 Element 1 K7516 TXW3-CC3
12 Bypass Assembly 1 K7516 4903005

7-68
 SG811-BV-MMA-010

Figure 7-19. Low Pressure Hydraulic Filter Parts Location

7-69
SG811-BV-MMA-010

Table 7-25. Submersible Suction Filter Parts List

FIG & ITEM MFG PART
NO. DESCRIPTION QTY CAGE NO.
7-20 Submersible Suction Filter 1 K7516 ATZ-120-
SAE16-SF1-60-
B-H
1 Element, O-ring, BUNA-N 1 K7516 R-174
2 Gasket, Nylon, BUNA-N 1 K7516 25X13X2
3 Cover, O-ring, BUNA-N 1 K7516 SOR-67
4 Gasket, Tank, BUNA-N 1 K7516 160X125X2
5 Element, O-ring, BUNA-N 1 K7516 R-174
6 Valve, O-ring, BUNA-N 1 K7516 SOR-27
Cover Assy. (Consisting of items 7 through 10) 1 K7516 221300107
7 Cover (Cast Steel) 1 K7516 5842116
8 Shaft Assy (Steel) 1 K7516 814304221
9 Valve (Steel) 1 K7516 842701601
10 Locknut (M6 Steel) 1 K7516 6812906
Housing Assy. (Consisting of items 11 through 14) 1 K7516 221300108
11 Housing Assy (Cast A1) 1 K7516
12 Valve Housing (Cast A1) 1 K7516
13 Check Valve (Cast A1) 1 K7516
14 Spring (Steel) 1 K7516
15 Element, Filter 1 K7516 SF1-60

7-70
 SG811-BV-MMA-010

Figure 7-20. Submersible Suction Filter Parts Location

7-71
SG811-BV-MMA-010

Table 7-26. Hydraulic System Diagram Assembly Parts List

FIG & ITEM MFG PART
NO. DESCRIPTION QTY CAGE NO.
7-21 Hydraulic System Diagram Assembly 1 A4867 11490130
7-22 Hydraulic System Diagram Assembly (with hydraulic cross con- 1 A4867 Additional
nects) items 63
through 75
1 Hydraulic Motor, Denison (W) 1 9F512 21490024
2 Double Control Valve (S) 1 8Z296 M619-2358VM
3 Double Control Valve (W) 1 8Z296 M619-2358VM
4 Overcenter Valve (W) 1 8Z296 M3672-2370
5 Antishock Valve (W) 1 8Z296 M3621-2353
6 Servovalve, Type P070FT 504NE (6) 1 94697 D631Z557A
7 Pilot Operated Relief Valve 1 9F512 R4V06-533-10-
11-G0Q-A1
8 Pressure Gage, Dial Size 3-1/2″, 0-5,000 psi 1 64467 SA 23
9 Cock, Riva VIF 120 1 A4867 50110055
10 Check Valve 1 8Z296 3C15-8W-15
11 Hydraulic Filter High Pressure 1 K7516 SH174A-2N35-
JZ121
12 Servo valve, Type P040FT504NE (M) 1 94697 D631Z556A
13 Electric Motor
14 Joint
15 Connection Bell
16 Hydraulic Pump, Denison 1 PV05-006-31R-
063
17 Control Joystick (J) 1 K1474 HCV1/SC/L
18 Check Valve 1 8Z296 3C12-3W-3
19 Hand Pump 1 D0637 HD 20
20 Main Cylinder MEP 1 A4867 11490111
21 Overcenter Valve (M) 2 D0637 LHK30VP-11-
250
22 Jib Cylinder MPD 1 A4867 11490117
23 Overcenter Valve (J) 2 D0637 LHK30VP-11-
250
24 Low Pressure In Line Filter 1 K7516 GA-90-TXW3-
CC3-B-22-V
25 Oil Load Plug 1 K7516 LE0817-51
26 Thermometer 1 64467 E-3-18-A2
27 Oil Level EEP 1 16199 EEP53A-1/2″
28 Check Valve (At pump discharge) 1 8Z296 3C14-6W-65
29 Submersible Suction Filter, 1/2 RSF1-60 MB 1 K7516 ATZ-120-
SAE16-SF1-60-
B-H
30 Sampling Valve 2 K7516 201A-1-1
31 Hydraulic Motor (S) 1 9F512 MF0502031
32 Overcenter Valve, 1EE15-PGW-505 45 (S) 1 8Z296 M3622-
2357VM
33 Antishock Valve (S) 1 8Z296 M3621-2353
34 Antishock Valve (M) 1 8Z296 M3621-2353
35 Antishock Valve (J) 1 8Z296 M3621-2353

