Thông Số Kỹ Thuật- Service Infomation

Örnsköldsvik MacGregor Sweden AB
Sjögatan 4G
SE-891 85 ÖRNSKÖLDSVIK
Sweden
Telephone +46 660 29 40 00
To whom it may concern
Assembly and installation manual
for NB : Port Cranes Project No.: 2/15023.01LMW
Crane type: GL4536-2 Crane 1-3
This file contains important delivery documents and necessary drawings for your
crane commissioning work.
The file should be forwarded to the responsible person for this commissioning.
We would also like to draw your attention to the importance of foundation flatness and
tensioning of foundation studs, see documents M 2020-035 E, 625/1467 E and
drawing ”Slewing bearing yard mount” in section mechanical assembly drawings.
Note that document 625/1467 E and protocols in M 2020-035 E should be returned to

our service division after being duly signed.
If you have any questions about the commissioning work or the content in the file,
please contact our Service Division.
Best Regards,
Anders Öberg
Manager,Technical Services
Cargo and Material Handling Systems
Global Lifecycle Support
MacGregor Sweden AB
Sjögatan 4G, 89185, Örnsköldsvik, Sweden
Phone +46 660 29 40 00
Mobile +46 70 606 10 64
www.macgregor.com
MacGregor shapes the offshore and marine industries by offering world-leading

engineering solutions and services with a strong portfolio of MacGregor, Hatlapa,
Porsgrunn, Pusnes and Triplex brands. MacGregor is part of Cargotec.
I:\WPDATA\Mallar\Förblad\Fbrev_montagebok_stora kranar
Date: 2017-12-05
ASSEMBLY AND INSTALLATION MANUAL
MacGregor Ref Shipyard Hull No/Ship

Nghi Son Port Port crane
MacGregor Project No. Shipowner Customer Reference
2/15023.01LMW Nghi Son Iron and Steel -
Document description Specification no Rev. Crane no

Technical data 2/15023.01LMW - 1 1
General arrangement - - 1, 2, 3 2
Jib parking arrangement - - 1, 2, 3
Crane arrangement 3
GL4536-2 - - 1, 2, 3
Order specification 491 0019 B 1, 2, 3 4
Loose gear specification 1000058832 - 1, 2, 3 5
Assembly Instructions 625/1321.33 E g 1, 2, 3 6
Handling, Installation and
6.222.1 E a 1, 2, 3
Maintenance of Steel Wire Ropes
Hydraulic Oil Tank 5.302.16 E f 1, 2, 3
Welding instruction 7
Welding of the crane foundation to
the ship's pedestal and inspection
before lifting on board the *M2020-035 E 15 1, 2, 3
crane or twin platform
Rust protection of components and

M6587-1E 10 1, 2, 3
fastening elements….
Tensioning/Tightening of the
Slewing Bearing Mounting *625/1467 E f 1, 2, 3 8
Studs/Bolts Mounted at the Yard
Rope Reeving Diagram 6.216.91 E a 1, 2, 3 9
Lubricants for Deck Machinery 5.421.40 E g 1, 2, 3 10
Lubricating Chart, crane PM51 1701-E00 - 1, 2, 3 11
Preserving Hydraulic Slewing
625/1388.13 E b 1, 2, 3 12
Cranes
Spare Part Kit 489 5017 J 1, 2, 3 13
Tools 14
*) Document to be returned to MacGregor Sweden AB after being duly signed. Page 1 (2)
MacGregor Sweden AB Address Telephone
SE-891 85 ÖRNSKÖLDSVIK +46 660 - 29 40 00
Sweden
Date: 2017-12-05
ASSEMBLY AND INSTALLATION MANUAL
MacGregor Ref Shipyard Hull No/Ship

Nghi Son Port Port crane
MacGregor Project No. Shipowner Customer Reference
2/15023.01LMW Nghi Son Iron and Steel -
Mechanical Assembly Drawings 15

Foundation with Ladders 1000058878 -/- 1, 2, 3
Slewing Bearing Yard Assembly 391 2003 A/A 1, 2, 3
Crane Jib Yard Assembly 1000057232 A/- 1, 2, 3
Ladder Assembly, under bottom plate 490 3651 - 1, 2, 3
Ladder Assembly, outside cabin 390 4168 - 1, 2, 3
Platform Assembly. crane house top 288 1875 B 1, 2, 3
Slip-ring Device Assembly 289 1903 - 1, 2, 3
Hydraulic Assembly Drawings 16
Hydraulic System Specification 1000056579 - 1, 2, 3
Electrical Assembly Drawings 17
El. Specification 491 0021 - 1, 2, 3
Electrical System Specification 1000056578 - 1, 2, 3
Power/Cable connection 1000055004 - 1, 2, 3
Slip-ring Device 1000029669 A/A 1, 2, 3
Jib Light Assembly (pack) 124 0637 - 1, 2, 3
Limit switches in hoisting and luffing
winch systems
6.320.401 E e 1, 2, 3 18
Speed adjustment CC3000 424 0731 A 1, 2, 3 19
Pressure cut-off instruction 489 3770 C 1, 2, 3
Plussing instruction 490 3741 E 1, 2, 3
Instruction for oil venting equipment on
490 7514 - 1, 2, 3
slewing gear box
Marking instruction 387 7704 E 1, 2, 3
Measuring procedure for wear in
625/1579 E m 1, 2, 3
slewing bearings
Slewing bearings grease sampling 625/1651 E b 1, 2, 3
Absolute encoder calibration 6.303.56 E c 1, 2, 3
Card front menus CT2, CC3000 6.303.61 E f 1, 2, 3
Emergency lowering in case of
complete power failure...
6.990.36 E i 1, 2, 3 20
*) Document to be returned to MacGregor Sweden AB after being duly signed. Page 2 (2)
MacGregor Sweden AB Address Telephone
SE-891 85 ÖRNSKÖLDSVIK +46 660 - 29 40 00
Sweden
TECHNICAL DATA Project No.: 2/15023.01LMW rev: - 2017-11-30
TECHNICAL DATA
GENERAL
Type of crane GL4536-2
Work order 2/15023.01LMW
Serial number 62516363- CRANE No. 1

62516364- CRANE No. 2
62516365- CRANE No. 3
Ambient temp range -25° to + 45° C
BASIC DATA
Hoisting capacity, MAX SWL 45 ton
Jib radius, Maximum 36 m
Jib radius, Minimum 5.0 m
Lifting height H 10 m
Lifting height K 30 m
Hoisting speed, high 0 - 18 T 24 m/min
Hoisting speed, low 18 - 45 T 15 m/min
Luffing time, Max - min radius 115 s
Slewing speed 0.7 rpm
1 (4)
MAIN SUPPLY
Rated voltage 380 V
Type of frequency 3 Phase ~ 50 Hz
Control voltage 230 V
ELECTRIC MOTOR, Pump unit

Rated power, continous 160 kW
Starting current 760 A
WIRE ROPE
Hoisting winch, wire rope Ø 38 mm × 317.5 m

No. 1226014
Luffing winch, wire rope Ø 32 mm x 260 m

No. 1279563
OIL VOLUME / OIL FILLING (per unit)
Hydraulic oil tank 560 litres
Hoisting winch 42.0 litres
Slewing gear 11.0 litres
Luffing winch 9.5 litres
2 (4)
Limit Switches in Hoisting and Luffing Winch Systems
See instructions 6.320.401
3 (4)
Fig. 1. Load diagram
4 (4)
ORDER SPECIFICATION Status Approved
Shipyard Shipowner Hull No / Ship
Nghi Son Port Nghi Son Iron and Steel Corporation Port Cranes
Deck crane type MacGREGOR Cranes project No MacGREGOR Cranes Reference No
GL4536-2 2/15023.01
Marking, sign 390 0188-001 Marking, sign
Deck crane type GL4536-2 Place 1-3 Deck crane type Control voltage 230 V
Mfg No 625 16 363 – 365 Year 2016 Mfg No Year
Test instruction See Item 095
Min radius 5 m Load 45T Min radius Load
Max radius 36 m Load 45T Max radius Load Marking instruction 387 7704
Horizontal jib m Load T Horizontal jib Load Surface treatment according to M 2061-16E
Motor AC 380 V 50 Hz Motor AC Colour external Finish colour See TOS
Crane project No Crane project No Crane project No Crane project No Crane project No Crane project No Crane project No Crane project No
2/15023.01
Hull No Hull No Hull No Hull No Hull No Hull No Hull No Hull No
Port Cranes Location
Mfg No Mfg No Mfg No Mfg No Mfg No Mfg No Mfg No Mfg No on ship Crane house complete Remarks
625 16 363 1 491 0019-801

625 16 364 2 491 0019-802
625 16 365 3 491 0019-803
Mfg No Mfg No Mfg No Mfg No Mfg No Mfg No Mfg No Mfg No Location Spare Part Complete
625 16 366 1-3 1279236
Drawn by Order Specification No Rev Ind Sheet
M Nilsson
B ECO-1020846 SGI 17 13 Year Week 491 0019 B 1 (6)
Rev Ind Revision Appd Year Week 16 10
Quantity / Sub-ass
Item No Description Article No 801 802 803 804 805 806 807 808 Remarks
001 Mechanical Specification 2/15023.01 491 0020-801 1
004
005
006 Slewing Specification RE 18R 491 0003-801 1 1 1
007
008 Crane System 2/15023.01 1279564 1 1 1
009
010
011 Electrical Specification 2/15023.01 491 0021-801 1
014
015
016 Hydraulic Specification 2/15023.01 491 0022-801 1
019
020 Load Wire Rope Ø34mm / L=317.5m 1226014 1 1 1
021
022 Luffing Wire Rope Ø32mm / L=260 m 1279563 1 1 1
023
M Nilsson
Quantity / Sub-ass
024 Foundation Complete Foundation with ladders 1282596 1 1 1
025
026
027
028 Crane House Assembly 1277053 1 1 1
029
030 Jib Welding 1284754 1 1 1
031
032 Lubrication Jib Extension 390 7176-801 1 1 1
033
034
035
036
037
038
039
040 Crane Jib Yard Assembly 2x4 bolt 1274371 1 1 1
041
042 Ladder Assembly Under bottom plate 490 3651-801 1 1 1
043 Ladder Assembly Outside Cabin 390 4168-801 1 1 1
044
045
046
047
M Nilsson
Quantity / Sub-ass
048 Slipring Device Assembly 289 1903-801 1 1 1
049
050 Sign Assembly Warning Signs, Foundation (English) 287 9758-801 1 1 1
051
052
053
054
055
056
057 Instructions book (English) - 4 x x 4 per shipset
058 Assembly and Installation Manual (English) - 3 x x 3 per shipset
059
060 Spare Part Complete 2/15023.01 1279236 1 x x 1 per shipset
061
062 Guide Pin M30, L=850 488 8324-004 4 x x Used for jib
063 Guide Pin M39, L=370 390 9328-009 2 x x Used for slewing
064 Guide Pin M39, L=450 390 9328-010 1 x x Used for slewing bearing
065
066
067
3
068 Paint Hempinol 10220 1176 2060-001 1 1 1 [dm ]
3
069 Modisulphide paste Molycote Pasta 1000 1263 2078-001 2 2 2 [dm ], pack
070 Tape Densyl Tape 1169 2130-001 1 1 1
071
M Nilsson
Quantity / Sub-ass
072 Bracket Assembly Brackets for footway 1198415 1 1 1
073
074
075 Footway Assembly 389 1442-801 1 1 1
076
077 Plugs Cable and Stab Winch Assembly GL 1272650 1 1 1
078
079 Platform Crane House Assembly Crane House Top 288 1875-801 1 1 1
080
081
082
083 Cargo Anchoring M39 390 2153-801 1 1 1
084
085 Bracket Assembly Warning Light 390 2516-801 1 1 1
086
087
088
089
090
091 Life Line 24 m 388 0962-801 1 1 1 Included in cabin
092
093 Instruction inside crane PM15023.01 1 1 1
094 Instr. for oil venting equipment on slewing gear 490 3894 1 1 1
095 Factory Acceptance Test protocol (FAT) Crane specific 1 1 1
M Nilsson
Quantity / Sub-ass
096
097
098
099
100
101
102
103
104
105
106
107
108
109
110 Sign Marking Sign, cabin 489 3454-001 x x x
The sign has to be marked High speed 18 T
Load
Low speed 45 T
111
112 Marking of jib 488 7331 1 1 1
The jib has to be marked
SWL 45T 5 – 36 m
M Nilsson
Loose Gear Specification Status Release
Identification/Distinguishing number
Lifting block 288 1423-805 SWL 60 ton
Location on ship
Mfg No
Item Description Identification No Identification No Identification No Identification No
Luffing wire rope

1 H-80696 H-80697 H-80698
1279563
Load wire rope
2 H-80693 H-80694 H-80695
1226014
3 Block H-80453 H-80454 H-80455
4 Swivel H-80453 H-80454 H-80455
5 Hook H-80453 H-80454 H-80455
6rawn by Year Week Hull No/Ship -

kersan 16-14 Shipyard Port crane
Order spec No Owner Nghi Son Port
491 0019 MacGREGOR Cranes Ref
Loose Gear Specification No MacGREGOR Cranes Ref 2/15023.01LMW
Description (Crane type) Rev ind Sheet
1000058832
GL4536-2 1 (1)
ASSEMBLY INSTRUCTIONS 625/1321.33 E rev.: g 2003-10-06
Hydraulic Deck Cranes

Assembly Instructions for Single Cranes Type GL
1 (14)
Contents
Introduction .............................................................................................. 3
Model designation ............................................................................................................. 3
Marking of cranes .............................................................................................................. 3
Scope of supply........................................................................................ 4
Introduction ....................................................................................................................... 4
Assembly units .................................................................................................................. 4
Packing list ........................................................................................................................ 4
Marking of parts ................................................................................................................ 4
Spare parts and tools ........................................................................................................ 4
Storage .............................................................................................................................. 4
Assembly procedure ................................................................................ 4

Introduction ....................................................................................................................... 4
Operations that may be performed by shipyard personnel ................. 5

Quayside assembly ........................................................................................................... 5
Onboard assembly ............................................................................................................ 5
Operations that must be supervised by a MacGREGOR Cranes’

service engineer during final checkout .................................................. 5
Recommended order of assembly .......................................................... 5

Introduction ....................................................................................................................... 5
Welding of foundation ........................................................................................................ 5
Preparatory quayside assembly ............................................................. 5

Crane house, standard type .............................................................................................. 5
Crane house accessories, if provided ............................................................................... 5
Crane jibs, standard type .................................................................................................. 6
Crane jibs accessories, if provided ................................................................................... 6
Raising the crane house from the horizontal to the vertical position ................................. 7
Onboard assembly (crane and jib) ......................................................... 8

Mounting crane house ....................................................................................................... 8
Assembling jib ................................................................................................................... 9
Reeving wire ropes ......................................................................................................... 10
Final checkout ................................................................................................................. 11
Lifting an assembled crane (crane house and jib) on board .............. 12
Onboard assembly (assembled crane) ................................................ 13

Mounting crane house ..................................................................................................... 13
Final checkout ................................................................................................................. 14
2 (14)
Introduction Model designations

MacGREGOR's single cranes are built in sizes up to
On leaving the assembly line, every deck crane is 45 tons lifting capacity (with heavy lift capacity up to
subjected to a rigorous test programme, where all 80 tons). The model designations denote the crane
functions are tested. type, lifting capacity, and jib working radius: thus GL
3024-2 i.e. stands for:
Every MacGREGOR deck crane is thoroughly
checked and thus the work at the shipyard mainly GL - single crane type GL
consists in re-assembling the crane house, jib, slip- 30 - lifting capacity, 30 tonnes
ring unit, extra load handling equipment (if any), filling 24 - maximum outreach, 24 metres
of hydraulic oil, and reeving the wire ropes. -2 - two fall rigging
When receiving the crane at the shipyard, carefully

Marking of cranes, see Fig. 1
check the completeness of the assembly parts against
the packing list. The cranes are numbered according to the ”General
Arrangement” drawing. If a shipment comprises, say,
Make a note of the weights of the included parts from 5 cranes, the cranes are numbered 1 to 5, inclusive,
the packing list to make sure that sufficient lifting capa- where No. 1 is the crane situated nearest to the bows
city is available before starting the installation. of the ship.
Carefully study the drawings provided with the

assembly and delivery documents.
Project No., example:

