Instruction and Spare Parts Manual

NB: 0105801

IMO No.: L9730206

Crane type
GLBE3528-2/2828gr

Crane position
1, 2, 3 & 4

Project No.
2/14008.01LMW
 INSTRUCTION MANUAL Project No. Page
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TABLE OF CONTENTS
No. of manuals 6 pcs + 1 pc CD-ROM
Certificate for
crane issued by: GL
Certificate for
foundation issued by: GL
IMO No. L9730206
Name of ship -
Newbuilding No. 0105801
Shipyard New Times S/Y
Owners Frontmarine
Project No. 2/14008.01LMW
Mfg. No. 62515401 Crane-1, 62515402 Crane-2, 62515403 Crane-3, 62515404 Crane-4
Type of crane GLBE3528-2/2828gr
Order specification 490 9679-801 - 804 /F
Mechanical spec. 490 9680-801 - 804 /-
Hydraulic spec. 490 9682-801 - 804 /-
Electrical spec. 490 9681-801 - 804 /D
Slewing spec. 490 8883-801 /-

SAFETY DOCUMENTS
Document names written with bold letters are documents with safety aspects.
INSTRUCTION NO. REV NAME OF INSTRUCTION

GENERAL 1 1.000.6 E f SAFETY INSTRUCTIONS

1.005 E f PREFACE
1.009 E a GENERAL INSTRUCTIONS, CLEANLINESS IN HYDRAULIC SYSTEMS
1.102 E c CONVERSION FACTORS
1.518.3 ED d HYDRAULIC AND ELECTRIC SYMBOLS

TECHN. DESCRIP. 2 2/14008.01LMW - TECHNICAL DATA

2.007.107 E - TECHNICAL DESCRIPTION

FUNCTION 3 3.110.127 E d ELECTRIC FUNCTION

3.110.132 E d HYDRAULIC BRAKE FUNCTION
3.142.41 E d CRANE CONTROL SYSTEM CC3000
3.155.6 E - THERMOSTATIC CONTROLLED VENTILATION FAN AND HEATER ELEMENTS
3.155.7 E a HEATING AND COOLING OF CABINETS IN ELECTRIC CRANES
3.156.2 E b TILT WARNING SYSTEM TO PREVENT JACK KNIFE

OPERATION 4 PM40 1885-E00 d CREW CHECKLIST

PM40 5500-E00 b OPERATING INSTRUCTION
PM40 6504-E00 a OPERATION, START AND STOP
PM40 7707-E00 - CONTROLS & INDICATORS
PM41 0001-E - EMERGENCY ESCAPE INSTRUCTIONS
PM41 0014-E00 a EMERGENCY ESCAPE INSTRUCTIONS, ROPE LADDER/FIXED LADDERS
4.620.31 E a PARKING THE CRANE, SEA STOWING, GENERAL INSTRUCTION
4.630 E - HANDLING HATCHES BY DECK CRANE
 INSTRUCTION MANUAL Project No. Page
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TABLE OF CONTENTS
INSTRUCTION NO. REV NAME OF INSTRUCTION

MAINTENANCE 5 5.005.76 E b MAINTENANCE CHART

5.018 E c INSPECTION OF STRESSED COMPONENTS AND STRUCTURES
PM51 1742-E00 b LUBRICATING CHART
5.250.1 E a SLEWING BEARING STUDS
5.302.40 E b BRAKE UNIT
5.315.3 E a SAMPLING OF OIL TO VERIFY THE CLEANLINESS IN HYDRAULIC SYSTEM
5.421.63 E b LUBRICANTS FOR DECK MACHINERY

SERVICE 6

6.0 6.000 E f HOW TO ORDER SPARE PARTS

6.000.1 E c STATEMENT REGARDING DELIVERY OF SPARE PARTS TO SWIVELS, LIFTING B
6.000.2 E h RETURN FORM
6.004.1 E bc WORLDWIDE SERVICE NETWORK
6.005.10 E - INTRODUCTION