7-72
 SG811-BV-MMA-010

Table 7-26. Hydraulic System Diagram Assembly Parts List - Continued

FIG & ITEM MFG PART

NO. DESCRIPTION QTY CAGE NO.
36 Servo valve, Type P070FT504NE (S) 1 94697 D631Z557A
37 Servo valve, Type P040FT504NE (J) 1 94697 D631A556A
38 Control Joystick (W) 1 K1474 HCV1/SC/L
39 Control Joystick (S) 1 K1474 HCV1/SC/L
40 Control Joystick (M) 1 K1474 HCV1/SC/L
41 Block of Valves, MEP 1 A4867 21490020
42 Ball Valve, Riva VSB 130 1 A4867 50110056
43 Ball Valve, Riva VSC 120 1 A4867 50110058
44 Ball Valve, Riva VSC 120 1 A4867 50110058
45 Ball Valve, Riva VSC 120 1 A4867 50110058
46 Air Bleed, MEP 2 A4867 21490304
47 Clutch One Way 1 A4867 11490122
48 Ball Valve, Riva VSB 150 1 A4867 50110200
49 Cock, Riva VIF 130 2 A4867 50110060
50 Plug 1 A4867 50110057
51 Control Panel 1 A4867 55998816
52 Electronic Control Unit 1 A4867 55998810
53 Plate of Valve, with Drain Cock 1 A4867 21490053
54 Plate of Valve, with Drain Cock 1 A4867 21490053
55 Plate of Valve, with Drain Cock 1 A4867 21490053
56 Plate of Valve, with Drain Cock 1 A4867 21490053
57 One Way Restrictor, FT. 2257/5-14 2 A4867 56921032
58 Sampling Valve 2 K7516 201A-1-B
59 Well 1 64467 W4 F4
60 Hydraulic Brake (S) 1 A4867 11490023
61 Air Bleed 2 A4867 21490304
62 Cock, Riva VIF 130 2 A4867 50110060
63 Ball Valve 3/4″, RIVA VSC140 1 A4867 50110061
64 Quick Disconnect Coupling 3/4″, RIVA IRK 140/A 1 A4867 58100302
65 Ball Valve 1″, RIVA VSB150 1 A4867 50110200
66 Quick Disconnect Coupling 1″ RIVA IRK 150/A 1 A4867 58100303
67 Three-way Ball Valve 1/2″ VS3L 130 1 A4867 58110302
68 Quick Disconnect Coupling 1/2″, RIVA IRK 130/A 1 A4867 58100301
69 Ball Valve 3/4″, RIVA VSC140 1 A4867 50110061
70 Check Valve 3/8″, MEP 56913025 1 82296 3C12-3W-45
71 Quick Disconnect Coupling 3/8″, RIVA IRK 120/A 1 A4867 58100300
72 Quick Disconnect Coupling Plug 3/8″, RIVA IRK 120.11 1 A4867 58100320
73 Quick Disconnect Coupling Plug 1/2″, RIVA IRK 130.11 1 A4867 58100321
74 Quick Disconnect Coupling Plug 1″, RIVA IRK 150.11 1 A4867 58100323
75 Quick Disconnect Coupling Plug 3/4″, RIVA IRK 140.11 1 A4867 58100322

7-73
7-74

SG811-BV-MMA-010
Figure 7-21. Hydraulic System Diagram
 SG811-BV-MMA-010
Figure 7-22. Hydraulic System With Cross-Connect
7-75
SG811-BV-MMA-010

