Check your displacement on your ship, the BO many have too much Recruits or Experts/vets or armor.
The Reason it worked is because you sold the ship and when you bought it back the ship was empty from weapons, Ammo, FSC, Engine, and armor, this is why you were able to put back the BO on the ship.
I bet when you loaded all the sailors and something went short like ammo or armor then before.
V/r Boku
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