KR95100 Crane No. 3
Fig. 1. Markings on the crane.
3 (14)
Scope of supply
Introduction
Every shipment is packed so as to facilitate assembly will be additionally marked with the number of the
as far as possible. All parts belonging to a specific crane to which they belong.
phase of assembly are packed together but separately
for each crane. To facilitate identification, every packing case, crate
etc. carries a label indicating to which sub-assembly
These packages are then made up into a larger unit - its contents belong: crane house accessories, jib
case, crate etc. - which, in its turn, contains accessories etc.
accessories and assembly parts required for a
specific unit, e.g. crane houses. Spare parts and tools
Spare parts are individually packed. Each case
It is therefore bad practice, and not recommended, contains a list of the spare parts included in that case.
to unpack small packages and separate parts at an
early stage without first understanding the principles The standard tool kit and special tools, if any, are
of the packing system. Thus, a case containing slip- packed together in tool cases.
ring unit parts should always be lifted, unopened,
Storage
directly into the crane foundation.
If the cranes are to be stored for some time before
Assembly units being assembled, crane houses must be kept where
- Foundation they are not exposed to dust and moisture.
- Slip-ring unit Accessories su ch as spare parts and tools should
- Crane house be placed in locked storage rooms.
- Jib
- Crane house accessories, quayside assembly In the instruction ”Preserving Hydraulic Slewing
- Crane house accessories, onboard assembly Cranes” complete information can be found on how
- Jib accessories, quayside assembly the cranes should to be stored.
- Wire ropes, load handling equipment
- Extra load handling tools and equipment, if Assembly procedure
provided
Introduction
Packing list The following description of the assembly procedure
The packing list specifies: may be used to advantage as a checklist as the
- all parts contained in the shipment, as identified assembly proceeds. It is most important that all sta-
by their consecutive item numbers in the packing ges of assembly are kept to and carried out as
list, article numbers, designations, and quantities scheduled here; this is a major prerequisite for per-
- in which package every specific part is to be found mission to start the crane(s).
- item number of parts in the relevant assembly
drawings The assembly procedure is rounded off by a complete
- to which stage of assembly the parts belong. checkout of the entire installation. As a rule, an
overload test is also included whose purpose is
The packing list should therefore always be available primarily to check the integrity of the welding of the
to the installation personnel during assembly.
foundation to the ship’s deck. This overload test calls
for certain manual overrides in the security system of
Marking of parts
the crane, and MUST be performed ONLY under the
Every part has a adhesive label giving its article
direction of a qualified MacGREGOR Cranes super-
number, designation, quantity, and item number in
visor. After the overload test, all safety devices of the
the packing list. When similar parts are not identical
crane are reset to normal.
for all of the cranes in a delivery, the respective parts
4 (14)
Operations that may be performed by the Recommended order of assembly

shipyard personnel acting on their own
responsibility Introduction
Preparations for the quayside and onboard assembly
Quayside assembly are of crucial importance for the rapid and efficient
- Assembling crane house accessories execution of the assembly.
- Assembling jib accessories
- Cleaning contact surfaces The suggestions given here are for general guidance
only; the ultimate decision how the work is to be
Onboard assembly actually carried out rests with the responsible fore-
men of the shipyard.
- Welding foundation to deck
- Electric installation work in foundation column
Look up the weights of foundation, twin platform, crane
- Slip-ring unit installation
houses, and jibs to make sure that sufficient lifting
- Mounting crane house
capacity is available.
- Mounting jib
- Electrical installation
- Preparations for reeving wire ropes Welding of foundation, see Fig. 2
- Lubrication 1. Weld the foundation in place on the deck.
- Filling hydraulic oil Note! Important to follow our separate welding
instruction M 2020-035E "Welding of the Crane
Foundation to the Ship's Pedestal and Inspection
before Lifting on Board"
Operations that must be supervised by a 2. Install ladders and platforms, if provided.
MacGREGOR Cranes service engineer 3. Arrange for electrical power supply to the slip-rings.
during final checkout Pull in the supply cables to a height of approx. 1
metre above the upper edge of the foundation.
- Start of crane Place the slip-ring unit in the foundation.
- Reeving the wire ropes 4. Erect a suitable scaffolding around the foundation
- Checking limit switch functions to facilitate assembly and mounting of crane jib.
- Overload test
Caution! Preparatory quayside assembly

It is forbidden to operate the crane before a
MacGREGOR Cranes' supervisor has carried out fi- Crane house, standard type, see Fig. 3
nal adjustments.
5. Install protective loops under operator's cab, if
removed during transportation.
6. The ladder, which later is installed in the upper
part of the foundation may be temporarily put in
the crane house.
Crane house accessories, if provided, see Fig. 3

7. Assemble outside platforms and ladders on crane
house.
8. Install extra worklights on crane house.
5 (14)
Crane jibs, standard type, see Fig. 4

9. Mount jib worklight.
Crane jibs accessories, if provided, see Fig. 4

10. Mount extra pulleys for stabilizing wires.
11. Install extra cable support pulleys.
12. Install extra limit switch devices for high hook.
13. Install extra catwalks.
Fig. 3. Preparatory quayside assembly.
Fig. 2. Welding of foundation.
Fig. 4. Crane jib.
6 (14)
Raising the crane house from the horizontal to the

vertical position
- Fasten lifting ropes to the lifting eyes on the crane

house. See Fig. 5.
- Lift crane house free of the floor, see Fig. 6.
- Lower crane house on to wooden gratings, see
Fig. 7.
Note!
The lifting ropes must be chosen with an appropriate
safety factor and of the correct length.
The ropes must be attached to the crane house in
such a manner that the paintwork is not damaged.
Wood or rubber protection pieces should be used if
necessary. Soft slings should be given preference.
Fig. 5. Fasten lifting ropes. Fig. 6. Lifting crane house Fig. 7. Lower crane house on to
free of the floor. wooden gratings.
7 (14)
Onboard assembly (crane and jib)
Mounting crane house, see Fig. 8

Place loose assembly parts such as foundation bolts/
studs, nuts, washers, slipring with accessories, limit
switches (if applicable) etc. in the foundation
Caution!
- The foundation and the slewing bearing surfaces
as well as the foundation lower side surface facing
towards the washer must be metallically clean
before assembly.
- Flatness of foundation to be checked and recorded
according to separate instruction, M 2020-035 E.
Protocol to be handed over to start-up engineer.
14. Lift crane house approx. 1 metre, remove the

plastic sheeting that protects the slewing bearing.
Clean the mounting surface.
15. Fit three guide pins (packed with the foundation

screws), equally spaced in the slewing bearing
circle of holes for the foundation mounting
screws.
Attach three or four bracing ropes to facilitate
positioning the crane on the foundation.
Lift the crane house onboard.
Turn the crane house so that the jibs, when
installed, can be placed on their parking cradles,
or supported in some other manner. Alternativ- Fig. 8. Mounting of crane house.
ely, the cradle may be attached to the jib; in this
case, only an approximate orientation of the crane
will be required.
16. Check that all foundation mounting screws can

be assembled without difficulty. If they do not
fit, you must not jack out the slewing bearing
or the foundation mounting ring. Mount the
nuts/studs so the markings are visible. See Fig.
9. Lubricate the foundation mounting screws and
washers.
Prestressing forces/tightening torques and
lubrication/rust protection are specified in
drawing "Slewing bearing yard mount".
17. Mount the slip-ring mechanically and connect it

electrically. The maximum permissible radial runout
of the slip-rings is ±1 mm. Check the seating of the
carbon brushes, phase order, hull connection, and
insulation resistances, see Fig. 10.
Fig. 9. Nut / Stud markings.
8 (14)
Assembling jib
18. Clean the jib bearing bracket surfaces on jib and 20. To facilitate installation, the jibs should be
crane house. Mating surfaces must be clean and suspended at a suitable angle. Put the jib bearing
free from rust, see Fig. 10. housing in position so as to facilitate the mounting
19. Fit four guide pins on the jib end (packed with of the crane. Lift the crane jib on board and install
foundation screws). The guide pins must after it in the correct position. Support the jibs
mounting be removed with a socket wrench. See provisionally or place them on their parking
drwg. "Jib mounting", see Fig. 11. cradles.
Lubricate the crane and fill hydraulic oil according
to the Lubricating Chart.
Fig. 10. Assembling jib and slip-ring unit.
20
19
Fig. 11. Crane jib.
9 (14)
Reeving wire ropes, see Fig. 12

21. MacGREGOR Cranes installation supervisor The length of the textile rope shall equal the length
shall check the direction of rotation of the main of the jib multiplied by the number of parts, plus
electric motor by jogging it, and run the hoisting approximately 10 metres. When unwinding a wire
and luffing winches to test their function before rope from its reel, great care must be taken to
the reeving of the wire ropes may be undertaken. prevent the formation of kinks or getting the wire
The slewing movement must not be operated. rope into a tangle. The unwinding is facilitated by
supporting the reel on a shaft and pulling the wire
The limit switches are installed, but not adjusted, straight out, or by letting the reel ”roll” on the gro-
so that it is possible to run the winches when und or deck while pulling out the wire. See
reeving the wire rope. Care must be taken to pre- instruction 6.222.1 E.
vent damage to the wire guides. NB. The wire rope thimble should be safely
To install the wire rope, a textile rope is threaded secured to the crane house top/jib. Tighten also
according to the reeving diagram for the crane the wire rope locking clamps.
type concerned. At the same time the lifting 22. If an additional load handling tool is provided -
accessories, swivel, hook, etc. should be placed e.g. power swivel (cargo spotter), spreader, or
so the reeving of the wire can be done in a smooth grab - it shall be installed and its function tested.
way.
Fig. 12. Reeving wire ropes.
10 (14)
Final checkout Important!

When the installation has been completed, lubricate Tighten the wire rope locking clamps and secure the
the crane according to the Lubricating Chart on the wire rope thimbles. Tighten all slewing bearing screws.
inside of the crane house. The assembly is then The torque values are stated on the drawing ”Slewing
rounded off by a final check and adjustment of all li- bearing mounting”. The tightening torque values are
mit valves, a comprehensive function test, and an also stated in the instruction ”Tightening Torques”.
overload test. Note! All slewing bearing screws mounted at the yard
should be retightened after the overload test and the
After installation follow the maintenance chart Document 625/1467 E "Tightening Torque for the
irrespective of whether the crane is in operation or Slewing Bearing Mounting Bolts/Studs Mounted at the
not. Yard" should be returned to our service department
after being duly signed.
11 (14)
Lifting an assembled crane (crane house

and jib) on board
- Fasten lifting ropes to the lifting eyes on the crane Note! The lifting ropes must be chosen with an
house. See Fig. 13. appropriate safety factor and be of the correct length.
- Attach lifting ropes to the crane jib according to The lifting ropes must be attached to the crane house/
Fig. 13. Do not use the jib's lifting eyes. jib in such a manner that the paintwork is not
- Turn the crane house so that the jib can be placed damaged. Wood or rubber protection pieces should
on its parking cradle or supported in some other be used if necessary.
manner. Alternatively, the cradle may be attached Soft ropes should be given preference.
to the jib; in this case, only an approximate
orientation of the platform will be required.
- Lift crane on board by use of two cranes.
- It is important to secure the block to the jib top
otherwise the crane jib will go up and the crane
and jib will be folded.
Chain
Shackle
Lifting block secured

to jib top
Fig. 13. Lifting of a complete crane.
12 (14)
Onboard assembly (assembled crane)
Mounting crane house

Place loose assembly parts such as foundation bolts/ 23. Check that all foundation mounting screws can
studs, nuts, washers, slipring with accessories, limit be assembled without difficulty. If they do not
switches (if applicable) etc. in the foundation fit, you must not jack out the slewing bearing
or the foundation mounting ring. Mount the
Caution! nuts/studs so the markings are visible. See Fig.
15. Lubricate the foundation mounting screws and
- The foundation and the slewing bearing surfaces
washers.
as well as the foundation lower side surface facing
Prestressing forces/tightening torques and
towards the washer must be clean and free from
lubrication/rust protection are specified in drawing
rust before assembly.
"Slewing bearing yard mount".
- Flatness of foundation to be checked and recorded
according to separate instruction, M 2020-035E.
24. Mount the slip-ring unit mechanically and connect
Protocol to be handed over to start-up engineer.
it electrically. The maximum permissible radial
runout of the slip-rings is ±1 mm. Check the sea-
ting of the carbon brushes, phase order, hull
connection, and insulation resistances.
24
23
Fig. 14. Onboard assembly.
13 (14)
Final checkout Important!

When the installation has been completed, lubricate Tighten the wire rope locking clamps and secure the
the crane according to the Lubricating Chart on the wire rope thimbles. Tighten all slewing bearing screws.
inside of the crane house. The assembly is then roun- The torque values are stated on the drawing ”Sle-
ded off by a final check and adjustment of all limit wing bearing yard mounting”. The tightening torque
valves, a comprehensive function test, and an over- values are also stated in the instruction ”Tightening
load test. Torques”.
Note! All slewing bearing screws mounted at the yard
After installation follow the maintenance chart should be retightened after the overload test and the
irresepctive of whether the crane is in operation or Document 625/1467 E "Tightening Torque for the
not. Slewing Bearing Mounting Studs/Bolts Mounted at the
Yard" should be returned to our service department
after being duly signed.
Fig. 15. Nut / Stud markings.
14 (14)
SERVICE 6.222.1 E rev.: a 1998-04-17
Handling, Installation and Maintenance

of Steel Wire Ropes
1 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
Unloading steel wire ropes It is advisable to lift a reel by means of a shaft which
is put through its axis bore.
When handling a steel wire rope, the first trouble often
occurs immediately upon receiving it: the fork of the
fork lift truck is either placed under the reel or inside
the coil.
If the fork of the fork lift truck is longer than the width
of the reel, the reel can also be lifted at the flanges.
In both cases it might damage the surface of the rope.

The damage may not be discovered until much later
and it could happen that the manufacturer of the wire
rope is held responsible.
If possible, the rope, when recieved on cils or reels,

should not have any contact with a metal hook or the
fork of a fork lift truck.
Storing steel wire ropes

Instead, it should be lifted by means of a wide textile
webbing sling.
Steel wire ropes should be stored in a clean, cool, dry
place indoors. The ropes must not be allowed to rest
on the floor. They can be placed on pallets.
2 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
If outdoor storage cannot be avoided the ropes must Unwinding steel wire ropes from the reel
be covered in a way that moisture cannot create cor-
rosion problems. Although plastic foil protects the An unreeling stand (turnable) should be used to un-
ropes from rain, condensation from beneath might wind a wire rope from its reel.
not be able to escape and could damage the ropes
permanently. To avoid condensation problems, it is Another accepted unreeling method is to mount the
advisable to use breathable water-proof fabric covers reel on a shaft supported by two jacks or a stand.
readily available from tarpaulin manufactures.
When storing a number of spare ropes, the following

rule should be applied: first in - first out. This means,
the ropes should be used in the order of delivery. In
this way it can be avoided that certain ropes are only
put in service after being stored for many years.
It is self-evident that the different ropes in stock must

be clearly marked to avoid the possibility of confusion
(e.g. if similar ropes of diffferent tensile strength are
stored).
In addition proper records have to be kept which make

it possible to trace the "history" of any rope back to the
manufacturer on the basis of storing number, specifi-
cation, date of order and date of delivery.
Installing steel wire ropes
When installing steel wire ropes, extra care must be

taken that the ropes are unwound from the ring or reel
without torsions and without any outer damage. The
same applies to reeving the ropes into the system.
Rolling the wire rope along the floor, as is sometimes
recommended in the relevant literature, does not work
Unwinding steel wire ropes from the coil very well in practice because the reel always unwinds
less wire than the distance the reel travels, so that
If a rope is delivered on a coil, it is either unwound with this method the rope has to be dragged along
on a turntable or the coil is rolled along the ground the worker.
like a hoop. In the latter case ensure that the surface
is clean; sand or grit that sticks to the lubricant might
damage the wires when the rope travels or sheaves.
3 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
Under no circumstances must the rope be pulled off a If one end of the ropes has a fitting attached, as it is
coil while it is lying on the ground or looped over the mostly the case with deck cranes, there is no other
head of the reel, because this will inevitably induce possibility than pulling the loose rope end through the
one torsion per wrap into the rope. whole reeving system.
The most common rope fittings for deck cranes are

shown below.
The aluminum ferrule with mechanical splice.
Every torsion will change the lay lengths of the stands

and of the wire rope; at the same time the proportions
of lengths of the rope elements and finally the distribu-
tion of load within the rope are changed. A rope that is
unwound at the sides of a coil or reel will try to resist The cast steel ferrule with mechanical splice.
the enforced torsions and form loops. When pulled taut
these loops will result in irreparable kinks.
Steel wire ropes with kinks are not safe to operate and
must be discarded.
The spelter socket.
The installation procedure Typical deck crane example
The most advantageous way of installing a steel wire Below is shown an example of a typical deck crane,
rope varies from crane to crane. In any case a pro- where the rope must be spooled from the reel via
cedure should be chosen that (under justifiable ex- sheaves S1 through S9 onto the drum.
penditure) guarentees the least risk of torsions and
avoids damage to the rope by contact with parts of
the construction.
With some cranes it may be advisable to discard the

old rope first and to install the new one afterwards. With
other cranes, particularly with bigger ones, it might be
better to pull in the new rope attached to the old one.
Another possibility is to use a thinner rope by which
the wire rope proper is pulled into the system. This
method is often used with new equipment.
In every single case careful consideration is ne-ces-