Table 7-27. Slew Limit Relay Box Assembly Parts List (MHC 52, 55, 58 &
59)
FIG & ITEM MFG PART
NO. DESCRIPTION QTY CAGE NO.
7-23 Boat Crane Slew Limit Relay Box and Relays (NAVSEA Dwg
320-7099869)
1 Enclosure, Hoffman, NFSS, NEMA 4X Clamp Cover, CRES, 1 - Hoffman
WTRTT A-8064NFSS
2 Panel, Hoffman, NFSS, CRES 1 - Hoffman
A-8P6SS
3 Relay, Rotary, 4P2P, Non-Latching, 28 VDC Coil 2 - MDR 135-1
5945-00-480-
8077
4 Terminal Board, Molded Barrier, Screw type, CL 37TB 1 - 37TB12 5940-
00-983-6053
5 Screw, Machine, pan head, Cres, 8-32UNC-2A, 1/2″ long 8 - 5305-00-054-
6670
6 Washer, Lock, Spring-helical, Cres, No. 8 8 - 5310-00-262-
3559
7 Nut, machine, hex, thread, Cres, 8-32UNC-2B, 1/8″ high 8 - 5310-00-934-
9759
8 Screw, machine, pan head, Cres, 6-32UNC-2A, 5/8″ long 4 - 5305-00-054-
6655
9 Washer, lock, spring-helical, Cres, No. 6 4 - 5310-00-929-
6395
10 Nut, machine, hex, thread, Cres, 6-32UNC-2B, 7/64″ high 4 - 5310-00-934-
9761
11 Hook-up wire, blue, low smoke, stranded, # 16 AWG 3 - 6145-00-681-
1522
12 Label Plate, Type B, Style II, Size 1, plastic 1 - MIL P-15024

7-76
 SG811-BV-MMA-010

Figure 7-23. Slew Limit Relay Box (MHC 52, 55, 58 & 59)

7-77
SG811-BV-MMA-010

Table 7-28. Release Hook Assembly Parts List

FIG & ITEM MFG PART
NO. DESCRIPTION QTY CAGE NO.
7-24 Boat Crane Release Hook Assembly
1 Release Hook Assy 1 - 5RA1172-1
2 Side Plate 1 - 5RA1174-2
3 Side Plate 1 - 5RA1174-3
4 Ejector Cam 1 - 5RA1174-4
5 Release Latch 1 - 5RA1174-9
6 Spring Assembly 1 - 3RA1359-1
7 Bushing 1 - 5RA1174-11
8 Name Plate 1 - 2RA1152-1
9 Screw, Flat Head, Socket, #10-24NCx1-3/16 2 - 5RA1172-9
10 Screw, Flat Head, Socket, 1/4-20NCx1-3/16 3 - 5RA1172-10
11 Screw, Flat Head, Socket,5/16-18NCx1-3/16 2 - 5RA1172-11
12 Rope, 1/2″ dia., braided, 63 ft 5RA1172-12
13 Seizing Twine 24 in - 5RA1172-13
14 Webbing 1″, Red 24 in - 5RA1172-14
15 Thread, Nylon, Natural 1 - 5RA1172-15