6.1 6.100.11 E a MEASURES BEFORE STARTING, DURING AND AFTER COMPLETED SERVICE/M
6.120.22 E c SLEWING GEAR
6.120.132 E - LUFFING WINCH
6.120.133 E - HOISTING WINCH
6.142.5 E a RECOMMENDATION FOR INSPECTION AND REPLACEMENT OF HYDRAULIC HO
6.189.2 E - HYDRAULIC BLADDER ACCUMULATOR

6.2 6.209.15 E a INSPECTION OF CLIMB PROTECTION, JIB AND CRANE HOUSE TOP
6.214.1 E a TIGHTENING TORQUES, STUDS/SCREWS AND BOLTS
6.215.21 E b SERVICE DOOR (OPENING AND CLOSING), SERVICE AND LUBRICATION OF DO
6.216.115 E - ROPE REEVING DIAGRAM FOR CRANES TYPE GLBE-2
6.222.1 E a HANDLING, INSTALLATION AND MAINTENANCE OF STEEL WIRE ROPES
6.223.26 E b REPLACEMENT OF WIRES, ONE OR TWO FALL RIGGING
625/1560 E g LIFTING BLOCK/BEAM
625/1579 E l MEASURING PROCEDURE FOR WEAR IN SLEWING BEARINGS FOR ROPE LUFF
625/1651 E b SLEWING BEARING GREASE SAMPLING PROCEDURE
625/1669 E - INDENTATION AND WEAR ON WIRE SHEAVES

6.3 6.303.66 E b TROUBLESHOOTING FOR CRANE CONTROL SYSTEM CC3000, ELECTRIC CRAN
6.303.61 E e CARD FRONT MENUS CT2, CC3000
6.303.67 E a ABSOLUTE ENCODER CALIBRATION, CC3000
6.306.7 E a INSTALLATION OF POWER SUPPLY CABLE AND CABLE FOR GRAB...
1000037602 - SIGNAL OVERVIEW, CRANE CONTROL SYSTEM CC3000
424 0739 k ERROR MESSAGES, CRANE CONTROL SYSTEM CC3000
1000004064 d INSULATION TEST, ELECTRICAL CRANE
6.305.19 E a ELECTRICAL EQUIPMENT, GENERAL MAINTENANCE
6.307.19 E - SLIP-RING UNIT
6.311.14 E b OIL LEVEL TEMPERATURE SENSOR, BRAKE UNIT
6.320.409 E b LIMITS FOR HOISTING AND LUFFING
6.321.18 E - SLACK WIRE SAFETY SWITCH, HOISTING AND LUFFING WINCHES
6.324.1 E b PREPARATION FOR OVERLOAD (OL) TEST MODE
6.324.2 E - PREPARATION FOR RIG MODE
6.990.61 E d EMERGENCY OPERATION IN CASE OF COMPLETE POWER FAILURE