sary as to whether the wire rope should be pulled
through the whole reeving system or whether it should
first be wound from the coil or reel onto the drum and
afterwards be reeved into the system.
4 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
Here, special attention must be paid to the hook block. of lay as rope to be installed.
It must be secured in an upright position so that the
rope can be spooled without any fleet angles occuring If the new rope is pulled in with help of the used one,
between the rope and the block´s sheaves. the two rope ends are often buttwelded together. A
connection of that kind can transfer the twist of the
old rope, built up in the reeving system, into the new
Winding the steel wire rope from the reel rope. By that method of installation the new rope may
onto the drum be extremely damaged.
During the manufacturing process every steel wire There are even more reasons why that procedure is
rope receives its preferred bending direction when highly problematic: It is true, that when using special
being drawn from the wire rope closer by means of electrodes the welded connection presents acceptable
a capstan. When delivered to the customer the rope results in a pull test with a straight rope; but because
is bent in that direction. Make certain that it bends of the great length of rigid connection zone the very
in the same direction when it is wound from the reel same connection could break due to the enormous
onto the drum. bending stresses when running over sheaves.
If that connection is applied, its safety should be in-

creased by using a Chinese finger. Fewer problems are
caused by connecting wire ropes with welded-on pad
eyes or chain links, which are joined by either strands
or thin wire ropes.
If the rope is wound at the bottom of the drum, it should
leave the reel at the buttom and vice versa: i.e., always
This connection pro-
reel from top to top or from bottom to bottom.
vides satisfactory load
capacity, it is flexible
If this procedure is not strictly followed, the rope will
and prevents the trans-
either try to twist between reel and drum or it will later
fer of twist from the old rope into the new one.
try to regain its preferred position when in practical
When using two strands to pull the rope into
service. In both cases structural changes of the rope
place, these will indicate the intensity of twist
may occur.
in the old rope on the basis of the number of
turns they have made during the installation
procedure.
Another possibility is connecting the rope ends

with Chinese fingers. These are tubes made out
of braided strands, which are pulled over the
Installing the rope with the help of the old rope ends and then secured at their ends with
one or by a thinner rope tape or seizing wire. Under load the Chinese
fingers will contract and hold the rope ends
If the new rope is pulled in by the old one or by a by friction.
thinner rope one must make sure that the connection
between these ropes is absolutely safe. In addition it When installing a lang lay rope one must take
must be ensured that the thinner rope cannot rotate. care that the Chinese finger cannot unwind
Rotation-resistant steel wire ropes or three-strand ibre from the rope like the nut from a screw. It is
ropes for instance, can be re-commended for this pur- recommended to wrap a tape around the whole
pose. When using conventional wire ropes one must rope length to be held by the Chinese finger to
at least make sure that they have the same direction increase the friction.
5 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
Installing under load
To achieve perfect spooling of the rope on the drum

it is very important to apply a tensioning load to the
wire ropes during the installation.
This is particularly important with drums spooling in

two or more layers, which, however, is not very com-
mon with deck cranes. If the first layer(s) are not under
tension, they might be too loose, so that the top layers
might be wedged into the bottom layers under load.
This could seriously damage the rope. The unwinding
rope might even be clamped, so that the direction of
spooling could suddenly be reversed during the course
of unwinding. The result could be the abrupt lifting of
the load that was actually travelling downwards.
The tensioning load should range from 1% to 2% of Attaching the rope termination to the fix
the minimum breaking load of the wire ropes. In many point
cases it might suffice to wind the rope quite normally
in order to unwind it and then rewind it with the help After the rope has been pulled through the reeving
of an outer load. system, the rope termination (e.g. the mechanical
splice with the aluminum ferrule) must be brought up
In other cases, however, the procedure mentioned to the fix point. A pulling jack can be used to pull the
above is not possible. In these cases the tensioning rope termination to the fix point, where it must secured
load must already be applied when installing the rope. with a bolt.
Ample rope tension can be provided by a simple plank Prior to fixing, if necessary, the rope termination may
bearing against the reel flanges or by a braking disk be aligned with the fix point by using a steel bar. The
attached to the reel. bar should be attached to the rope by means of a short
length of chain. Under no circumstances should the
Under no circumstances should one attempt to gen- rope be gripped with a wrench, as this will damage
erate the tensioning load by jamming the rope, for the outer wires.
instance between two boards. Structural changes
would deform the rope beyond repair.
6 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
"Breaking-in" the steel wire rope The rope and this wire end are now wrapped moving
away from the location of the intended cut.
After the rope has been installed and before it is go-
ing to do its proper job, several run-throughs of the
normal operational circle should be carried out under
light load. The new rope should be
"broken-in", so that the component
parts can settle and adjust them-
selves to the actual operating con-
ditions. It is most unfortunate that The rope is tightly wrapped for a distance of approx.
in practice only too often the exact three rope diameters.
opposite of this recommendation
is performed: quite frequently after
installing the rope overload tests
are carried out with loads beyond
the safe working load of the system.
Both ends of the seizing wire are then pulled tight and
Cutting steel wire ropes twisted together for a length of one rope diameter.
In some cases the user must cut steel wire ropes.

Hand cutters are sufficient for rope diameters up to 8
mm. Mechanical or hydaulic cutters will be required
for larger sizes.
The best method is to use a high speed disk cutter. The twisted connection is then hammered into a gus-
Unless the rope is being scrapped the use of flame set between the strands. After preparing the other
cutting equipment is not recommended. side of the intended cut accordingly the rope can
now be cut.
Careless cutting can result in the balance of tension in
the rope being destroyed. This is particularly important
when cutting rotation resistant ropes where the strands
may have been deliberately non- preformed as part
of the manufacturing specification.
In every case, each side of the cut must be properly

seized to prevent strand disturbance. Insulating tape Instead of using one long seizing it is also possible
cannot prevent strand movement, so annealed (iron) to apply at least three seizing the size of one rope
wire should always be used. diameter each on both sides of the intended cut.
After marking the position of the cut the end of the

seizing wire is laid along the rope axis leaving suf- The maintenance of steel wire ropes
ficient length to secure both ends by twisting when
the seizing complete. Steel wire ropes must be serviced regularly, the kind
of maintenance depending on the lifting device, its use
and the selected rope. Regular maintenance may con-
siderably increase the service life of a steel wire rope.
7 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
Relubricating steel wire ropes It is important with all different methods of relubri-
cation of steel wire ropes that they are carried out
During production the rope receives intensive lubrica- regularly right from the beginning of the service life
tion. This in-process treatment will provide the rope of the rope and not only after the first damage has
with ample protection against corrosion and is meant been ascertained.
to reduce the friction between the elements which
make up the rope as well as the friction between
rope and sheaves or drums. This lubrication, however, Cleaning steel wire ropes
only lasts for a limited time and should be re-applied
periodically. DIN 15 020 recommends: "From time to time very
dirty steel wire ropes should be cleaned externally".
German Standard DIN 15 020, e. g. specifies: "Steel
wire ropes must be relubricated at regular intervals, This applies particularly to ropes operating in ex-
depending on their use, particularly along the zones tremely abrasive conditions and to those that take up
subjected to bending. If for operational reasons relu- chemicals.
brication cannot be carried out, shorter service life of
the rope is to be expected and the inspection intervals Effective cleaning without proper tools is quite a labori-
have to be arranged accordingly." ous job. For cleaning steel wire ropes the Canadian
Rigging Manual recommends an appliance with three
When choosing the relubricant, it must be ensured rotating wire brushes and an air blast drying system
that it is in accordance with the recommendations of to follow. An American manufacturer offers a "rope
the rope manufacturer. porcupine", a sleeve equipped with brushes, which is
drawn along the steel wire rope.
There are several techniques of lubricant application:
The most common ones at present are painting or
swabbing. Removing broken wires
Quite often the lubricant is applied at a sheave, some- If during an inspection ends of broken wires are de-
times a continuous drip method is used. If only a little tected which might cross adjacent wires and destroy
lubricant is required, pressure spray nozzles can be them when running over sheaves, these broken wire
applied. ends must be removed.
Maximum penetration of the lubricant into the gaps of Under no circumstances should the broken wire ends
the rope, can only be quaranteed if high pressure lubri- be pinched off with a pair of nippers. The best method
cation is applied with the help of a pressure lubricator. is to move the wire ends backwards and forwards
until they break deep in the valley between two outer
With this method the two halfs of a sleeve, which is strands. With thicker wires a tool should be moved
equipped with rubber sealings, are clamped round backwards and forwards on the surface of the rope,
the rope and screwed together. While the rope runs thus bending the wires until they break.
through the lubricator the lubricant is pressed into the
sleeve at a pressure upto about 30 bars.
8 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
Cutting or shifting steel wire ropes
Very often wire ropes must be discarded although

only short rope sections, e. g. the one that climbs to
the second layer on the drum, are seriously damaged,
while the rest of the rope is still in perfect condition.
In cases such as this the service life of wire ropes

can be enormously increased by shortening, shifting
them at the fixing point by a span that removes the
section of the rope which has had most abuse out of
the critical zone.
After this procedure an adjacent section will be sub-

jected to the abuse.
Another typical local damage occurs on the drum at

those sections where the rope rubs against the adja-
cent winding (crossover point) and must be deflected
to the side. If the damage caused in these sections
is the main reason for discarding the rope, several
cuttings or shiftings will move the stresses to differ-
ent rope zones and possibly multiply the service life
of the rope.
9 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
Examples of damage to steel wire ropes
The following pages illustrate some typical examples

of damage to steel wire ropes which should always
decree immediate rejection of the rope.
Surfacelayer wires frayed by abrasion; wire ropes has

been running over sharp edges under load.
Localized wear caused by chafing against adjacent

steel structures possibly because of vibrations of the
length of wire rope laying between drum and sheave.
Heavy wear caused by high contact pressure in

sheave groove.
Severe corrosion.
Typical wire rupture caused by bending fatigue.
Typical example of localized wear and indentation

caused by a kink in the rope.
Nonrotating multi-strand wire rope with outer strand

partially disengaged because of nonuniform torsional
stress.
High shock loads have caused outer layer to split open

exposing steel wire rope core between strands that
have come apart.
10 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
Some examples of wire rupture
Contraction rupture caused by excessive stress, (e.g., Wear and identations of surface wires also promote
if a slack line suddenly snaps taut under full load). fatigue and lead to premature wire rupture.
Crown wires of outer strands may wear so thin that the Corrosion may cause wire ropes to break. As a safety
residual cross sectional area of steel in the rope will measure, inspect ropes regularly and carefully to pre-
not support the normal design load and contraction vent catastrophes; observe manufacturer's instruc-
rupture may ensue. tions
Rupture from fatigue will often occur when undersize

sheaves are used. Vibrations and torsional stress
loads in the rope accelerate fatigue rupture.
11 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
THIS PAGE IS INTENTIONALLY LEFT BLANK
12 (12)
MAINTENANCE 5.302.16 E rev.: f 2014-07-09
Hydraulic Oil Tank
General Oil level check

The oil tank has a dipstick to indicate the oil level.
The hydraulic oil tank is placed on the crane house Make sure that the oil level is between min. and max
floor. The feed pump is inside the oil tank. The main on the dipstick.
pump unit gear box is lubricated by oil from the hy-
draulic system, internal leakage oil are returned to the
Oil level float switch
tank by a drain line.
If the oil level decreases below a minimum level the
oil level float switch operates a alarm signal on the
control panel in the operator's cabin. See "Controls
Maintenance and Indicators" in section 4.
For maintenance intervals see "Lubricating Chart" and Make sure that the switch is correct, start the crane
"Maintenance Chart" in section 5. and loose the nut that holds the switch and lift it up
For type of oil see"Lubricants for Deck Machinery" in slowly, see Fig. 1.
section 5.
For oil volume see "Technical data", section 2.
4 1. Filters
2. Oil fill valve
3. Air filter with oil level dipstick
4. Oil level float switch and temperature guard
5. Thermometer
6. Quick coupling
7. Vedge valve
8. Feed pump
9. Radiator hose
9 8 7 6
Fig. 1. Tank with feed pump unit.
1 (2)
MAINTENANCE 5.302.16 E rev.: f 2014-07-09
Drain oil and clean the tank

Park the crane jib, push the stop button and switch
off the power on switch Q1. Drain the oil into clean
empty barrels.
Remove the tank cover. Use a rubber scraper to remove

sediment from the tank bottom and sides. Flush the
tank with white spirit.
Wipe the tank dry with clean rags. Do not use cotton
waste or other material that releases dust. Apply new
sealing compound and install the tank cover.
If the drained oil is in good condition and can be used

again, make sure it is filtered before it is filled into the
tank. Do not fill oil directly into the tank.
Pump and hoses used to fill oil must be clean.
Fill oil
Oil is filled at an ”aero-quip” type quick-release coupling
on the filter unit, see Figs. 1 and 2. To fill oil the crane
must be off, electric power and hydraulic system must
be off.
Fill oil to immediately below the MAX mark on the

dipstick.
Do not fill oil directly into the tank.
Oil filling
Fig. 2. Oil filter unit.
2 (2)
Instruction
Name Version Modified Responsible Page No.
M2020-035E 15.0 2015-05-22 Forsberg Roy Page 1 of 16
Welding of the crane foundation to the ship’s pedestal and

inspection before lifting on board the crane or twin platform
1. INSTRUCTIONS FOR WELDING THE CRANE FOUNDATION

TO THE SHIP’S PEDESTAL
1.1 The Quality Manager is responsible for the contents of this instruction
and the Service Manager for the surveillance that it is observed. Note!
The manufacture of the foundation shall enclose this instruction
when the foundation is delivered.
1.2. The shown joints or shapes of foundations are typical, but the design
differs from ship to ship.
1.3. To avoid fitting problems, the dimension of the pedestal shall be

checked before welding to the foundation. Pushing and pulling
foundation to fit the pedestal is not allowed.
1.4. The numbers of beads in the welding depends on the thickness of the
material and must thus be taken into consideration when making the
welding procedure.
1.5. The welding shall be carried out by two welders working

simultaneously.
1.6. Use suitable welding procedures and welding consumables. Electrodes

must be properly handled in order to prevent moisture pickup.
IMPORTANT
…. 1.7. No gap between foundation and pedestal is allowed before welding. If

necessary adjust acc. to page 16. Tack weld foundation to pedestal.
Tacks approx. 70 mm long and 300 mm apart.After tack welding, check
flatness and roundness. If possible, tack weld from inside and remove
tacks when back gouging.
Cargo & Material Handling Systems (CMH)

Instruction
Stay
Foundation
Cylindrical foundations are often equipped with diagonal stays ( see above)
from the supplier; those stays shall not be taken away before welding, the
foundation to the pedestal and the pedestal to the ships structure. However
please note that they shall be removed before the flatness and dimensions are
checked.
1.8. Weld according to proposed welding sequence (see page 3-7).

Full penetration welding is always needed.
Use back gouging when necessary.
1.9. Non-destructive test shall be performed in accordance with requirement

from Classification Societies.
IMPORTANT
....
After welding the foundation to the pedestal, the flatness and roundness of the
top flange has to be checked.
The tolerances of the foundation (see drawing of foundation) must be held.

See chapter 2 for instruction for measuring of flatness.
If the flatness/roundness requirements are not obtained, it is necessary to cut

down the foundation and reweld it.
IMPORTANT
Welding of extra lifting eyes (or similar) to the foundation is not allowed.
Exceptions can only be approved by MacGREGOR Cranes head office.

Instruction
1.10 Welding of foundation to Pedestal
Crane house
Foundation
Welding zone ”A”
Pedestal
IMPORTANT! The foundation and pedestal shall be in vertical

position.
The welding zone ”A” can be as one of the two alternatives below.
Alt 1 Stiffening plate at the welding zone ”A”
W3 (Shall be welded by the

supplier of the foundation)
W2
W1
Circular cross section of foundation:

- W1: All runs according to welding sequence 1 (WS1)
- W2: All first 2 layers acc to welding sequence 1 (WS1), remaining
according to welding sequence 2 (WS2)

Instruction
Rectangular section with stiffening plate zone “A”:

…..
W1: All runs except for the last three according to welding sequence 3
(WS3),
last three runs according to welding sequence 4 (WS4).
W2 :All runs except for the last three according to welding sequence 4
(WS4). last three runs according to welding sequence 5 (WS5).
Alt 2 No stiffening plate at the welding zone ”A”

…..
Outside Inside
W2 W1
Circular cross section of foundation:

…..
- W2: All first 2 layers acc to welding sequence 1 (WS1),
remaining runs according to welding sequence 2 (WS2)
Rectangular section:
- W1: All runs according to welding sequence 3 (WS3).