7-78
 SG811-BV-MMA-010

Figure 7-24. Release Hook Assembly

7-79
SG811-BV-MMA-010

Table 7-29. Hydraulic System Piping Parts List

FIG & ITEM MFG PART
NO. DESCRIPTION QTY CAGE NO.
FO-15 Boat Crane Piping and Tubes
1 Pipe Fitting 1 A4867 58100010
2 Pipe Fitting 1 A4867 58100009
3 Pipe Fitting 1 A4867 58100008
4 Pipe Fitting 1 A4867 58100012
5 Pipe Fitting 1 A4867 58100007
6 Pipe Fitting 1 A4867 58100732
7 Pipe Fitting 1 A4867 58100017
8 Pipe Fitting 1 A4867 58100048
9 Pipe Fitting 1 A4867 58100019
10 Pipe Fitting 1 A4867 58100034
11 Pipe Fitting 1 A4867 58100033
12 Pipe Fitting 1 A4867 58100032
13 Pipe Fitting 1 A4867 58100031
14 Pipe Fitting 1 A4867 58100024
15 Pipe Fitting 1 A4867 58100046
16 Pipe Fitting 1 A4867 58100045
17 Pipe Fitting 1 A4867 58100044
18 Pipe Fitting 1 A4867 58100042
19 Pipe Fitting 1 A4867 58100041
20 Pipe Fitting 1 A4867 58100022
21 Pipe Fitting 1 A4867 58100038
22 Pipe Fitting 1 A4867 58100037
23 Pipe Fitting 1 A4867 58100036
24 Pipe Fitting 1 A4867 58100020
25 Pipe Fitting 1 A4867 58100790
26 Pipe Fitting 1 A4867 58100028
27 Pipe Fitting 1 A4867 58100027
28 Pipe Fitting 1 A4867 58100026
29 Pipe Fitting 1 A4867 58100002
30 Pipe Fitting 1 A4867 58100001
31 Pipe Fitting 1 A4867 58100003
32 Pipe Fitting 1 A4867 58100016
33 Pipe Fitting 1 A4867 58100791
34 Pipe Fitting 1 A4867 58100792
35 Pipe Fitting 1 A4867 21490788
36 Pipe Fitting 1 A4867 58100022
37 Tube No 1 1 A4867 21490576
38 Tube No 2 1 A4867 21490577
39 Tube No 3 1 A4867 21490578
40 Tube No 4 1 A4867 21490579
41 Tube No 5 1 A4867 21490580
42 Tube No 6 1 A4867 21490581
43 Tube No 7 1 A4867 21490582
44 Tube No 8 1 A4867 21490583
45 Tube No 9 1 A4867 21490584
46 Tube No 10 1 A4867 21490585

7-80
 SG811-BV-MMA-010

Table 7-29. Hydraulic System Piping Parts List - Continued

FIG & ITEM MFG PART

NO. DESCRIPTION QTY CAGE NO.
47 Tube No 11 1 A4867 21490586
48 Tube No 12 1 A4867 21490587
49 Tube No 13 1 A4867 21490588
50 Tube No 14 1 A4867 21490589
51 Tube No 15 1 A4867 21490590
52 Tube No 16 1 A4867 21490591
53 Tube No 17 1 A4867 21490592
54 Tube No 18 1 A4867 21490593
55 Tube No 19 1 A4867 21490594
56 Tube No 20 1 A4867 21490595
57 Tube No 21 1 A4867 21490596
58 Tube No 22 1 A4867 21490597
59 Tube No 23 1 A4867 21490598
60 Tube No 24 1 A4867 21490599
61 Tube No 25 1 A4867 21490600
62 Tube No 26 1 A4867 21490601
63 Tube No 27 1 A4867 21490602
64 Tube No 28 1 A4867 21490603
65 Tube No 29 1 A4867 21490604
66 Tube No 30 1 A4867 21490605
67 Tube No 31 1 A4867 21490606
68 Tube No 32 1 A4867 21490607
69 Tube No 33 1 A4867 21490608
70 Tube No 34 1 A4867 21490609
71 Tube No 35 1 A4867 21490610
72 Tube No 36 1 A4867 21490611
73 Tube No 37 1 A4867 21490612
74 Tube No 38 1 A4867 21490613
75 Tube No 39 1 A4867 21490614
76 Tube No 40 1 A4867 21490615
77 Tube No 41 1 A4867 21490616
78 Tube No 42 1 A4867 21490617
79 Tube No 43 1 A4867 21490618
80 Tube No 44 1 A4867 21490619
81 Tube No 45 1 A4867 21490620
82 Tube No 46 1 A4867 21490621
83 Tube No 47 1 A4867 21490622
84 Hose No 1 1 A4867 21490725
85 Hose No 2 1 A4867 21490725
86 Hose No 3 1 A4867 21490731
87 Hose No 4 1 A4867 21490731
88 Hose No 5 1 A4867 21490731
89 Hose No 6 1 A4867 21490731
90 Hose No 7 1 A4867 21490726
91 Hose No 8 1 A4867 21490726
92 Hose No 9 1 A4867 21490727