EXTRA EQUIPMENT 7 7.075.12 E a MacHEAVYVISOR RELEASE 3.6

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TABLE OF CONTENTS
INSTRUCTION NO. REV NAME OF INSTRUCTION

EXTRA EQUIPMENT 7 7.076.2 E d USER MANUAL DISPLAY, CC PILOT XS

APPENDICES 8

SPARE PARTS 9 SEE SEPARATE TABLE OF CONTENTS

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TABLE OF CONTENTS
GROUP DESCRIPTION PART NUMBER FIG

9.0 HOW TO ORDER SPARE PARTS f 6.000 E

9.1 HOISTING WINSCH 1245850 A/- 625-1450.251

LUFFING WINCH 1245848 -/ 625-1450.252A
GEAR, COMPLETE 875 13019-168 -/ 625-1451.314
FLANGE, COMPLETE 875 13021-065 -/ 625-1451.316
DRIVE IN, COMPLETE 875 13004-216 -/ 625-1451.391
DRIVE IN 875 13004-217 -/ 625-1451.392
BEVEL GEAR, COMPLETE 1264802 -/ 625-1451.393
OIL TANK 1264810 -/ 625-1451.394
WINCH ASSEMBLY SET 1260705 -/ 625-2250.049
ASSEMBLY SET LUFFING W. MOTOR 1192483 -/ 625-1440.195
ASSEMBLY SET HOISTING W. MOTOR 1192647 A/ 625-1440.196A
SLEWING GEAR ASSEMBLY SET 391 0247-801 C/ 625-3254.024A
ASSEMBLY SET SLEWING W.MOTOR 1192648 -/ 625-3254.029
SLEWING GEAR 1206725 C/ 625-3255.043B
DRIVE IN, COMPLETE 875 13004-128 -/ 625-3256.008A
DRIVE IN, COMPLETE 875 13004-209 -/ 625-3256.027

9.2 BRAKE UNIT 1241416 -/ 625-4935.268

9.3 CRANE HOUSE ASSEMBLY 1260436 A/ 625-6102.681

SLEWING SPECIFICATION 490 8883-801 -/ 625-6122.062A
SLEWING BEARING MOUNTING 1205119 A/ 625-6123.005A
SLEWING BEARING YARD MOUNTING 1205120 -/ 625-6124.005A
COVER MOUNTING 390 3274-801 -/ 625-6169.005A
COVER ASSEMBLY 390 3282-801 -/ 625-6169.006
JIB BEARING ASSEMBLY 1212174 A/ 625-6170.104A
BEARING HOUSING ASSEMBLY 391 0468-801 A/ 625-6170.069
JIB TOP ASSEMBLY 1195437 -/ 625-6244.073A
LIMIT SWITCHES BOX 1212772 A/ 625-6245.707
LIMIT SWITCHES BOX 1212830 A/ 625-6245.708
SHAFT COUPLING, COMPLETE 875 15006-008 -/ 625-6246.001A
LIMIT SWITCH BOX, MOUNT. 489 6415-801 C/ 625-6248.001B
SLACK WIRE DEVICE 289 3396-801 B/ 625-6250.023
CRANE JIB, YARD MOUNTING 489 5409-801 C/ 625-6275.004C
MOUNT. WIRELOCK JIB TOP 1184729 -/ 625-6404.003A
LOAD CELL ASSEMBLY 1229076 -/ 625-6404.005
CRANE JIB ASSEMBLY 1195436 -/ 625-6408.115
CRANE TOP ASSEMBLY 1195407 A/ 625-6459.071A
PROTECTIVE PLATE MOUNT. 390 7581-801 -/ 625-6459.051
INCLINOMETER, C 388 0176-801 B/ 625-6509A
CAB INSTALLATION 1241263 -/ 625-6540.061
CABIN ASSEMBLY 1189585 -/ 625-6545.072
CAB CUPOLA ASSEMBLY 289 2251-801 A/ 625-6560.007B
CAB DOOR ASSEMBLY 390 8573-801 A/ 625-6546.008
EMERGENCY DOOR ASSY 390 4053-801 A/ 625-6546.001
WINDSCREEN CLEANER 1222876 -/ 625-6561.012
ROPE LADDER MOUNTING 390 4537-801 A/ 625-6562.017A
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TABLE OF CONTENTS
GROUP DESCRIPTION PART NUMBER FIG

9.3 VENTILATION FAN ASSEMBLY 1192902 -/ 625-6625.027

VENTILATION FAN 390 2115-801 D/ 625-6625.014A
LIFTING BLOCK 1205163 B/ 625-7013.123A
LOAD WIRE ROPE 1255643 -/ -
LUFFING WIRE ROPE 1261736 -/ -