- W2: All first 2 layers acc to welding sequence 3(WS3),
remaining runs acc to welding sequence 4 (WS4)

Instruction
WELDING SEQUENCES
FOUNDATIONS WITH CYLINDRIC CROSS SECTION
Welding sequence 1 (WS1)

Instruction
FOUNDATIONS WITH RECTANGULAR CROSS SECTION
Inside foundation with

stiffening plate
W2 (WS 5)

Instruction

Instruction
2 INSPECTION OF FOUNDATION BEFORE LIFTING ON

BOARD THE CRANE OR TWIN PLATFORM.
It is of great importance that the surface of the slewing ring assembly is

within the tolerance of flatness. If the top flange is out of tolerance the
life time of the slewing ring might be considerably reduced. A condition
for MacGREGOR Cranes guarantee is therefore, that the foundation top
flange is within the tolerances or that possible deviation is approved by
MacGREGOR Cranes.
The foundation is a flexible construction and the top flange can quite easily
come out of tolerance due to pushing and pulling foundation to correct
dimension and welding activity.
IMPORTANT
…. When lifting on board the joint pedestal/foundation it is not allowed to use the
lifting eye on the foundation
If it should be manufacturing problems due to the height of the pedestal when

welding the foundation to the pedestal, the pedestal can be cut in two pieces.
The upper part of the pedestal shall be minimum 2 m, and shall be welded to
the foundation according to (page 1-7) and in vertical position. The lower part
shall be welded to the ship according to the drawing.
…. Welding the upper part of the pedestal to the lower part shall be carried out
according to one of following weld joints.
Outside Inside Outside Inside
Gouging (Cleaning) Weld 1-10(n) Gouging (Cleaning) Weld 1-9(n)

11-n Weld 10-n Weld

Instruction
The shipyard, which is responsible for the installation of the pedestal as well
as the crane, has to check the flatness of the top flange after that all welding
on the foundation and pedestal is completed. The verification must be made
before or in connection with the crane/platform being lifted onboard. The
records from the verification shall be presented to MacGREGOR Cranes
commissioning engineer.
There are two alternative methods to verify the flatness of the top flange on
the foundation/pedestal.
A. INSPECTION BY USE OF LASER
The best method of inspection is by use of laser equipment. If laser

equipment is used the result shall be recorded either on a printer
connected to the equipment or in a protocol similar to page 13. Neither
welding nor straightening is allowed to take place on the pedestal after
the record of flatness.
IMPORTANT
If the Quality Control department at MacGREGOR mean that the

shipyard not have good experience of welding the foundation to the
pedestal, laser equipment shall be used.
B. INSPECTION OF FLATNESS IN TWO STEPS WITHOUT USE

OF LASER.
STEP 1. INSPECTION BEFORE THE CRANE/PLATFORM IS

LIFTED ON BOARD.
…. After final welding and straightening the flatness check shall be

performed by use of a straightness batten with as a minimum the same
length as the outer diameter of the foundation top flange. The batten to
be placed in 8 positions according to the figure below. At each position
the clearance has to be checked on both sides with a thickness gauge.
The result shall be recorded in a protocol similar to page 14.
Note! This check makes it possible to discover if the top flange is

twisted. Possible clearance has to be checked on both sides of the
straightness batten.

Instruction
Side A Side B
STEP 2. INSPECTION DURING INSTALLATION OF THE

CRANE/TWIN PLATFORM.
The check using a straightness batten only verifies that the top flange
has not been twisted. After lifting on board, but before tightening the
screws between the top flange and the crane/platform, the yard shall
carefully check that no daylight can be observed from the inside of
the foundation. If daylight is observed, the gap between the slewing
ring and the top flange shall be measured by use of a thickness gauge.
(In case of installation during evenings and nights the yard must arrange
with sufficient lights in order to be able to discover possible gap.) The
gap shall be recorded in a protocol similar to page 14. If the gap exceeds
the permissible flatness as specified on the drawing, the crane must not
be installed and MacGREGOR Cranes must be consulted..
The slewing ring shall be assumed as flat, while the permissible gap
shall be the same as the tolerance specified for the machined top flange.
In order to correct the foundation it can either be machined at spot by use of a

mobile boring machine or cut down and re-welded again.
Correction by jacking or heating must not be used.

Instruction
PERMISSIBLE OUT-OF- FLATNESS INCLUDING SLOPE OF THE

MACHINED TOP FLANGE
The maximum permissible out-of-flatness including slope is specified

on the drawing. The drawing is delivered with the foundation as an
attachment to this instruction. Should the figure measured exceed the
ones specified on the drawings, MacGREGOR Cranes must be
consulted. Please note that the maximum value shall be reached only
once per 180o sector. To avoid larger deviations and the occurrence of
peaks in smaller sectors, any deviations in the range of 0o - 90o - 180o
must only rise or fall gradually.
If not otherwise is specified on the drawings, the following guidelines

can be used.
Diameter in Permissible gap

mm
< 1000 0,10 mm
1000-1500 0,12 mm
1500-2000 0,15 mm
2000-2500 0,17 mm
2500-4000 0,20 mm
4000-6000 0,30 mm
6000-8000 0,40 mm
…. FORE AND AFT LOCATION OF THE FOUNDATION
The Shipyard has to secure that the fore and aft location is correct
according to the drawings in the “Assembly drawing documents”
Make sure foundation is tack welded in correct forward and aft

direction; in case of question contact MGC head office.

Instruction
Position/sequence of foundations on ship
On each foundation, there is one name plate. The manufacture number of each
foundation is stamped on the name plate. (e.g. 625× ××××).
See below for example:
Position Manufacture Number
No.1 625× ××01 Ship Fore

No.2 625× ××02
No.3 625× ××03
No.4 625× ××04 Ship Aft
The foundations should be placed on ship from ship’ fore to ship’s aft, with
the manufacture numbers from small to large.
Alignment of foundation’s centre line to ship’s centre line.
Circular foundations and pedestals shall be market at forward/aft position

according to drawing 1000018950
See the below sketch on the round foundation for example:

Instruction
MEASUREMENT PROTOCOL - INSPECTION WITH LASER
Shipyard:....................................................................
Hull No:.........................
Crane No:.......................
POSITION RECORD REMARK

12
1
2
3
4
5
6
7
8
9
10
11
We hereby certify, that no welding is carried out on the foundation pedestal

after this measurement.
Date . . . . . . . . . . Signature . . . . . . . . . . . . . . . . . . . . . .

Instruction
MEASUREMENT PROTOCOL - INSPECTION WITHOUT

LASER, STEP 1
Shipyard:....................................................................
Hull No:.........................
Crane No:.......................
POSI- MEASURED
TION CLEARANCE
Side A Side B
1
2
3
4
5
6
7
8
We hereby certify, that no welding is carried out on the foundation

pedestal after this measurement.
Date . . . . . . . . . . . . . Signature . . . . . . . . . . . . . . . . . .

Instruction
MEASUREMENT PROTOCOL - INSPECTION WITHOUT

LASER STEP 2
Shipyard:....................................................................
Hull No:.........................
Crane No:.......................
POSITION GAP REMARK

12
1
2
3
4
5
6
7
8
9
10
11
We certify, that no welding is carried out on the foundation pedestal

after this measurement.
Date . . . . . . . . . . . . Signature . . . . . . . . . . . . . . . . . . .

Instruction
REPAIR OF ROOT GAPS
Adjustment
If root gaps have occurred, a first measure should be to make an adjustment of

the respective details. If those measures are not sufficient, i.e. the root gaps are
too large, the details may be repaired according to the instructions below.
Repair of butt joints
Repair of too large root gaps with respect to butt joints is carried out by means
of building up the plate edge(s) by welding according to the figures below.
When welding from one side, a backing bar of approved material may be
used. The backing bar shall be placed on the rear of the plate. The backing bar
may, under no circumstances, be placed between the plates so that material of
the plates is mixed with material of the backing bar. A repair when welding
from one side is carried out according to the figure below.

Instruction
M6587-1E 10.0 2016-01-07 Larsson Erik Page 1 of 6
Rust protection of components and fastening elements

externally installed on cranes
The Quality department is responsible for the contents of this instruction and
for the surveillance that it is observed.
This instruction is valid:

- At separate assembly of crane housing at the manufacturing place
- At separate assembly of crane jib at the manufacturing place
- During assembly of crane housing and crane jib together
- During assembly of slewing limits on GP/HH cranes
- When replacing of old components with new ones
Installation of hydraulic hose
On hydraulic hoses with coupling-nut the thread shall be applied with

CORTEC VCI 368, 1241 0000-001, during assembly.
Densyl tape apply to press sleeves, hydraulic couplings and nipples
After painting the Densyl Tape, 1169 2130-001, shall be winded on the hose
couplings as far upwards the component as possible, and further up on the hose
so that it creates a protecting shell.
Cargotec Sweden AB Marine

Crane business line
Instruction
Wind the object with 55% overlapping, i.e 2 layers of tape. Press the first turn
of tape against the object, lock it with the next turn of tape. The tape shall be
winded spirally on the object. The sketch below shows how the tape shall be
winded. The laps have to be be plane.
Right Wrong
The tape shall be tightened a bit in order to get contact with the surface, but
note that is shall not be stretched too much.
After the winding the complete surface shall be flattened (it is recommended to
use protection gloves), so that the overlapping will be completely protected
against water, and without air hole.
Areas, which cannot be covered with Densyl Tape, for example flanges on
hydraulic hoses, shall be applied with CORTEC VCI 368.
Note that Densyl Tape shall be applied before CORTEC VCI 368. Otherwise
the tape will not stick to the material.

Crane business line
Instruction
The screws for flanges shall be applied with protection grease Multifak EP2,
1171 4157-052, and protected with a suitable protection cap according to
table1. In case of lack of space for an external protection cap, a smaller plug
have to be fitted in the allen key handle.

Crane business line
Instruction
Installation of valves/flange couplings on block
The surface between the valve block and the valve or flange (valid for the
surface outside the sealing element) shall be applied with CORTEC VCI 368 in
connection with the installation.
Other screw joint
Other screws type MC6S or similar should be applied with protection grease
Multifak EP2, thereafter the hole shall be protected with a protection cap
according to table 1. In case of lack of space for an external protection cap, a
smaller plug should be fitted in the allen key handle.

Crane business line
Instruction
Oil cooler installation
The bolt track on the electric motor shall be greased with CORTEC VCI 368
( if this type of electric motor is installed)
Cortec VCI 368
....

Crane business line
Instruction
Table 1
Screw Protection cap over Protection cap in key

screw head handle
MC6S 8 12.9 2522 4506-189
MC6S 10 12.9 2522 4506-243
MC6S 12 12.9 2522 4506-203 2522 4506-239
MC6S 14 12.9 2522 4506-204 2522 4506-189
MC6S 16 12.9 2522 4506-248 2522 4506-241
MC6S 20 12.9 2522 4506-250
M6S 8 12.9 2522 4506-242

M6S 10 12.9 2522 4506-203
M6S 12 12.9 2522 4506-204
M6S 16 12.9 2522 4506-153
M6S 16 10.9 2522 4562-124

M6S 16 10.9 2522 4563-241
M6S 20 12.9 2522 4562-126
M6S 24 10.9 2522 4562-128

Crane business line
S E RV I C E I N F O R M AT I O N
625/1467 E rev.: f 2009-05-07
Tensioning/Tightening of the Slewing Bearing

Mounting Studs/Bolts Mounted at the Yard
All the slewing bearing mounting studs/bolts must be installed and tensioned/tightened
according to the drawing "SLEWING BEARING YARD MOUNTING" (can be found in
the "Assembly and delivery documents" that was sent with the crane shipment). All
the studs/bolts must be tensioned/tightened twice, during the installation and after
the overload test of the crane.
This instruction is valid only for the studs/bolts mounted at the yard.
When the studs/bolts are tensioned/tightened to the correct value, please sign and
return the below document to MacGREGOR Cranes, Service Division!
To
Cargotec Sweden AB
MacGREGOR Cranes
Service Division
Sjögatan 4G
SE-891 85 ÖRNSKÖLDSVIK, Sweden
Re.: Deck cranes, slewing bearing mounting studs/bolts mounted at the yard
Name of ship: ...................................................................................................
New building no.: ...................................................................................................
Crane type: ...................................................................................................
Crane serial no.: ...................................................................................................
We hereby certify that the slewing bearing mounting studs/bolts mounted at the yard on
above crane(s) are tensioned/tightened to the correct value according to the drawing
SLEWING BEARING YARD MOUNTING before and after the overload test.
Date: .......... ..............................................................................................................

Sign: ........................................................................................................................
Name (block letters, please!): ................................................................................
Company: ..............................................................................................................
1 (2)
625/1467 E rev.: f 2009-05-07
2 (2)
SERVICE 6.216.91 E rev.: a 2006-06-30
Rope Reeving Diagram for Cranes Type GL-2 (new version)
Luffing, 6 parts Hoisting, 6 parts
Jib top
Crane house top
Crane house top
Crane house top
Crane house top
Hoisting wire rope Luffing wire rope
Slack wire safety switch, hoisting and luffing. Slack wire condition.
1 (2)
SERVICE 6.216.91 E rev.: a 2006-06-30
Protective plate Securing the luffing wire socket to crane house top.
Protective plate
Important!
It is of utmost importance to grease the wire socket
according to instructions "Lubricating Chart" and
Protective plate "Lubricants for Deck Machinery".
Sliding plate
Securing the hoisting wire socket to crane house top.
Note! The wire rope socket should be safely secured..
2 (2)
MAINTENANCE 5.421.40 E rev.: h 2016-09-28
Lubricants for Deck Machinery

A. OILS
The oil shall be refined oil containing additives against Power swivel oil tank (if applicable)
oxidation, rust and foaming, as well as wear inhibitor Viscosity 32 cSt/40oC approx. (ISO VG 32 HV).
and/or EP additives. Viscosity index (VI) min. 150.
Solidification point -45oC or better.
Example: SHELL Tellus T 32.
Slewing gear
Synthetic oil (polyglycol type).
Viscosity 220 cSt/40°C.
Viscosity index (VI) 210. Cable winch, turbo coupling (if applicable)
Solidification point -30°C or better. Viscosity 22 cSt/40°C (ISO VG 22).
The oil must fulfil specifications according to DIN Example: SHELL MORLINA 22.
51354, FZG stage 12.
CAUTION! The oil must not be mixed with mineral oil Cable winch, gear box (if applicable)
or synthetic gear oil on PAO-basis. The oil can also Synthetic oil brand.
dissolve paints and some seals. Example: SHELL TIVELA S 150.
Example: SHELL OMALA S4 WE 220 or similar.
Stabilizing winch, turbo coupling (if appli-

Hoisting, luffing and whip winches cable)
Synthetic oil (polyglycol type).
Viscosity 220 cSt/40°C. Viscosity 22 cSt/40°C (ISO VG 22).
Viscosity index (VI) 210. Example: SHELL MORLINA 22.
Solidification point -30°C or better.
The oil must fulfil specifications according to DIN Stabilizing winch, gearbox (if applicable)
51354, FZG stage 12.
Synthetic oil brand.
CAUTION! The oil must not be mixed with mineral oil Example: SHELL TIVELA S 150
or synthetic gear oil on PAO-basis. The oil can also
dissolve paints and some seals.
Example: SHELL OMALA S4 WE 220 or similar.
Crane hydraulic system

For service in normal conditions:
Viscosity 68 cSt/40o C approx. (ISO VG 68 HV).
Viscosity index (VI) min. 150.
Solidification point -35o C or better.
Example: SHELL TELLUS S2 V 68.
For service in arctic climate:

Viscosity APPROX. 46 cSt/40o C (ISO VG 46 HV).
Viscosity index (VI) approx. 150.
Solidification point -45o C or better.
Example: SHELL TELLUS S2 V 46 (-30°C to +130°C)
SHELL TELLUS ARTIC 32 (-40°C to +45°C)
1 (2)
MAINTENANCE 5.421.40 E rev.: h 2016-09-28
B. GREASES
Plain bearings and wire rope sockets

Lithium grease with molybdenum disulphide.
Base oil viscosity 150 cSt/40°C.
Dropping point 180°C.
Example: MOBILUX EP 2.
Crane jib bearing

Lithium/mineral oil-based grease.
NOTE: MUST NOT contain molybdenum disulphide.
Example:
SKF LGMT2 or SKF LGEP2. (-30°C to +110°C).
TEXACO MULTIFAC EP2. (-30°C to +100°C).
Roller/ball bearings
Grease with EP additives.
Must withstand wet conditions.
Example: SHELL GADUS S2 V 220.
Ropes
Grease resistant to salt water and with antirust pro-
perties. (Very thin.)
Temperature range -30 to +100°C.
Viscosity 9.8 cSt/40°C.
Example: FUCHS Cedracon.
Arctic climate: FUCHS Ceplattyn.
Open spur gear units

Grease with good adhesion properties.
Example: SHELL GADUS S2 V 220 OGH.
Slip-ring unit, signal slip-rings

Example: "Cramolin B".
Please contact MacGregor (SWE) when choosing

lubricants for extreme temperatures.
2 (2)
LUBRICATING CHART PM51 1701-E00 rev.: j 2011-12-15
Item Part of crane (see page 2-3 for location) a b c d e f

1 Wire sheaves, Crane house top: 1 nipple/sheave (5-8 nipples) *
2 Wire sheaves, Jib stay: 1 nipple/sheave (1-2 nipples) (if installed) *
3 Wire sheaves, Jib top: 1 nipple/sheave (4-9 nipples) *
4 Wire sheaves, Lifting block: 1 nipple/sheave (1-2 nipples) *
5 Wire rope sockets: 2 pcs (in some cases on jib or block) **
6 Swivel, Lifting block (Single) or Lifting beam (Twin): 1 nipple
7 All wire ropes
8 Electric main motor: 2 nipples
9 Door hinges: 3 nipples, see Instruction manual section 6.2.
10 Jib bearings: 2 nipples
11 Oil tank
12 Air breather cap, oil tank
13 Oil filters
14 Slewing gear
15 Slewing bearing teeth
16 Slewing bearing (10 or 20 nipples, see section 9.3 Slewing specification/Slewing Bearing)
17 Hoisting + Luffing winches, journal bearing: 1 nipple/winch *
18 Hoisting + Luffing winches, gearbox
19 Parking cylinders: 4 nipples (if installed)
Key to symbols Key to symbols

a Daily Grease for ball and roller bearings
b Every 100 working hours Grease for plain bearings
(or before taking winch into operation, item 17) Grease for wire ropes
c Every 200 working hours or every two months Grease for open spur gears
d Every 500 working hours or every six months Grease for jib bearings
e Every 1000 working hours or every year Oil level, check
f Every 2000 working hours or two years Oil filters, check
Oil filters, replace
Air breather cap, check
Hydraulic oil, replace
Gearbox oil, replace (Replace oil after the first
200 hours, running-in period)
Instructions with supplementary data:

Oil quantity required: “Technical data”, section 2
Maintenance intervals: “Maintenance chart”, section 5
Location of nipples etc: “Lubricating and Maintenance”, section 5
Lubricants: “Lubricants for deck machinery”, section 5
Note! The crane must to be lubricated more frequently in tropical climates.