7-81
SG811-BV-MMA-010

Table 7-29. Hydraulic System Piping Parts List - Continued

FIG & ITEM MFG PART

NO. DESCRIPTION QTY CAGE NO.
93 Hose No 10 1 A4867 21490727
94 Hose No 11 1 A4867 21490729
95 Hose No 12 1 A4867 21490730
96 Hose No 13 1 A4867 21490732
97 Hose No 14 1 A4867 21490733
98 Hose No 15 1 A4867 21490728
99 Extension, Threaded 1 A4867 21490822
100 Extension, Threaded 1 A4867 21490823
101 Bleeder 1 A4867 21490824
102 Threaded Reduction 1 A4867 58100744
103 Handle, Ball Valve 1 A4867 56921301

7-82
 SG811-BV-MMA-010

Figure FO-15. Boat Crane Piping and Tubes.

7-83 / (7-84 Blank)

7-84
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

Figure FO-15. Boat Crane Piping and Tubes (Sheet 2 of 4)

7-85 / (7-86 Blank)

7-86
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

Figure FO-15. Boat Crane Piping and Tubes (Sheet 3 of 4)

7-87 / (7-88 Blank)

7-88
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

Figure FO-15. Boat Crane Piping and Tubes (Sheet 4 of 4)

7-89 / (7-90 Blank)

7-90
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

CHAPTER 8

INSTALLATION

8-1. INTRODUCTION.
This chapter provides instructions for installation of the boat crane onboard the MHC 51 class ships.

8-2. TOOLS AND MATERIALS REQUIRED FOR INSTALLATION.

Special tools for the boat crane are listed in table 8-1. Torque values are listed in table 6-2.

8-3. SPECIAL FOUNDATION PREPARATION.

The foundation for the boat crane is installed with the pedestal bolted to a foundation arrangement. This con-
figuration is used because of the unique deck mounting requirements. Refer to figure 8-1 for a layout of the foun-
dation arrangement.

8-4. INSTALLATION PROCEDURES.

Install boat crane as follows:

WARNING

Ensure the mobile crane being used to move the boat crane is adequate for
the weight of the boat crane as injury or death to personnel could occur.

NOTE

The lifting points of the boat crane are marked with label plates.

a. Using a mobile crane (refer to table 8-1) attach four chains with lifting hooks to the four lifting points on the
boat crane (refer to figure 8-2).
b. Lift the boat crane onto the ship and position over deck/stanchion foundation.
c. Lower the boat crane onto mounting holes, ensuring proper alinement between pedestal and deck/stanchion
foundation holes.
d. Install (refer to figure 8-1) bolts (1), lockwasher (2) and self locking nuts (3), in the corner holes of the ped-
estal through the holes in the main deck.
e. Verify dimensions of the sixteen remaining holes, before installing remaining bolts, lockwashers and self
locking nuts.

f. Torque all twenty bolts (82, figure FO-12 or figure FO-13) and self locking nuts (84). Torque to values in table
6-1.

8-1
SG811-BV-MMA-010

NOTE

Ensure that between 1 and 5 threads protrude, after torquing bolts (82) and nuts
(84).

g. Disconnect chain lifting hooks from the four lifting points on Boat Crane.

Table 8-1. Special Tools

ITEM DESCRIPTION SIZE MFR. PART NUMBER
1 Mobile Crane 10 ton MIL-STD-179
2 Wrench set, comb. -- A-A-1358
3 Wrench set, socket -- 323 TWM
4 Wrench, Impact 3/4″ AT750
5 Socket, Impact 1″ IMD322
6 Wrench, torque 3/4″ TECP100FU
7 Wrench, torque 1″ TE602A
8 Ratchet 1/2″ Drive W-960-2437

8-5. ELECTRICAL CONNECTIONS.

As shown on figure 8-3, under crane connect electrical connector J1 (1) to plug (2). Access connector by
removing bolt (3), washer (4), and access panel (5).