9.4 VALVE UNIT 1204092 C/ 625-7207.018A

OIL FILTER 1259686 -/- 625-7314.017
DIRECTIONAL VALVE 1204093 B/ 625-7322.082
DIRECTIONAL VALVE 1224690 A/ 625-7322.097
PRESSURE SWITCH, C 387 7053-803 L/ 625-7444
BRAKE UNIT, PRESSURE SWITCHES 1238188 B/ 625-4935.261
ACCUMULATOR 1219345 -/ 625-7951.007
HYDRAULIC HOSES 625-7970G
TUBING BRAKE 1244170 A/ 625-7994.019
HYDRAULIC SYSTEM SPECIFICATION 1000042662 -/- 1000042662

9.5 DRIVERS DESK 1241214 A/ 625-8563.096

EL.INST.CRANE HOUSE 1212847 F/ 625-8564.023A
EL. INST. JIB LIGHT, CRANE 124 0647-801 B/ 625-8567.045B
EL. INST. JIB LIGHT (PACKING) 124 0648-801 C/ 625-8567.046D
CONTROLLER, C 314 2721-802 C/ 625-8595
CONTROLLER, LUFFING/SLEWING 314 2006-802 D/ 625-8592C
CONTROL PANEL 1243589 -/ 625-8596.004
CONTROL PANEL 1189898 -/ 625-8597.057
EL. INST. JIB LIGHT (CABIN) 324 2043-801 A/ 625-8597.061
EL. INST. FORCE LIMIT GRAB (CA 324 1724-801 A/ 625-8597.063
EL. INST. PMS (CABIN) 324 1723-801 A/ 625-8597.064
EL. INST. DECK LIGHT (CABIN) 324 1722-801 A/ 625-8597.062
CABIN DISPLAY ASSEMBLY 1182879 -/ 625-8597.081
EL. INST. TILT SWITCH (CAB) 324 2260-801 A/ 625-8597.088
EL.INST.AIR CIRCULAT FAN (CAB) 1213193 A/ 625-8597.090
EL. CABINET (CT14) 1189233 D/ 625-8598.110A
EL. CABINET (CT10) 1214611 -/ 625-8598.138
ELECTRICAL CABINET (CT13) 1214529 A/ 625-8598.139A
EL. CABINET (CT1/CT2) 1262672 A/ 625-8598.220
RELAY CARD WITH LED'S 324 0089-801 A/ 625-8599.020
CABINET CONTROL 1196427 C/ 625-8600.020
FILTER KIT (GLBE 30-36 TON) 1196564 -/ 625-8602.002A
EL. INST. IMPULSE RELAY 224 0116-801 A/ 625-8650.001
EL. INST. PMS ELECTRIC CABINET 224 0119-801 E/ 625-8650.003A
EL. INST. FORCE LIMIT GRAB CT1 224 0547-801 A/ 625-8650.005
BEVEL GEAR COOLING (CT1) 1250617 -/ 625-8650.067
COOLING, BEVEL GEAR (CT1) 1249005 A/ 625-8650.068
CABIN DISPLAY 424 0715-801 C/ 625-8655.001
CABIN DISPLAY ASSEMBLY 1182916 -/ 625-8655.009
ELECTRICAL EMERGENCY LIGHT 1240669 -/ 625-8655.014
ELECTRIC MOTOR, HOISTING 1255549 -/ 625-8635.021
ELECTRIC MOTOR, LUFFING 1255537 -/ 625-8635.022
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TABLE OF CONTENTS
GROUP DESCRIPTION PART NUMBER FIG

9.5 ELECTRIC MOTOR, SLEWING 1255533 -/ 625-8635.023

EL. INST. IMPULSE RELAY (CT1) 224 0511-801 -/ 625-8650.058
SLIPRING DEVICE 1241177 -/ 625-8750.031
MC-SPARE CARD 1194171 B/ 625-8760.001
CC-SPARE CARD 1194172 B/ 625-8760.002
POWER / CABLE CONNECTION 1000040795 A/ 1000040795
ELECTRICAL SYSTEM SPECIFICATION 1000042872 B/ 1000042872