Note! Lubricate the crane before storage.
Note! If the crane has not been operated for an longer period of time it must be lubricated before operation.
* Check the number of nipples for your crane, see section 9.3. Make sure you apply grease to all nipples.
** Before greasing:
If the jib is parked on parking support: - Park the crane in support and slacken the luffing and hoisting wire.
If the jib is parked in wires: - Lower the lifting block to deck to slacken the hoisting wire.
- Hoist the block up against the jib top to slacken the luffing wire.
1 (4)
Red lamp on right control panel in operator’s cabin Jib top with lifting block
CHECK 3. Wire sheaves
OIL FILTER
7. Wire ropes
4. Wire sheave(s)
6. Swivel
CAUTION!
Renew all filter cartridges when this lamp comes on. The lifting block can have either 1 or 2 wire sheave(s).
1. Wire sheaves
5. Wire rope sockets
Filter service
indicator
13 8. Electric motor
Filter 4135
13. Oil filters
13
Oil filling
Filter
4136-1
9. Door hinges
12. Air breather cap
11. Oil tank
17, 18. Luffing winch 14. Slewing gears
17, 18. Hoisting winch 19. Parking cylinders
16. Slewing bearing 10. Jib bearings
15. Slewing bearing teeth
2 (4)
Wire sheave(s) on jib stay for cranes Lifting beam with hook for twin Example: Wire sheaves jib top,
with special design cranes central greased
3
7
6. Swivel 4
2. Wire sheave(s)
6
Example: Wire sheaves crane top, manual

and central greased
Example: Wire sheave(s) on

jib stay central greased 2
The sheave(s) to be lubricated
from the crane house top with
the crane jib positioned in min.
outreach.
Grease central Manual greased
Slewing Bearing Lubrication

The slewing bearing is lubricated with grease trough grease nipples placed around the bearing. They are in the
foundation between the bearing and the crane house bottom. There are 10 or 20 grease nipples.
Relubricate the slewing bearing when the crane turns. If that is not possible, relubricate bearing through all grease
fittings, then slew the crane approximately 0.2 m at the bearing and relubricate again. Repeat this procedure until
the whole bearing circumference is filled with new grease at the gaps and seals. Approximately five rotations is
sufficient. Use approximately 2 kg grease.
Note! The figure is only an example of a bearing.
15
16
C-00226
3 (4)
4 (4)
625/1388.13 E rev.: b 2008-01-21
Preservation of Hydraulic Slewing Cranes, Type GL
1. Storage prior to installation
A. General precautions
The crane is stored indoors or outdoors under a
watertight tarpaulin. Crates and cartons containing
loose gear must be stored indoors.
The major components (crane house, twin platform,

jib) should be placed on wood blocks as shown in the
Crane house, stored horizontally.
figures to the right.
Note! In case of longer durations of storage, upright

storing of crane houses is preferred because of easier
access to the interior of the crane house and to the
operator’s cabin.
B. Storage for one month or more

Inspect crane house and operator’s cabin once a
month. Inspect CT1-cabinet and CT2-cabinet for
moisture. When storing for longer periods than one
month, apply a coat of grease on all uncovered piston
Crane house, placed upright.
rods, valve pistons and machined surfaces; see
recommendation “Lubricants for Deck Machinery” for
suitable greases. Furthermore, the following
components should be treated with “Dinitrol” or similar
preservative:
- Springs.
- Jib bearing bundles on crane house.
In adverse climatic conditions, a portable electric

heater should be placed in the crane house to prevent Twin platform, stored horizontally.
condensation of moisture.
C. Storage for three months or more

Same precautions as in 1B, and:
During monthly inspections, pay particular attention to
any evidences of incipient corrosion and, if found, take
corrective action. Crane jib, stored horizontally.
To protect electric motors, it is recommended that

electric power is continuously supplied to the motor
heaters. = Wood blocks.
1 (2)
625/1388.13 E rev.: b 2008-01-21
Power for the electric heaters is taken from the CT1- B. Run the feed pump motor for at least 10 minutes
cabinet in the crane housing. once a month by closing the main power switch and
setting the WINTER/SUMMER starting selector switch
D. Connection of heater to winter.
The easiest way of having the anti-condensation
In a salt-air environment, particular attention must be
heater (220V - 2x50W + 3x15W + 16W) of the main
paid during inspections to any evidence of incipient
electric motor (2x50W), oil cooler motor (16W) and
corrosion and, if found, effective corrective action
CT2-cabinet (3x15W) activated is to connect 220V
should be taken.
supply to CT1 X2:111 and CT1 X2:112. (Check electric
circuit diagram valid for the crane.)
Relubricate slewing bearing during rotation not later
than after 3 months' standstill and thereafter every 3
Note! Lighting in crane house and cabin will shine if the
months. Before and after prolonged stoppage of the
light switches are in on-position. Outlet on CT1-cabinet
equipment relubrication is absolutely necessary. When
door and extra equipment (e.g. ventilating fans) will
cleaning the equipment care must be taken to prevent
have electric power.
cleaning agents from damaging the seals or penetrating
the traceways.
Warning!
This means 220V is applied to the CT1-cabinet in the
crane house. Before anybody touches or enters into C. Connection of feed pump
the crane this supply must be disconnected. “Danger - Connect main supply cables to the crane (L1, L2, L3
to life!” corresponding warning signs to be put up etc. and earth).
- Set switch S50 on CT1-cabinet in winter position.
Place bags of desiccator in electronic equipment - Set main switch in start position.
boxes. - Check correct rotation of the feed pump by checking
the oil flow in the main pump gear box.
2. Protecting cranes on board ship when
not used for extended periods Warning!
Voltage in the CT1-cabinet. Separate feed (orange
A. Inspect crane houses and operator’s cabins
cables).
once a month. Inspect CT1-cabinet and CT2-cabinet
for moisture. Pull a watertight tarpaulin over the top of
Before connecting, check the electric diagram or
the crane house. When storing for longer periods than
contact MacGREGOR (SWE), Service Division.
a month, be sure that all unprotected piston rods and
valve pistons are well coated with grease, for a
suitable grease, see recommendation “Lubricants for
Deck Machinery”. Components specified in 1B are to
be inspected regularly and treated with “Dinitrol” or a
similar preservative.
Connect the electric motor heaters to a power supply

for continuous operation. The heaters are usually
connected to the deck lighting circuit which may be
supplied either from the ship’s generators or by shore
power.
2 (2)
Last revised by: Daniel Eriksson
Last revision date: 2016-09-09
Part Specification
Name Rev Title Spare Part Title State Name Rev State
489 5017-801 K Spare Part Kit Release 489 5017 J Release
Part Specification
F/N Qty Unit Name Rev Title Spare Part Title State Name Rev State
001 2 PC 489 2570-801 A Test Hose Release 489 2570 A Release
002 2 PC 489 2566-801 B Manometer-connection device Release 489 2566 B Release
003 1 PC 5693 4121-060 F Pressure Gauge Release 5693 4121 G Release
004 1 PC 5693 4121-400 F Pressure Gauge Release 5693 4121 G Release
005 1 PC 6888 4111-801 - Lubrication Gun Release 1000011354 - Release
006 1 PC 6888 4121-112 - Lubrication Hose Release 6888 4121 A Release
009 2 PC 2669 4190-025 D Diode terminal Release 2669 4190 E Release
011 2 PC 2152 2118-943 F O-Ring Release 2152 2118 J Release
021 2 PC 2152 2151-181 C Bonded Seal Release 2152 2151 C Release
030 5 PC 5911 4145-060 E Bulb Release 5911 4145 F Release
032 10 PC 5672 4212-120 - Fuse Release 5672 4212 - Release
Last revised by: Daniel Eriksson
Part Specification
489 5017-801 K Spare Part Kit Release 489 5017 J Release
Part Specification
033 10 PC 5672 4212-140 - Fuse Release 5672 4212 - Release
034 5 PC 5910 2510-100 B LED Lamp Release 5910 2510 B Release
035 1 PC 400006406 - Pressure Sensor Release 1000006664 C Release
1 2 3 4 5 6 7 8 9 10 11 12
TOL. SYSTEM General tol. for dimensions
ACC. TO ISO Machining ISO 2768 tol-class: m
Surface roughness Welding ISO 13920 tol-class: A
Rm in m Therm. cut ISO 9013 tol-class: | | A
Blank: See Slew. spec.
0.2 3010 REF
A 3010 REF (106X) Eq. grade 42H12 A

B a5 1
a5
2620 REF
12.5 A
(600)
0.2
1x45
600
009
2x45
25
001
1087(COG)
+3
120 - 0
No paint
B B
005 004 a4 12.5

2100
+5
2300 - 5
Scale ( 1 : 3 )
007
a5
1x45
a5
(2100)
R5
0.1 A
744
88
a4
C (4x) C
2821
2924 1
Scale ( 1 : 3 ) = =
a4
+2 (2x)
Inside 2930 - 002 006 003 2930
500
2.0 A
2 006
2.0
4B
F-F ( 1 : 15 )
View H
C-C ( 1 : 2 )
D D
NOTE!
After machining, the weld and
the transition between the weld
and the material must be ground
or treated by TIG. Smooth transition
G D
005 C/L a4
005 (4x)
50
400(4x)
5(4X) 15
(4x)
15
E E E
90
D(1:3) Scale ( 1 : 1 )
(3X WJ1 (Ground) WJ1
)
a6
E WJ1
45 003
25 004
0
B
a4
A B B B a4
D D
263
010
F F
Forward
F 1B C C F 6 005
A
E-E ( 1 : 5 )
B-B ( 1 : 2 )
J Unless otherwise specified

010 welding:
a4
005
G G
Welding WELDING DATA
a4 Rules for welding
All excl.
WJ1, WJ2 M 2020-024
etc. Welding
005 class Electrode class
B EN 499-E 35 2 B 55 H5 Transition to deck or pedestal should
G J D 008 WJ1 B EN 499-E 35 4 B 55 H5
C/L
be masked acc. to M2061-16E section 4

(250)
Instruction M2020-035E
Plastic case with instruction and this drawing
A-A ( 1 : 5 ) Shall be fastened inside crane foundation
Designed by Checked by Date ECO Similar drawing Project
F Zhuo J Arvidsson 2016-04-15 1000054624 2/15023

H Title Weight H
106 Foundation Welding
x(83 8819 kg
,6) Description Scale
1 : 15
Scale ( 1 : 5 ) This document must not be copied without our written
permission, and the contents thereof must not be imparted Revision Sheet
to a third party nor be used for any unauthorized purpose.
Contravention will be procecuted. 1000058878 - 1/2
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
TOL. SYSTEM General tol. for dimensions
ACC. TO ISO Machining ISO 2768 tol-class: m
Surface roughness Welding ISO 13920 tol-class: A
Rm in m Therm. cut ISO 9013 tol-class: | | A
A A
B B
C C
006
011
= =
2680 REF
83 REF
a5 82,5 REF
D a5 D
G-G ( 1 : 15 )
720
=
011
240
E E
320
Scale ( 1 : 2 )
200
012
320
320
J-J ( 1 : 10 )
230
F F
230
320
320
320
G G
m 001)
20 (ite
View H ( 1 : 15 )
Designed by Checked by Date ECO Similar drawing Project
F Zhuo J Arvidsson 2016-04-15 1000054624 2/15023

H Weld joint location for item 001 Title Weight H
Foundation Welding 8819 kg
Description Scale
This document must not be copied without our written

1 : 15
permission, and the contents thereof must not be imparted Revision Sheet
to a third party nor be used for any unauthorized purpose.
Contravention will be procecuted. 1000058878 - 2/2
1 2 3 4 5 6 7 8 9 10 11 12
Last revised by: Felix Zhuo
Last revision date: 4/12/16
Part Specification
1282596 - Foundation Welding Release 1000058878 - Release
Part Specification
001 2 PC 1282597 - Sheet Casing Release 1000058882 - Release
1000000231 A Release
002 1 PC 1282598 - Floor Plate Release 1000058883 - Release
003 1 PC 390 0590-801 - Cover Release 390 0590 - Release
004 1 PC 1282665 - Bracket Release 1000058920 - Release
005 4 PC 1185608 - Lifting Eye Release 1000000568 - Release
006 2 PC 1282664 - Plate Release 1000058919 - Release
007 1 PC 390 0059-801 A Ladder Release 390 0059 A Release
008 1 PC 391 3557-001 - Plastic case with instruction Release 391 3557 - Release
009 1 PC 1282599 - Support Ring Release 1000058885 - Release
010 1 PC 2121 2034-536 L Hexagon Screw Release 2121 2034 V Release
011 11 PC 314 2491-001 B Bracket Release 314 2491 B Release
1324 2251 F Release
1000006652 - Release
012 1 M 1366 2212-082 A Tubes of steel hot drawn Release 1366 2212 C Release
Last revised by: Niklas Westerlund
Part Specification
391 2003-801 A Slewing Bearing Yard Assembly Release 391 2003 A Release
Part Specification
001 106 PC 390 9268-022 S Screw Release 390 9268 U Release
002 106 PC 1196563 - Washer Release 1000004598 H Release
1351 2751 G Release
003 106 PC 2126 2039-133 D Hexagon nut Release 2126 2039 F Release
004 0 L 1176 2060-001 - Paint Release 1176 2060 - Release
005 0 PC 390 9328-009 E Guide Pin Release 390 9328 E Release
1351 2411 C Release
006 0 PC 390 9328-010 E Guide Pin Release 390 9328 E Release
1351 2411 C Release
Last revised by: Sören Gidlund
Part Specification
1274371 A Crane Jib Yard Assembly Release 1000057232 - Release
Part Specification
001 8 PC 1268767 - Screw Release 1000048246 A Release
002 8 PC 490 3816-008 H Washer Release 490 3816 H Release
1351 2751 G Release
003 0 PC 488 8324-004 C Guide Pin Release 488 8324 C Release
1351 2411 C Release
004 0 L 1263 2078-001 - Modisulphide Paste Release 1263 2078 - Release
005 8 PC 2522 4563-510 - Protection Cap Release 2522 4563 B Release
006 0 PC 1171 4157-052 B Grease Release 1171 4157 B Release
Item Description(s) moved to separate EBOM Report.
Last revised by:
Part Specification
490 3651-801 - Ladder Assembly Release 490 3651 - Release
Part Specification
001 1 PC 390 3502-801 B Ladder Release 390 3502 B Release
002 4 PC 2121 2032-536 G Hexagon Screw Release 2121 2032 S Release
003 4 PC 2151 2022-178 B Washer Release 2151 2022 E Release
Last revised by: Sören Gidlund
Part Specification
288 1875-801 B Platform Crane House Assembly Release 288 1875 B Release
Part Specification
001 1 PC 288 1874-001 A Platform Release 288 1874 A Release
1613 2929 - Release
002 2 PC 2121 2034-542 L Hexagon Screw Release 2121 2034 N Release
003 4 PC 2151 2054-178 A Washer Release 2151 2054 A Release
004 2 PC 2126 2634-122 B Locking nut Release 2126 2634 D Release
005 2 PC 2183 2511-064 B Schackle Release 2183 2511 B Release
006 1 M 1194622 - Chain Release 1000003786 - Release
007 1 M 1194622 - Chain Release 1000003786 - Release
008 2 PC 2183 4634-090 - Spring Hook Release 2183 4634 - Release
Last revised by:
Part Specification
289 1903-801 - Slipring Device Assembly Release 289 1903 - Release
Part Specification
002 1 PC 389 0985-801 - Driver Release 389 0985 - Release
003 4 PC 2121 2032-501 G Hexagon Screw Release 2121 2032 T Release
004 4 PC 2151 2022-173 B Washer Release 2151 2022 E Release
005 4 PC 2641 2101-924 E Cable terminal Release 2641 2101 J Release

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This document must not be copied without
our written permission, and the contents
Status «Stat»
threrof must not be imparted to a third party
noor be used for any unauthorized purpose.
Contravention will be prosecuted.
Quantity / Sub-ass
801 802 803 804 805
Item No Title Description Article No Remarks
GL4536-2 Crane 1 x
GL4536-2 Crane 2 x
GL4536-2 Crane 3 x
Electrical system x x x See Crane System 1279564