8-6. INSTALLATION CHECKS.

The following installation checks need to be performed before boat crane is operational.

8-6.1 Preoperational Checks on Installation. Before turning power on the Boat Crane, perform the following
checks and tasks:

a. Check oil level of hydraulic tank.

b. Remove spring split pins from holes in boom head assembly.

c. Ensure slew ring locking device is disengaged.

8-2
 SG811-BV-MMA-010

Figure 8-1. Boat Crane Foundation

8-3
8-4

SG811-BV-MMA-010
Figure 8-2. Boat Crane Lifting Points
 SG811-BV-MMA-010

Figure 8-3. Electrical Connections

8-5
SG811-BV-MMA-010

8-6.2 Operational Checks on Installation. Perform system operational checks according to the following:

a. Press MOTOR ON pushbutton (2, figure 2-1) at operator control panel.

b. Verify hydraulic motor operating pressure reads 3,000 psi on gage (6, figure 2-7) at control panel.
c. Check the NIGHT/DAY pushbutton (6, figure 2-1) operation on control panel.
d. Lower main boom from its elevated position to its lowest position using M control stick (2, figure 2-2).
e. Verify main boom control stick returns to neutral position.
f. Move main boom control stick (2, figure 2-2) to the up position, move main boom to its highest position.

WARNING

Verify area around crane is clear of personnel and equipment before rota-
tion. Failure to comply may result in injury to personnel or damage to
equipment.
g. Move boat crane rotation control joystick, (3, figure 2-2) to left position. Rotate crane to limit stop.
h. Hove boat crane rotation control joystick to right position. Rotate crane to limit stop.
i. Move jib boom control joystick (1, figure 2-2) to the out position until jib boom reaches maximum extended
position.
j. Move main boom control joystick (2, figure 2-2) to the down position, lower main boom to five feet off main
deck.
k. Test rotary limit switch by tying nylon rope eye to winch wire rope bitter end.
l. Move winch control joystick (4, figure 2-2) to down position, manually pull wire rope, using minimum resis-
tance.
m. Pay out eight feet of wire rope.

CAUTION

Be prepared to quickly press MOTOR OFF pushbutton (3, figure 2-1) if

u-bolt contacts boom head.

NOTE

Motor circuit should deenergize and motor shut off before bitter end contacts
boom head.
n. Move winch control stick to up position until winch motor is shut off by rotary limit switch.

NOTE

With rotary limit switch tripped, circuit to winch motor will be de-energized.
o. Move control joystick to down position, winch motor will be energized.

8-6
 SG811-BV-MMA-010

p. Return wire rope to stowed position and remove nylon rope from winch rope bitter end.
q. Move jib boom control joystick (1, figure 2-2) in, retracting jib boom cylinder and install jib boom turn-
buckle.
r. Move main boom control joystick (2, figure 2-2) to the up position, extending main boom cylinder to its
position over the stowage stand.
s. Rotate crane to its stowed position, and lock crane in stowed position.
t. Press MOTOR OFF pushbutton (3, figure 2-1) at operator control panel.
u. Return system to operational readiness.

8-7. STORAGE.
The following paragraphs describe storage considerations.

8-7.1 Replacement Parts. Replacement components should be stored in original packing in a clean, dry area.

8-7.2 Defective Parts. Damaged or defective components should be tagged ″DO NOT USE″ and returned to
supply.

8-7 / (8-8 Blank)

8-8
@@FIpgtype@@BLANK@@!FIpgtype@@
 SG811-BV-MMA-010

GLOSSARY

Battle Short A condition in which the overtemperature shutdown is disabled; used only during times
of critical operation.
Boat Crane Is used to deploy the Rigid Inflatable Boat.
Dirty Box Consists of Electromagnetic Interference filters that provide the Boat Crane immunity
against disturbances and compatability problems.
Electronic Control Unit
A unit that inputs votage to various components of the Boat Crane.
ECU See Electronic Control Unit

Gloss-1 / (Gloss-2 Blank)

Gloss-2
@@FIpgtype@@BLANK@@!FIpgtype@@