9.7 MOUNTING ENCODER 390 9852-801 A/ 624-2180.015

ENCODER ASSEMBLY 1191997 A/ 624-2180.018A
ABSOLUTE ENCODER 324 1408-801 A/ 624-2180.023A
INCREMENTAL ENCODER 324 1409-801 A/ 624-2180.025A
EL INST. TILT SWITCH 1203126 -/ 624-2195.019
EL. INST. EMERG. STOP PEDESTAL 1202955 -/ 624-2196.008
JUNCTION BOX 1253706 A/ 624-2196.028A
HAND PUMP 189 6211-801 D/ 624-2498
LIFE LINE 388 0962-801 -/ 624-2501
FIRE EXTINGUISHER ASSEMBLY 1240026 -/ 624-2523.003
SERVICE 6.303.66 E rev.: b 2013-08-27

Troubleshooting Crane Control System CC3000

Electric crane GLBE

CT2 Cabinet

Contents
1. Description of input and output signals ............................................................................................. 2
2. Control system input and output signal levels................................................................................... 6
3. Troubleshooting for the control system............................................................................................ 8
4. Spare parts ....................................................................................................................................... 9

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SERVICE 6.303.66 E rev.: b 2013-08-27

Error MP SP

Display

Select / Info
Up
Down / Exit

Backplane

Fig 1. Crane Control System CC3000

Description of input and output signals

General the instruction manual, section "Spare Parts
The following description refers to the Manual", section 9.5.
microcomputer based crane control system
CC3000 for MacGregor hydraulic deck cranes.

Minor variations in the use of control system input

and output signals due to differences in hydraulic
and electric system may occur, the objective of this
description is only to provide a general orientation
concerning the principles of control system
interface signals and of troubleshooting.

For a general description of the principles of the

Crane Control system CC3000 see "Function",
chapter 3. For detailed information about the
control system a complete electric circuit diagram,
relating specifically to your crane, will be found in

2 (10)
SERVICE
Power supply, Control system operation
The power supply transforms the input
380/400/440V AC to 24V DC. See Fig. 2.
It consists of a three-phase power supply. The
output 24V DC is divided into two supplies, one for
the control system and its output signals (terminal
48) and one for the limit switches, pressure
switches (terminal 42). There are fuses on each
supply in the CT1 cabinet.
The 0V level for 24V DC is grounded in power
supply unit.
Fig. 2. CC3000 Power supply principle.
6.303.66 E rev.: b 2013-08-27
Power supply, Control system anti-
condensation heating
The anti-condensation heating in CT2 cabinet is
powered with 24V DC when the control system is
switched off and the crane is not in operation. A
separate power supply is used for all anti-
condensation heating in the crane.
A separate power line feeds the power supply.
3 (10)
SERVICE 6.303.66 E rev.: b 2013-08-27

Control levers - potentiometers, outputs to and Control levers - direction signal inputs
inputs from The control lever for hoisting selects two out of four
The control levers linear potentiometers are fed 24V direction signals, for selection of
with 0V, +6V and +12V from their appropriate MC hoisting/lowering. See Fig. 3. The control lever for
and CC card. The potentiometer output is approx. luffing/slewing gives two out of four 24V direction
+6V with the lever in neutral. The output signal is signals for selecting luffing in/luffing out and
controlled by the lever and is depending on the slewing left/slewing right.
direction of lever movement. The output signal is
increased to approx. +10.5V for maximum speed
hoisting, luffing in, and slewing left respectively.
The output signal is decreased to approx. +1.5V for
maximum speed lowering, luffing out, and slewing
right respectively.