002 Power/Cable connection x x x 1000055004
003 Component marking 1 1 1 424 0554-801
010 El inst cranehouse 124 0639-801 1 1 1

011 Cabinet Combined (CT1/CT2) 1262730 1 1 1
012 Cabinet Cabling Assembly (CT1/CT2) 124 0640-801 1 1 1
013 Ventilation Fan 388 9464-801 1 1 1
014 Drivers Desk 1271783 1 1 1 (AC)
015 Slipring device 1241164 1 1 1 (4+20)
021 Force Limit Assembly 124 0385-801 1 1 1 (1312)

022 Sensor Assembly El inst Angle/Speed encoder (Crane) 1205622 1 1 1
023 El inst. Card rely (CT2) 224 0118-801 1 1 1
031 Display 1245815 1 1 1 (XS2)

032 Cabin Display Assembly (CT1/CT2) 1182916 1 1 1
033 Cabin Display Assembly (Cabin) 1269193 1 1 1
034 Cabin Display Assembly (Crane) 1183168 1 1 1
Assembly drawing Description (English)
2/15023 El specification
Drawing checked by Weight kg Description (own language)
SSu Elspecifikation
Drawn by Year Week Drawing No Rev Ind Sheet
Rev Ind Revision Appd Year Week J Holter 16 01 491 0021 - 1 (2)
This document must not be copied without
our written permission, and the contents
Status «Stat»
threrof must not be imparted to a third party
noor be used for any unauthorized purpose.
Contravention will be prosecuted.
Quantity / Sub-ass
801 802 803 804 805
Item No Title Description Article No Remarks
041 Deck Light Assembly Cabin 1270937 1 1 1 (2x400W, S16)
045 Jib Light Assembly Crane 124 0636-801 1 1 1

046 Jib Light Assembly Pack 124 0637-801 1 1 1 (1x400W)
047 Jib Light Assembly Cabin 1270901 1 1 1 (S18)
048 Light Assembly Impulse relay (CT1) 224 0116-801 1 1 1 (K40)
051 Warning Light Assembly El inst warning light (cabin) 1270325 1 1 1 (S10)
052 Warning Light Assembly El inst. warning light top (Crane) 124 0653-801 1 1 1
053 Warning Light Assembly El inst. warning light top (Pack) 124 0654-801 1 1 1 (HW2 Red)
054 Light Assembly Impulse relay (CT1) 224 0510-801 1 1 1 (K57)
061 El inst Loudhailer Loudhailer (Cabin) 1267694 1 1 1

062 Electrical Communication Assembly Loudhailer (CT1) 1227297 1 1 1
065 Crane Assembly Extra cable (CT1) 124 0524-801 1 1 1 (W1013, XC4)
066 Crane Assembly Extra cable (cabin) 324 1236-801 1 1 1 (XC4)
Assembly drawing Description (English)
2/15023 El specification
Drawing checked by Weight kg Description (own language)
SSu Elspecifikation
Drawn by Year Week Drawing No Rev Ind Sheet
Rev Ind Revision Appd Year Week J Holter 16 01 491 0021 - 2 (2)

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SERVICE 6.320.401 rev.: e 2016-06-07
Limits for Hoisting and Luffing
Index
2
Section Page
General 1
Sensors and switches 1
Limits 2
How to set cams 2
How to measure limit values on winch drum 4
Luffing winch limits 7 1 3
C-00147
Hoisting winch limits 9
Safety functions at large outreaches 11
High hook function 11
Tilt warning system, "Jack knife" 13
1. Limit switch
2. Angle encoder (absolute)
General 3. Cam
The movement and outreaches of the jib and lifting Fig. 1. Limit switch box, luffing winch
block are controlled by a limit switch system. The sys-
tem makes sure that the crane operates with correct
speed and outreach for the load.
You must read the instruction "Technical Data" in

section 2 together with this instruction, all values for
outreaches and hook travel are there.
2 3
Sensors and Switches 1

C-00167
Limit switch boxes

The limit switch boxes are connected to the winches
and contain cams, limit switches and encoders. The
winches operates the cams and encoders through the
limit switch gearbox, see Fig.1 and Fig. 2. 1. Limit switch
2. Speed encoder (incremental)
3. Cam
Fig. 2. Limit switch box, hoisting winch
1 (14)
SERVICE 6.320.401 rev.: e 2016-06-07
Limit switches and cams How to set cams

A limit switch is a microswitch that is operated by a
rotating cam. They are set with values from instruction
Set cam degrees operating area
"Technical data".
Open the adjustment screw to adjust the cam
degrees. Use the cam end as a measure line when
The cams in the hoisting winch limit box are marked
you adjust the cam as on Figs. 3, 4 and 5. It is 5°
"BH" followed by the number of the cam in "Technical
between each hole. The figures are only examples
data".
of cams.
The cams in the luffing winch limit box are marked "BL"
followed by the number of the cam in "Technical data".
5
Encoders
The encoders gives a position of hook and jib to the
crane control system and to be viewed on the display.
Encoders are of two types, angle (absolute) and speed
(incremental). They are installed in the limit switch box,
and can also be installed at the jib bearing connected 4
directly to the jib.
3
The angle encoders must be calibrated when replaced.
C-00150
When a wire rope has been replaced the encoder for 2
that winch system must be calibrated.
1
Hydraulic pressure sensors
Hydraulic pressure transmitter and pressure switches
1. Lock screw
gives information to the control system about the weight
2. Maximum cam degree 55°
of the load. Refer to hydraulic diagram.
3. Minimum cam degree 30°
4. Adjustment screw
5. Measure line
Measure limits Fig. 3. Cam 30°-55° set to 45°operating area
The limits can be measured in different ways. Outreach

and hook travel can be measured with corresponding
values from the angle encoder and wire position on
the winch.
The jib outreach values refer to the crane house slew-
ing centre, not to the jib bearing centre.
The values for hook travel refer to the jib bearing centre.
2 (14)
SERVICE 6.320.401 rev.: e 2016-06-07
Set cam to operate limit switch

Open the lockscrew of the cam with a 10 mm
3 wrench and rotate the cam to to the correct position.
The cam operates the limit switch when it "clicks",
see Figs. 6 and 7. Tighten the lock screw when the
cam is in correct position.
C-00151
CLICK!
C-00153
1. Lock screw
2. Adjustment screw
3. Measure line
Fig. 6. Limit switch activated
Fig. 4. Cam 110°-270° set to 170° operating area
CLICK!
C-00154
C-00152
Fig. 7. Limit switch deactivated
Fig. 5. Cam 110°-270° set to minimum 110°

operating area
3 (14)
SERVICE 6.320.401 rev.: e 2016-06-07
How to measure limit values on winch

drum to make sure that the limits are set
correctly
AT and BT refers to the luffing winch and AL and BL

refers to the hoisting winch. Measure AT, BT, AL, and
BL on the front side of the winch. Measure from inside
of the winch drum.
C-00158
Fig. 10. Hoisting winch first layer AL
Second layer wire

Values BT and BL are measured from the full drum
flange side to the wire, see Figs. 11 and 12.
C-00576
Fig. 8. Measure view
First layer wire

Values AT and AL are measured from the wire lock
side (empty drum flange side) to the side of the wire,
see Figs. 9 and 10.
C-00160
Fig. 11. Luffing winch second layer BT

C-00157
Fig. 9. Luffing winch first layer AT

C-00159
Fig. 12. Hoisting winch second layer BL
4 (14)
SERVICE 6.320.401 rev.: e 2016-06-07
Note!
Applicable to GLB cranehouse.
1
C-00146
1. Center line of jib profile, jib at Minimum outreach

2. MV distance
3. Center line of the crane house
Fig. 13a. Jib at Minimum outreach, to measure MV distance. Applicable to GLB cranehouse.
5 (14)
SERVICE 6.320.401 rev.: e 2016-06-07
Note! Note!
Applicable to GL cranehouse. Measure two dimensions from the sunroof and
make two paunch type to get a straight line.
Measure the MV distance between the straight
line and the center line of the jib profile.
306
306
2
C-00222
1. Center line of jib profile

2. MV distance
3. Center line of the crane house (Alt. 1)
4. Center line of the crane house (Alt. 2)
Fig. 13b. Jib at Minimum outreach, to measure MV distance. Applicable to GL cranehouse.
6 (14)
SERVICE 6.320.401 rev.: e 2016-06-07
Luffing winch limits Min Outreach Lu, Speed reduce

10. Move the jib to "Min Outreach Lu, Speed reduce"
Refer to instruction "Technical Data" for values position, refer to Fig. 14.
of luffing limits. To operate in Rig mode refer to 11. Set the cam for "Min Outreach Lu, Speed reduce".
instruction"Preparation for Rig Mode", section 6.3. Jib Check Cam Lu (Optional)
outreach is measured from crane house slewing center. 12. Move the jib to "Check Cam Lu" position, refer
to Fig. 14.
WARNING! 13. Set the cam for "Check Cam Lu".
When the crane is operating in Rig mode the crane Max Outreach Lu, Speed reduce
has no software limits. 14. Move the jib to "Max Outreach Lu, Speed reduce"
It is not permitted to have any load in the hook. position, refer to Fig. 14.
Inappropriate use may cause severe damage to the 15. Set the cam for "Max Outreach Lu, Speed reduce".
crane and bodily injury.
Max Outreach Lu, Stop
16. Move the jib to "Max Outreach Lu, Stop" position,
WARNING! refer to Fig. 14.
Use a safety belt when you are on the crane top. 17. Set the cam for "Max Outreach Lu, Stop".
A fall from the crane top can cause death or injury. 18. Luff in to come out from maximum outreach area
and then luff out, to make sure that the cam stops
the luffing out movement.
CAUTION!
Keep a distance between the front of the crane house Force Limitation Lu, Parking
and the first jib stay. If you luff in to much the jib can 19. Turn the key switch "Force Limitation Lu, Park-
cause damage to the crane house. ing" to position "1", read "Control and Indicators",
section 4.
20. Move the jib to "Force Limitation Lu, Parking"
Min Outreach Lu, Stop
position, refer to Fig. 14.
1. Start the crane in Rig Mode, refer to "Preparation
21. Set the cam for "Force Limitation Lu, Parking".
for Rig Mode".
2. Hoist the lifting block close to the jib top and move Empty Drum Lu, Stop
the jib to "Min Outreach Lu, Stop", refer to Fig. 22. Turn the key switch "Parking of Jib" to position "1",
13 and 14. read "Control and Indicators", section 4.
3. Calibrate the luffing angle encoder, to set MV 23. Move the jib close to "Empty Drum Lu, Stop"
measurement. Refer to instruction "Absolute En- position, refer to Fig. 14. Do not put the jib in the
coder Calibration". parking support when you set the "Empty Drum Lu,
4. Set the cam for "Min Outreach Lu, Stop", refer Stop" cam. Make sure that there is at least three
to Fig. 5. locking turns of the wire on the drum.
5. Stop the crane and exit Rig Mode, refer to "Prepara- 24. Set the limit switch for "Empty Drum Lu, Stop",
tion for Rig Mode", and start crane in Normal Mode. refer to Fig. 14.
6. Luff out from minimum outreach area and then luff 25. Luff in from the parking area.
in, to make sure that the cam stops the luffing in 26. Turn the key switch "Parking of Jib" to position
movement. Make sure that the jib does not touch "1"and luff out to make sure that cam stops the jib.
the crane house.
7. Measure the MV distance to make sure it is correct.
Make sure limits are set correctly
Min Outreach Lu, Stop, Grab
After the cam adjustments are done, do a control
8. Move the jib to "Min Outreach Lu, Stop, Grab"
measure the AT (and BT if second layer wire) on the
position, refer to Fig. 14.
luffing winch. Start at minimum outreach and luff out
9. Set the cam for "Min Outreach Lu, Stop, Grab".
to maximum outreach. Refer to Figs. 9 or 11..
7 (14)
SERVICE 6.320.401 rev.: e 2016-06-07
1
2
3
8
C-00560
1
2
6
Fig. 14. Luffing limits

Fig. pos. Cam
1 Min Outreach Lu, Stop (Optional) BL(x)*
2 Min Outreach Lu, Stop BL5
3 Min Outreach Lu, Speed reduce BL4
4 Check Cam Lu (Optional) BL(x)*
5 Max Outreach Lu, Speed reduce BL2
6 Max Outreach Lu, Stop BL3
7 Force Limitation Lu, Parking BL6
8 Empty Drum Lu, Stop BL1
*For BL(x) see "Technical Data" Basic limit switches luffing winch
Table 1. Luffing limits
8 (14)
SERVICE 6.320.401 rev.: e 2016-06-07
Hoisting Winch Limits
Read the instruction "Technical Data" for values of

hoisting limits. Lifting height is measured from jib
bearing center.
CAUTION!
Hoist the lifting block close to the jib top before you
luff in to minimum outreach. The lifting block can
start to swing and hit the cabin.
Empty Drum Ho, Stop

1. Move the jib to "Min Outreach Lu, Stop" position,
refer to Figs. 13 and 14.
2. Lower the hook to "Empty Drum Ho, Stop", refer to
Fig. 15 and "Technical Data" . Make sure the winch
has at least three locking turns. You may need to
sink the hook in the water to reach this position.
3. Set the cam for "Empty Drum Ho, Stop".
4. Hoist a few meters and stop. Lower until it stops
at position empty drum. Make sure the value AL
is correct.
Empty Drum Ho, Speed Reduce

5. Hoist the hook to "Empty Drum Ho, Speed Reduce"
position, refer to Fig. 15 and "Technical Data".
6. Set the cam for "Empty Drum Ho, Speed Re-
duce".
Check Cam Ho (Optional)

7. Move the hook to "Check Cam Ho" position, refer
to Fig. 15.
8. Set the cam for "Check Cam Ho".
Full Drum Ho, Speed Reduce

9. Hoist the hook to "Full Drum Ho, Speed Reduce"
position, refer to Fig. 15 and "Technical Data".
10. Set the cam for "Full Drum Ho, Speed Reduce".
Full drum Ho, Stop

11. Hoist the hook to "Full Drum Ho, Stop". Make sure
the value AL is correct, refer to Fig. 15.
12. Set the cam for "Full Drum Ho, Stop".
Make sure limits are set correctly

After the cam adjustments are done, do a control
measure the AL (and BL if second layer wire) on the
hoisting winch. Start at Empty drum and hoist to Full
drum, refer to Figs. 10 or 12.
9 (14)
SERVICE 6.320.401 rev.: e 2016-06-07
H
C-00561
Fig. 15. Hoisting limits
Fig. pos. Cam

1 Full Drum Ho, Stop BH4
2 Full Drum Ho, Speed Reduce BH3
3 Check Cam Ho (Optional) BH(x)*
4 Empty Drum Ho, Speed Reduce BH2
5 Empty Drum Ho, Stop BH1
* For BH(x) see "Technical Data" Basic limit switches hoisting winch
Table 2. Hoisting limits
10 (14)
SERVICE 6.320.401 rev.: e 2016-06-07
Safety functions close to max outreach "High Hook" function (optional, if installed)
At large outreaches there is a possibility that the lift- "High Hook" function prevents the lifting block to collide
ing block and jib top will touch. This will not cause any with the jib top when the crane operates near maximum
damage to the crane, the crane is designed for that. outreach. When the crane is operated in this area, the
system will set the motion in speed reduce before it
At outreaches from min outreach to near max outreach stops, see Fig. 16.
the hoisting limit "Full drum, stop" will stop the lifting
block from touching the jib top, see Fig 16. It is only possible to luff in the jib or lower the hook
when the crane is stopped by "High Hook". "High
The luffing wire rope will slack if the lifting block lifts Hook" function is operated by software limits and the
the jib or the jib is lowered to the block. Then the slack control system.
wire safety switch will engage and hoisting and luffing
movement stops.
Calibration of "High Hook"
"High hook" must be calibrated when the wires have
To be able to operate the crane you must lower the lift-
been replaced. When the crane’s all encoders are
ing block or raise the jib until the wire rope is tightened.
calibrated, calibrate the "High Hook" function.
If the load is close to max SWL and the block is hoisted

to the jib top the weight from the load and the jib to- WARNING!
gether will cause an overload alarm. When the crane is operated in Rig Mode the crane
has no software limits.
Refer to instruction "Slack Wire Safety Switch Hoist- It is not permitted to have any load in the hook.
ing and Luffing Winches" in section 6.3 for more Inappropriate use may cause severe damage to the
information. crane and bodily injury.
1. Lower the jib to max outreach. Stop the crane.

2. Start the crane in Rig Mode, refer to "Preparation
for Rig Mode" (to deactivate "High Hook").
3. Hoist the lifting block carefully until it reaches the
C-00137
jib top.
4. Push the "Select/Info" button on the front of the
hoisting MC-card, refer to instruction "Card front
Fig. 14. Safety function at large outreaches
menus CT2, CC3000" in section 6.3. The display
on the Ho-card shows "ERROR".
5. Push the "Down/Exit" button on the Ho-card until
the display shows "CAL".
6. Push "ENCODER CALIBRATION" button in the
cabinet CT2 . The display in the Ho-card starts
flashing and shows "ANG".
7. Push the "Down/Exit" button until the display shows
"LIF" flashing.
8. Push the "Select/Info" button. Now "High Hook" is
calibrated.
9. Lower the hook.
10. Stop the crane and exit Rig Mode.
11 (14)
SERVICE 6.320.401 rev.: e 2016-06-07
2
500mm
Full drum 3
5
C-0577
High Hook Ho, Stop
"High Hook" area
Fig. 16. "High Hook" area
Fig. pos. Luffing limit Cam

1 Min Outreach Lu, Stop BL(x)*
2 High Hook Lu, Speed reduce BL(x)*
3 High Hook Lu, Max Outreach BL(x)*
4 Max Outreach Lu, Stop BL(x)*
Fig. pos. Hoisting limit Cam

5 High Hook Ho, Speed reduce** BH(x)*
6 High Hook Ho, Stop*** BH(x)*
* For BL(x)/ BH(x) see "Technical Data" High hook

** Speed reduce switch towards jib top
*** Preventing jib from touching lifting block (Detector switch)
Table 3. "High hook" area
12 (14)
SERVICE 6.320.401 rev.: e 2016-06-07
Tilt warning system, "Jack knife" Jack knife Lu, Min Outreach
(optional, if installed) 1. Move the jib to "Jack knife Lu, Min Outreach" posi-
tion, refer to Fig. 17.
Refer to instruction "Tilt Warning System to Prevent 2. Set the cam to touch the limit switch when the jib
"Jack Knife"" in section 3 for description of function. moves in to "Jack knife Lu, Min Outreach".
Read "Technical Data" for value of luffing limit.
2
C-00571
1
Fig. 17. Extra minimum outreach "Jack knife"
Fig. pos. Luffing limit Cam

1 Min Outreach Lu, Stop BL(x)*
2 Jack knife Lu, Min Outreach BL(x)*
* For BL(x) see "Technical Data" Jack knife Lu, Min Outreach
Table 4. Extra minimum outreach "Jack knife"
13 (14)
SERVICE 6.320.401 rev.: e 2016-06-07
14 (14)
625/1579 E rev.: m 2015-10-26
Measuring Procedure for Wear in Slewing Bearings
General be used at any future measuring, see Fig. 4. Write "A"

at the reference point in the front of the crane and
Below measuring procedure is valid for the crane "B, C" at the reference point at the back of the crane.
types G, TG, GL, TGL, GLB, H, TH, L, and TL. Remove excessive wear (burr) from slewing gear teeth
before measuring.
Note!
The procedure is not valid for measuring the slewing Measurements shall be taken at four positions of the
bearing under the twin platform. slewing bearing, if possible. With the jib pointing:
- Forward to the ship
The slewing bearing is an essential part of the crane - Starboard
and must be well maintained. Over the years the slew- - Aft
ing bearing will have some wear, and to be able to - Port side
know if there is a need for changing the slewing bear- It is important to use the same position for all further
ing records of the wear are needed. measurements to be able to compare the measure-
ments.
The initial measurements should be taken when With the jib at maximum outreach two measurements
the crane is installed at yard or within 2 months are to be taken, see Fig. 1.
from crane installation.
With the jib at minimum position one measurement is
If the records of the play measurements show signifi- to be taken, see Fig. 2.
cant wear, grease samples must be sent for analysis.
Enclosed table can be used to record the measure-
For slewing bearing grease sampling procedure see ments.
inspection instruction 625/1651 E.
Allowed play for slewing bearing

Measurements should be recorded with an accuracy
Measuring
of 0.1 mm.
The measurements should be taken regularly, every

As a guidence the maximum allowed play is:
6 months. Use a Vernier caliper, see Fig. 4.
- for roller bearings 1.5 mm
Measurements can be sent to MacGregor Service
- for ball bearings 3.0 mm.
Organisation for evaluation.
Contact MacGregor Service Organisation for exact

Note!
maximum slewing bearing play for your crane.
When measurements are to be taken the ship shall
have as little list/trim as possible.
See Slewing Specification spare part picture or Slew-
ing Bearing drawing for type of bearing in your crane,
Neither a load nor cargo handling equipment should
section 9.3 in spare parts manual.
be attached to the hook.
Deviation
Procedure
The deviation is related to differences in production
First time a measurement is to be taken two reference
tolerances and material. For MacGregor a part for a
points on the crane's bottom plate must be grinded
more accurat evaluation of the bearing play.
and marked. These reference points shall then always
1 (4)
625/1579 E rev.: m 2015-10-26
Jib at maximum outreach
Empty hook
Jib direction Jib direction
Measurement B Measurement A
(back of crane) (front of crane)
Fig. 1. Jib in outer position.
Measurement C
(back of crane)
Jib direction
Min. outreach,
empty hook
Fig. 2. Jib at minimum outreach.
2 (4)
625/1579 E rev.: m 2015-10-26
Note!
If there is a machined surface this shall be used as
reference point. In other cases a reference point must
be grinded and marked.
Machined surface/ Machined surface/

reference point reference point
Jib
B,C A
Fig. 3. Machined surface on crane bottom plate.
Remove excessive
Reference point
wear (burr) from slew-
ing gear teeth before
measuring.
Reference point
A
B,C
Vernier caliper
Fig. 4. Reference points, how to measure
3 (4)
625/1579 E rev.: m 2015-10-26
Vessel name: ...........................................................

Fore Note!
IMO No.: ................................................................... - If B - C = 0 or negative the
Ps Stb measurement is wrong.
Date: ......................................................................... - B - A = deviation bottom plate
crane house + play in bearing.
Crane No.: 1 Aft
Measurement (accuracy 0.1 mm) Play Deviation Jib direction

Jib at max. outreach Jib at min. outreach
A (front of crane) B (back of crane) C (back of crane) B-C B-A
Fore
Stb
Aft
Ps
Crane No.: 2
Fore
Stb
Aft
Ps
Crane No.: 3
Fore
Stb
Aft
Ps
Crane No.: 4
Fore
Stb
Aft
Ps
4 (4)
INSPECTION INSTRUCTION
625/1651 E rev.: b 2014-11-13
Slewing Bearing Grease Sampling Procedure
General
One of the criteria's to evaluate a slewing bearing's - Clean up the seal and the surrounding areas where
condition is to analyse the grease samples. The other the sample will be taken. When cleaning the area
is to make play measurements. The grease analysis of the seal, prevent the cleaner from contacting the
can be done in two steps, simplified or in a laboratory. seals or from entering the raceway's system.
What method to be used must be decided after the - Push new grease into the grease nipples / bearing
play measurement is taken. It must be noted that a without rotation.
single laboratory test of a grease sample gives very - Collect the first used grease that comes out at the
little information. Laboratory tests must be done on seal with a clean tool.
regular basis to see trends.
Attention: Do not take fresh grease for analysing!
The play measuring normally tells more about the The required quantity of grease for analysing is ap-
bearing condition than a grease sample. Both methods proximately 3 cm3.
provide together the best basis for evaluation of the
bearing condition. The normal interval for grease sampling is 6 months.
If steel particles are seen when the simplified grease

Procedure of grease sampling analysis is done or if the laboratory grease analysis
shows a too high value the grease sampling period
Following information is necessary in order to give a should be increased to each 50 crane operating hours
correct statement and allow further advice: or every two months.
1. Type of grease used at lubrication (manufacturer

and type).
2. Lubrication intervals (crane running hours or
months).
3. Crane operation hours.
4. Information where the samples are taken.
5. Has the slewing bearing been replaced? If so, when
was this done. Also write bearing article no.
A correct procedure of grease sampling is very impor-

tant, do this procedure.
Grease sampling procedure

- Slew the crane until the jib is in the main working
area.
- The grease sample should be taken at the inner or
outer seal of the bearing, see Fig. 1 and 2.
- One sample should be taken from the front part of
the crane and one sample from the back part of the
crane.
1 (6)
625/1651 E rev.: b 2014-11-13
Grease sampling area Grease sampling area

(see below figures) (see below figures)
Grease sampling
area at inner seal Grease sampling
area at inner seal
Outer seal Outer seal

Slewing bearing with rollers Slewing bearing with balls
Fig. 1. Grease sampling areas.
2 (6)
625/1651 E rev.: b 2014-11-13
Grease sampling area Grease sampling area

(see below figure) (see below figure)
Inner seal
Grease sampling
area at outer seal
Slewing bearing with balls
Fig. 2. Grease sampling area.
3 (6)
625/1651 E rev.: b 2014-11-13
Simplified grease analysis
1. Take a grease sample.
2. Spread the grease on a white paper.
3. Spread it out in a very thin layer.
4. Place the sample under a lamp and look for steel

particles.
4 (6)
625/1651 E rev.: b 2014-11-13
Laboratory grease analysis
Normally a grease laboratory analysis should give

results showing Fe, PQ, Si and water.
To best interpret the grease analysis a corresponding

analysis of fresh grease should be available to recog-
nize the deviations of the used grease.
Recommended analyze limits
Ok Attention Risk
Fe ≤ 1500 ≤ 5000 > 5000
PQ Index = Fe >5μ ** ≤ 500 ≤ 1500 > 1500
Si ≤ 100 ≤ 200 > 200
Water * ≤ 1000 ≤ 2000 > 2000
All values in ppm = mg/kg Example: 5000 ppm = 0,5 mg/kg
* Depend on the fresh grease / max. allowable water content of the manufacturer
** Thus a high PQ - index always indicates wear.
Actions to take based on grease

analysis
When the grease sample shows within limits

(green):
Do normal maintenance, refer to "Maintenance Chart"
and "Lubricating Chart".
If the grease sample shows yellow or red:

All grease in the slewing bearing must be replaced
before cargo handling.
See grease procedure in the instruction "Lubricating
chart" in section 5 in the "Instruction and spare parts
manual".
See total grease volume in instruction "Technical Data"
in section 2 in the "Instruction and spare parts manual"
or "Lubricating chart".
The maintenance of slewing bearing must be in-
creased. Increase the grease quantity 100% at each
grease procedure or do the grease procedure every
two weeks.
5 (6)
625/1651 E rev.: b 2014-11-13
6 (6)
SERVICE 6.303.56 E rev.: c 2013-08-30
Absolute Encoder Calibration

CC3000 GL-crane
General
Absolute encoders are used for position control Absolute encoders for hoisting and luffing winches
purposes. Each encoder gives an accurate position are installed in the limit switch box and on jib bearing.
feedback to the control system.
For slewing motion the absolute encoder is mounted
The encoder calibration has to be done when the wire under the crane towards the slewing bearing.
or the absolute encoder has been replaced.
Rotation center on crane

house top (Alt. 1)
306
306
MV
(m
m)
Rotation center on crane house First jib stay
top (Alt. 2)
Measure the "Distance MV"
Center line of jib profile

(calibration point)
There must be a distance

between the front of the
crane house and the first jib stay.
Fig. 1. Crane house top, GL-crane.
1 (4)
SERVICE 6.303.56 E rev.: c 2013-08-30
Preparation of minimum jib outreach Preparation of hoisting

luffing
- Activate Rig mode.
WARNING! - Start by driving the crane to "AL" (hoisting winch),
Always use safety belt when measuring the "Distance see Fig. 2, according to table "Limit switches -
MV". hoisting winch" in Technical Data, section 2 in
instruction manual.
WARNING! - Measurement to be done in front of the hoisting
When the crane is operated in Rig mode the crane winch, from the empty drum flange to the side of
has no software limits. the wire.
It is not permitted to have any load in the hook. - Set the limit switch for empty drum. Hoist the
Inappropriate use may cause severe damage to the hoisting wire a few meters and stop. Lower the wire
crane and bodily injury. until it stops at position empty drum, i.e. at least
three locking turns or tank top.
CAUTION! - Calibration of the encoder in the cabinet CT2, see
Make sure the the first jib stay on jib do not touch the page 4.
front of the crane house . Do a visual inspection of - Exit Rig mode by stopping the crane and switch
the distance between them. the key switch to Normal.
To operate the crane in Rig mode see instruction

"Preparation for Rig Mode" in section 6.3.
- Activate Rig mode.

- Carefully position the jib to minimum jib outreach
until the measure "Distance MV" is achieved.
- Measure the "Distance MV" on top of the crane
house, see Fig. 1, according to table in Technical
Data, section 2 in instruction manual. AL
- Calibration of the encoders in the cabinet CT2, see
page 4.
- Set the limit switch for "Min Jib Outreach", see table
"Basic limit switches - luffing winch" in Technical
Data, section 2 in instruction manual.
- Luff out a few meters and stop. Luff in until the jib
stops at "min jib outreach".
- Exit Rig mode by stopping the crane and switch the
key switch to Normal. Fig. 2. Definition of "AL" hoisting winch.
- Recheck the "Distance MV".
2 (4)
SERVICE 6.303.56 E rev.: c 2013-08-30
Preparation of slewing
To calibrate the absolute encoder for slewing aim the

crane jib straight ahead, i.e. 0°, see Fig. 3. Calibration
of the encoder in the cabinet CT2, see page 4.
0°
Fig. 3. Reference points.
3 (4)
SERVICE 6.303.56 E rev.: c 2013-08-30
Calibration of encoders in the cabinet CT2
Hoisting Luffing/slewing
1. Push the "Select/Info" button on the front of the To calibrate the encoder on the other cards proceed
MC-card which you want to calibrate, for example in the same way as in items 1, 2, and 3 in above
Ho-card. The display on the Ho-card shows paragraph except for choosing the corresponding card.
"ERROR".
2. Push the "Down/Exit" button on the Ho-card front.
The display on the Ho-card shows "CAL".
3. Push the "ENCODER CALIBRATION" button in the
cabinet CT2. The display in the Ho-card then starts
flashing, showing "ANG".
Push the "Select/Info" button on the Ho-card. Angle
encoder is calibrated in this position.
Function/Mode Purpose Calibration position

Ho Zero position of hoisting winch Empty drum, at least three locking turns (AL).
Lu Zero position of luffing winch Full drum, minimum jib outreach (MV). Encoder in limit switch box.
Sc Zero position of luffing winch Full drum, minimum jib outreach. Encoder on jib bearing.
SL Zero position of slewing Aim crane jib straight ahead for 0°.
Table 1. Encoder calibration modes
Hardware Hardware Hardware Hardware

xxx xxxx-xxx xxx xxxx-xxx xxx xxxx-xxx xxx xxxx-xxx
Error MP SP Error MP SP Error MP SP Error MP SP
Input Output Input Output Input Output Input Output

07 18 27 33 36 33 36 33 36
07 07 07
08 19 28 39 43 39 43 39 43
09 20 29 34 37 34 37 34 37
08 08 08
10 26 30 40 45 40 45 40 45
6 11
12
49
51
31
32
09
10
31
32
30
09
10
31
32
30
09
10
31
32
30
13 56 33 19 Sw19 19 Sw19 19 Sw19

Encoder 14 57 34 20 Sw20 55 20 Sw20 55 20 Sw20 55
15 58 35 11 14 Sw14 11 14 Sw14 11 14 Sw14
calibration
16 59 36 56 Sw56 56 Sw56 56 Sw56
17 60 37 12 15 Sw15 12 15 Sw15 12 15 Sw15
24V 38 26 27 26 27 26 27
C1
Com
R1
39
40
58
49
59
17 29
58
49
59
17 29
58
49
59
17 29
1
C2 R2 53 51 18 53 51 18 53 51 18 53
C3 R3 61 52 54 52 54 52 54
C4 MP 57 C1 R1 57 C1 R1 57 C1 R1
C2 MP C2 MP C2 MP
Com Com Com
CC MC MC MC
Sc Ho Lu Sl
5 Select / Info Select / Info Select / Info Select / Info
Rigg
Normal
OL-Test
Up Up Up Up 2
Down / Exit Down / Exit Down / Exit Down / Exit
3
PC COM PC COM PC COM PC COM
4
Software Software Software Software
Fig. 4. Cabinet CT2, CC3000

1. Display
2. Select/Info button
3. Up button
4. Down/Exit button
5. Keyswitch Rigg/OL
6. Encoder Calibration button
4 (4)

SERVICE 6.303.61 E rev.: f 2016-06-10

Card front menus CT2, CC3000

General Depending of crane type there can be

additional cards. On the front of each card
This instruction describes how to use the
there is a display and three buttons: Select/
display and buttons on the Micro Processor Info, Up and Down/Exit.
Cards (MC- and CC) placed inside the CT2-
cabinet.
Each crane with CC3000 is equipped with at Note! Depending on equipment or software
least one CC-card and three MC-cards. versions the number of alternatives may vary.
1
2
3
4
5
6
1. Error MP (Main Processor) and SP

4. Select/Info
(Safety Processor)
Push the button = Select.
 Flashing LED = there are active
Push and hold the button = Information
errors that have not been
will scroll by on the display.
acknowledged.
 The LED is on (fixed) = there are 5. Up button
active errors but they have been Browse upwards
acknowledged.
 The LED is off = there are no 6. Down/Exit
active errors. Push the button - Browse downwards.
2. Encoder Calibration button Push and hold the button - Exit, back to
top menu.
Used for calibrating encoders
3. Display
See below

1 (4)

SERVICE 6.303.61 E rev.: f 2016-06-10

Display
At “power on” the software version will appear. For more information about errors refer to
To view that in a later stage, see below Troubleshooting CC3000 in section 6.3 in
paragraph 6 VER. the Instruction Manual.
For each card there will be two letters
representing the card. When holding the Select
button the complete name will appear. 2. CAL - CALIBRATION MODE
(RIGGING REQUIRED)
Standard Complete Calibration mode makes it possible to
view name calibrate one or several encoders and
Sc Supervisor other equipment depending of crane type.
Ho Hoisting Calibration can only be done if Rig-mode
Lu Luffing is on. For more information see Absolute
Sl Slewing Encoder Calibration in section 6.3 in the
Au Auxiliary Instruction Manual.
Cl Closing Each card will be calibrated at a time.
Ec Eccenter For twin cranes, when in twin mode and
Ll Lift Line from the master crane and from card Sc:
Tl Tag Line Left Ho Ll Tl Tr but not Lu will be calibrated.
Tr Tag Line Right
Io Input/Output 3. PLU – Plussing Adjustment
Only on Sc card
Menu tree
Only to be used during commissioning of
All errors must be acknowledged before you
can move on to other modes. (LED must not the crane.
be flashing). There are seven main modes.
Push Select/Info to enter menu tree. 4. CUT – Cut off valve Adjustment
Only on Sc card
1 ERR Error Mode
Only to be used during commissioning of
Calibration Mode
2 CAL (Rigging required) the crane.
3 PLU Plussing Adjustment
4 CUT Cut off valve Adjustment 5. VAL - VALUE MODE
5 VAL Value Mode
Value Mode makes it possible to monitor
6 VER Software Version different values. How many values that
Manufacturing number appear is dependent on equipment and
7 MFG (from version H04.00) parameter settings.
 Push Select/Info to enter menu tree.
1. ERR - ERROR MODE  Push Down/Exit until the display shows
VAL
Error mode shows all active errors in the  Push Select/Info to select Value Mode
respective control card.  Push Down/Exit until the value is on
 Push Select/Info to enter menu tree. display.
 Push Select/Info to select Error Mode.  Push select to see the value.
 Push Down/Exit or Up to browse
between errors.