Fig. 3. Control lever signals, hoisting movement

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SERVICE
Brake release outputs
Each MC card has an output driver for the brake
release signal. The system is capable of detecting
short-circuited output and then giving an error-
message, see sign ERROR MESSAGES.
6.303.66 E rev.: b 2013-08-27
Lamp output "Control System Error in CT2"
The LED no 28 on the CC Card are wired to a lamp
in crane operator's cabin. The first time an error
occurs, the lamp flashes. When the error is
acknowledged by pushing the Select/Info push-
button on the appropriate MC or CC card the lamp
is on if the error remains or out if the error is not
present for the moment. See page 9 “Error
message codes from CC3000” for detailed
information about error messages.
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SERVICE 6.303.66 E rev.: b 2013-08-27

Control system input and output signal levels

Power for control system input and output CT2-X10:48

+24V. 0V, connected to ground.
signals CT2-X10:50
CT2-X10:42
Power for limit switches, pump servos, etc +24V. 0V, connected to ground.
CT2-X10:50
CT2-X10:44 24V AC, powered when crane
Anti-condensation heating -
CT2-X10:46 stopped.
Parking of jib CT2-X10:109
CT2-X10:201 +12V from MC "Ho"
Outputs to control lever potentiometer hoisting CT2-X10:202 Ho +6V from MC "Ho"
CT2-X10:203 0V from MC "Ho".
Analogue input signal 1.5 to
Control lever potentiometer input hoisting CT2-X10:204 Ho
10.5V with 6V in neutral position

Control lever direction inputs hoisting 24V when control lever actuated
CT2-X10:207 Ho
Hoisting hoisting
CT2-X10:208 Ho
Lowering lowering

CT2-X10:301 +12V from MC "Lu"

Outputs to control lever potentiometer
CT2-X10:302 Lu +6V from MC "Lu"
Luffing
CT2-X10:303 0V from MC "Lu"
Analogue input signal 1.5 to
Control lever potentiometer input signal luffing CT2-X10:304 Lu 10.5V with 6V in neutral
position.
Control lever direction inputs slewing 24V when control lever actuated
Luffing In CT2-X10:307 Lu luffing in
Luffing Out CT2-X10:308 Lu luffing out
CT2-X10:401 +12V from MC "SL"
Outputs to control lever potentiometer slewing CT2-X10:402 SL +6V from MC "SL"
CT2-X10:403 0V from MC "SL"
Analogue input signal 1.5 to
Control lever potentiometer input signal slewing CT2-X10:404 SL 10.5V with 6V in neutral
position.
Control lever direction inputs slewing 24V when control lever actuated
CT2-X10:407
Slewing Left SL slewing left
CT2-X10:408
Slewing Right SL slewing right
Brake #1 open
Ho
Hoisting CT2-X10:230 24V, max. 2A, open circuit gives
Lu
Luffing CT2-X10:330 error message.
SL
Slewing CT2-X10:430
Brake #2 open
Ho
Hoisting CT2-X10:231
Lu
Luffing CT2-X10:331
SL
Slewing CT2-X10:431
Limit switch inputs hoisting 24V at normal operation, 0V at
CT2-X10:214
Hoisting Ho limit. At limit movement is
CT2-X10:215
Lowering, slack wire stopped and brake closed.
Limit switch inputs luffing CT2-X10:314 Lu 24V at normal operation, 0V at

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SERVICE 6.303.66 E rev.: b 2013-08-27

Luffing In CT2-X10:315 limit. At limit movement is

Luffing Out, slack wire stopped and brake closed.
Limit switch inputs slewing 24V at normal operation, 0V at
CT2-X10:414 SL
Slewing left limit. At limit movement is
CT2-X10:415
Slewing right stopped and brake closed.
CT2-X10:256 Ho
Slack wire
CT2-X10:356 Lu
24V outputs wired together to
Output “Error in control system CT2” CT2-X110:128 Sc
error lamp in driver’s cabin.
Ho 24V when the hoisting pressure
Output for "Hoisting Overload" indication lamp CT2-X10:255
Lu exceeds adjusted value.
Tilt switch, Jack-knife CT2-X11:351 Lu 24V (Optional)
CT2-X10:259 Ho
Klixon High Motor temperature CT2-X10:359 Lu 24V
CT2-X10:459 SL
Brake low oil temp CT2-X11:452 SL 24V