2 (4)

SERVICE 6.303.61 E rev.: f 2016-06-10

Values
Sc Ho Lu Sl Au Cl Ec LL TL TR IO
JOY Joystick % ● ● ● ● ● ● ● ● ● ● ●
AN1 Jib angle degrees (360) ● ● ● ●
AN2 Winch angle degrees (360) ● ● ● ● ● ● ● ● ●
AN3 Cabin A angle degrees (360) ●
AN4 Cabin B angle degrees (360) ●
AN5 Swivel angle degrees (360) ●
AN6 Gyro yaw angle degrees (360) ●
SP1 Speed rpm rpm ● ● ● ● ● ● ● ● ●
SP2 Speed mpm mpm ● ●
PRE Pressure bar ● ●
WE1 Weight Dynamic ton ● ●
WE2 Weight max ton ● ●
LIF Lift height m ● ● ●
OUT Outreach m m ●
FOR Hook to hook FOR m m ●
AFT Hook to hook AFT m m ●
AL1 ALM line voltage V ●
AL2 ALM line current A ●
AL3 ALM power kW ●
AL4 ALM DC voltage V ●
AL5 ALM temperature Degrees ●
VF1 VFD temperature Degrees ● ● ● ● ● ● ● ● ●
VF2 Motor speed Percent ● ● ● ● ● ● ● ● ●
VF3 Motor torque Percent ● ● ● ● ● ● ● ● ●
VF4 Motor current A ● ● ● ● ● ● ● ● ●
VF5 Motor temperature Degrees ● ● ● ● ● ● ● ● ●
PW0…4 PWM0…4 mA ● ● ● ● ● ● ● ● ●
AI1…11 "Parameter" Parameter value ● ● ● ● ● ● ● ● ● ● ●
CAR Card Temperature Degrees ●
7. MFG – MANUFACTURING NUMBER

6. VER - SOFTWARE VERSION
From software version CC3K H04.00 it is
Software Version makes it possible to
possible to see the manufacturing number
read the version of the software. This will
of the crane.
also appear at “ power on”.
 Push Down/Exit until the display shows
 Push Down/Exit until the display shows
MFG.
VER.
 Push Select/Info to see the MFG-
 Push Select/Info to select Version
number
Mode

3 (4)

SERVICE 6.303.61 E rev.: f 2016-06-10


4 (4)

SERVICE 6.990.36 E rev.: i 2009-05-18
Emergency Lowering in Case of Complete Power Failure

Operation of Crane Using a Hand Pump (Optional)
Introduction Twin operation

When the cranes are to be used in twin operation the
In the case of a power failure the hoisting, luffing and brakes must be released by using two hand pumps,
slewing circuits of a deck crane may still be operated one for each crane. The necessary crew for this opera-
to a limited extent by releasing their respective brakes tion is two "brake releasers" and one crane operator.
with utmost care.
Contact between the two "brake releasers" and the
The release of the brakes of the hoisting, luffing, and crane operator is absolutely essential, e.g. by use of
slewing functions is facilitated by employing a hand head-sets.
pump designed for this purpose. Quick couplings and
shut-off valves are also installed in the hydraulic sys- All necessary material comprising this emergency
tem of the crane for this purpose. equipment including the hydraulic pressure source
are included in the supply. See Fig. 1.
Connection to quick coupling on

hoisting (1664), luffing (2664), and slewing (3664)
Plug *), included in pump set.

To be used when emergency
slewing.
Pressure
gauge1D
T-coupling to MA on
pump, hoisting or luffing
Port 3A-B Port 3A-F
Needle valve 3B
Flow control valve 3A
Connection to quick cou-
pling (4333) to tank By-pass line Bushing Screw
**) Plug to pilot hose and included in pump set,
Fig. 1. Hand pump 1A (optional).
1 (12)
SERVICE 6.990.36 E rev.: i 2009-05-18
Hoisting circuit, see Fig. 4 and 5
Hoisting pump 1111
MA (gauge connec-
tion 3.2)
CAUTION! MB (gauge
- This work has to be done with great care by skilled connection 3.1)
personnel.
- Only one function to be activated at a time.
- Verify that nobody is within the working area of the
crane.
- Ball valves 1663, 2661 and 3661 must not be actu-
ated except in emergency brake release operation.
CAUTION!
Hose must be connected to MA-port (gauge con- By-pass line,
nection 3.2) on hoisting pump to avoid uncontrolled included in
emergency
lowering. equipment
3B
Flush-unloading unit 1128
3A
Ball valve 1663
Connection P
Pilot hoses (dis-
connected)
Directional valve 1221
Wedge
valve 4332
Oil tank
Quick
coupling
4333
Quick
coupling1664 Pilot hose,
disconnect and plug **)
Hand pump 1A
Fig. 2. Connection of hand pump 1A, hoisting winch.
2 (12)
SERVICE 6.990.36 E rev.: i 2009-05-18
Function
The emergency lowering system works in such a way - Connect the hoses from the hand pump as shown
that the motor hydraulically controls the load. If the in, Fig. 2, and in the hydraulic diagram Fig. 4.
motor tends to overspeed, by the force from the load, - Disconnect the pilot hose from connection “P”, flush-
the brake will close. unloading unit 1128. Plug the disconnected hose.
See Fig. 2, 3, and 4.
Hand pump 1A builds up pressure on the low pres- - Remove check-restriction valve 1241-1 from flush-
sure side of the motor and on the brake. The pressure unloading unit 1128, see Fig. 3.
can be read on pressure gauge 1D. The brake opens - Attach the bushing and screw into coupling in con-
at approx. 1.2 MPa. Oil from the high pressure side nection “P”, flush-unloading unit 1128-1. Screw in
(pump MB-port) goes through the needle valve 3B and the threaded bushing up to the neck, screw to actu-
flow control valve 3A to the low pressure side (pump ate the piston to blocked position. See Fig. 3.
MA-port). Flow control valve 3A is fixed and load inde- - Close ball valve 1663 and open wedge valve 4332.
pendent. With a load in the cargo hook, needle valve See Fig. 2 and 4.
3B can be completely or partially closed in order to
reduce the speed.
Operation
Release the brake by pumping oil from the hand pump.
Connection, see Fig. 2 and 4 The load must be lowered slowly and carefully con-
- Install the hand pump to the base plate using the trolled. Speed can be reduced by closing needle valve
provided screws. 3B, partially or completely.
- Disconnect pilot hoses at MA- and MB-port on the
pump. The load must be lowered slowly by pumping in a slow
- Connect the by-pass line. See Fig. 2 and 4. and even pace.
Caution!
Twin operation
It is of most importance that the hoses to MA and
The twin beam must be as horizontal as possible dur-
MB are not switched, because the load could be
ing emergency lowering.
dropped.
After operation
After the lowering operation is completed, reset the
crane to “NOT EMERGENCY COUPLED“ and close
wedge valve 4332 and open ball valve 1663. See Fig.
2 and 5.
Check-restriction Coupling Connection P

valve 1241-1
Pilot hose
Bushing
Screw
Piston
Fig. 3. Flush-unloading unit 1128.
3 (12)
SERVICE 6.990.36 E rev.: i 2009-05-18
Note! Flush-unloading unit - con-

nection P mec. affected.
3B
3A
Fig. 4. Hydraulic circuit, hoisting. Emergency coupled.
4 (12)
SERVICE 6.990.36 E rev.: i 2009-05-18
Fig. 5. Hydraulic circuit, hoisting. Not emergency coupled.
5 (12)
SERVICE 6.990.36 E rev.: i 2009-05-18
Luffing circuit, see Fig. 8 and 9
MB (gauge connection 5.1)

MA (gauge connection 5.2)
Luffing pump 2111

CAUTION!
Hose must be connected to MA-port (gauge
connection 5.2) on luffing pump to avoid uncon-
trolled lowering.
Gauge
connections
removed
3B 3A
By-pass line
Unloading unit 2127 Included in

Pilot hose,
emergency
disconnect and plug **)
T-connection equipment

Wedge valve 4332
Oil tank
Connection P Quick
coupling
4333
Quick coupling 2664

Ball valve 2661
Hand pump 1A
Fig. 6. Connection of hand pump 1A, luffing winch.
6 (12)
SERVICE 6.990.36 E rev.: i 2009-05-18
Function
The emergency lowering system works in such a way - Remove check-restriction valve 2241-1 from un-
that the motor hydraulically controls the load. If the loading unit 2127, see Fig. 7.
motor tends to overspeed, by the force from the load, - Attach the bushing and screw into coupling in
the brake will close. connection P, unloading unit 2127. Screw in the
threaded bushing up to the neck, screw to actuate
Hand pump 1A builds up pressure on the low pressure the piston to blocked position. See Fig. 7.
side of the motor and on the brake. The pressure can - Close ball valve 2661 and open wedge valve 4332.
be read on pressure gauge 1D. The brake opens at See Fig. 6 and 8.
approx. 1.2 MPa. Oil from the high pressure side (pump
MB-port) goes through the needle valve 3B and flow
Operation
control valve 3A to the low pressure side (pump MA-
Release the brake by pumping oil from the hand pump.
port). Valve 3A is fixed and load independent. Valve
The jib must be lowered slowly and carefully controlled.
3B can be completely or partially closed in order to
Speed can be reduced by closing needle valve 3B,
reduce the speed.
partially or completely.
Connection, see Fig. 6 and 8 The load must be lowered slowly by pumping in a slow
- Install the hand pump on the base plate with screws and even pace.
provided.
- Before connecting the by-pass line, remove the
Twin operation
gauge connections from MA- and MB-port.
The jibs must be as parallel as possible to each other
during the lowering.
Caution!
It is of the utmost importance that the hoses to
If only the luffing circuit is out of operation, try to lower
MA- and MB-port are not switched, because the
the load onto deck or quay with the hoisting winch.
load could be dropped.
Remove the twin beam and lower the jibs one by one.
- Connect the by-pass line. See Fig. 6 and 8.

- Connect hoses from the hand pump as shown in After operation
Fig. 6 and hydraulic diagram Fig. 8. After the lowering operation has been completed, reset
- Disconnect the pilot hose from connection P, un- the crane to “NOT EMERGENCY COUPLED“, wedge
loading unit 2127. Plug the disconnected hose. See valve 4332 must be closed and ball valve 2661 must
Fig. 6, 7, and 8. be open. See Fig. 6 and 9.
Check-restriction valve 2241-1 Connection P

Coupling
Pilot hose
Screw Bushing Piston
Fig. 7. Unloading unit 2127.
7 (12)
SERVICE 6.990.36 E rev.: i 2009-05-18
Note! Unloading unit 2127 -

connection P mec. affected.
3B
3A
Fig. 8. Hydraulic circuit, luffing. Emergency coupled.
8 (12)
SERVICE 6.990.36 E rev.: i 2009-05-18
Fig. 9. Hydraulic circuit, luffing. Not emergency coupled.
9 (12)
SERVICE 6.990.36 E rev.: i 2009-05-18
Slewing circuit, see Fig. 11 and 12
Connection Note!
- Install the hand pump 1A onto the base plate with The brake opens at approximately 1.2 MPa.
the screws provided. See Fig. 10.
- Connect the hoses from the hand pump as shown
Warning!
in Fig. 10 and hydraulic diagram Fig. 11.
If the crane is tilted, the brake must be released with
- Close ball valve 3661 and open wedge valve 4332.
great caution. If the speed increases too much, the
See Fig. 10.
brake can be activated by ceasing to pump or opening
ball valve 3661.
Operation
- Release the brake by pumping oil from the hand
After operation
pump.
After the slewing operation has been completed, reset
- The crane may now be slewed to a set position with
the crane to NOT EMERGENCY COUPLED. Wedge
the help of another crane. Use caution.
valve 4332 must be closed and ball valve 3661 must
be opened. See Fig. 10 and 12.
Quick-coupling 3664
Ball valve 3661
Wedge valve 4332
Plug*)
Quick coupling 4333
Hand pump 1A
T-coupling
To be plugged at
emergency operation
*) Plug included in pump set.
Fig. 10. Hand pump 1A connected to slewing machinery.
10 (12)
SERVICE 6.990.36 E rev.: i 2009-05-18
Fig. 11. Hydraulic circuit, slewing. Emergency coupled.
11 (12)
SERVICE 6.990.36 E rev.: i 2009-05-18
Fig. 12. Hydraulic circuit, slewing. Not emergency coupled.
12 (12)

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Örnsköldsvik MacGregor Sweden AB

To whom it may concern

Assembly and installation manual

for NB : Port Cranes Project No.: 2/15023.01LMW

Crane type: GL4536-2 Crane 1-3

Note that document 625/1467 E and protocols in M 2020-035 E should be returned to

MacGregor shapes the offshore and marine industries by offering world-leading

ASSEMBLY AND INSTALLATION MANUAL

MacGregor Ref Shipyard Hull No/Ship

Document description Specification no Rev. Crane no

Rust protection of components and

ASSEMBLY AND INSTALLATION MANUAL

MacGregor Ref Shipyard Hull No/Ship

Mechanical Assembly Drawings 15

Type of crane GL4536-2

Work order 2/15023.01LMW

Serial number 62516363- CRANE No. 1

Ambient temp range -25° to + 45° C

Hoisting capacity, MAX SWL 45 ton

Jib radius, Maximum 36 m

Jib radius, Minimum 5.0 m

Hoisting speed, high 0 - 18 T 24 m/min

Hoisting speed, low 18 - 45 T 15 m/min

Luffing time, Max - min radius 115 s

Slewing speed 0.7 rpm

Rated voltage 380 V

Type of frequency 3 Phase ~ 50 Hz

Control voltage 230 V

ELECTRIC MOTOR, Pump unit

Starting current 760 A

Hoisting winch, wire rope Ø 38 mm × 317.5 m

Luffing winch, wire rope Ø 32 mm x 260 m

OIL VOLUME / OIL FILLING (per unit)

Hydraulic oil tank 560 litres

Hoisting winch 42.0 litres

Slewing gear 11.0 litres

Luffing winch 9.5 litres

Limit Switches in Hoisting and Luffing Winch Systems

See instructions 6.320.401

Fig. 1. Load diagram

625 16 363 1 491 0019-801

625 16 366 1-3 1279236

Drawn by Order Specification No Rev Ind Sheet

Drawn by Order Specification No Rev Ind Sheet

Drawn by Order Specification No Rev Ind Sheet

Drawn by Order Specification No Rev Ind Sheet

Drawn by Order Specification No Rev Ind Sheet

Drawn by Order Specification No Rev Ind Sheet

Lifting block 288 1423-805 SWL 60 ton

Luffing wire rope

6rawn by Year Week Hull No/Ship -

Hydraulic Deck Cranes

Assembly procedure ................................................................................ 4

Operations that may be performed by shipyard personnel ................. 5

Operations that must be supervised by a MacGREGOR Cranes’

Recommended order of assembly .......................................................... 5

Preparatory quayside assembly ............................................................. 5

Onboard assembly (crane and jib) ......................................................... 8

Lifting an assembled crane (crane house and jib) on board .............. 12

Onboard assembly (assembled crane) ................................................ 13

Introduction Model designations

When receiving the crane at the shipyard, carefully

Carefully study the drawings provided with the