Brake low oil level CT2-X11:456 SL 24V

Overload test CT2-X10:107 Sc 24V

Rig mode CT2-X10:108 Sc 24V

Cooling fan #1 CT2-X11:354 Lu
24V
Cooling fan #2 (if needed) CT2-X11:454 SL
Brake failure lamp CT2-X10:138 Sc 24V
CT2-X10:217 Sc 24V
Derating (Limiting) of high speed movement for
CT2-X10:317 Sc 24V
hoisting, luffing and slewing
CT2-X10:417 Sc 24V
Backplane Card
Temperature Cabinet CT10 Sc:AI3
Temperature Cabinet CT13/ Ho:AI3
Temperature Cabinet CT14/ Lu:AI3
Temperature Cabinet CT2 Sl:AI3
Ho:SSI
Absolute encoder Lu:SSI
Sl:SSI
Ho:Sp
Incremental encoder Lu:Sp
Sl:Sp
Sc:C1
Ho:C1
FQC
Lu:C1
SL:C1

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SERVICE 6.303.66 E rev.: b 2013-08-27

Troubleshooting the Crane Control system

General
Troubleshooting Chart
This section provides information for identifying and
When troubleshooting a malfunction: Locate the
correcting malfunctions, which may develop while
symptom or symptoms that best describes the
operating the cargo crane. Before performing
malfunction. If the appropriate symptom is not
troubleshooting, read and follow all safety
listed, notify your supervisor.
instructions found in section "General", section 1, of
this manual. This chapter cannot list all
Read this section in conjunction with the electrical
malfunctions that may occur, nor all inspections
and hydraulic diagrams in “Spare Parts Manual” in
and corrective actions. If a malfunction is not listed,
section 9.4 and 9.5.
or is not corrected by the listed corrective actions,
notify your supervisor.

Troubleshooting the
Crane Control System
CC3000.

Crane movement Crane movements function but the lamp

malfunction. "Control System Error" in driver's cabin
is flashing or on.

Check the lamps "Control

System Error CT2" in
driver's cabin.

Both lamps One or both lamps are Check the error code in
are off. flashing or on. Control System cabinet
CT2.

Check 24V power Check limit switches,

supply, see page 9. joysticks, see page 9.

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SERVICE
Checking Power supply 24V DC in CT2 cabinet
See page 3 for explanation of the power supply
function.
 Check over-current relay F3 in cabinet
CT1.
 Check fuse F16 in CT1 for 24V in terminal
48 in CT2 cabinet.
 Check fuse F17 in CT1 for 24V in terminal
42 in CT2 cabinet.
 Check relay K34 in cabinet CT1, see
electric circuit diagram.
 No LED and display readout on MC card
indicates missing 24V in terminal 48.
Checking Limit switches and Joysticks
Check Limits
 No LEDs on and no display readout -
indicates missing 24V in terminal 48.
 Check for Red LEDs - indicating stop limits.
 Check for Yellow LEDs - indicating speed
reduces.
 Check electric cable connections for limit
switches.
 For checking and adjustment of limit
switches see instruction for “Limit Switches
in Hoisting …” in "Service", section 6.3.
Check control lever (joystick)
See page 4 for explanation of the control lever
functions.
 Check for missing Green input signal LEDs
- from joystick.
 Check electric cable connections to control
lever.
 Check analogue input signal from joystick
potentiometer.
 Check for missing Green output signal
LEDs: Exchange the MC card with other
movement MC card. Replace broken MC
card with a new one.
Error message codes from CC3000
If the error from the CC3000 has no influence on
the performance of the crane the “control system
error” lamp in the driver’s cabin will not flash.
With the crane still running, the following steps are
necessary to obtain the error code(s).
6.303.66 E rev.: b 2013-08-27
Spare parts
MC card and CC card
When ordering a MC or CC card do one of the
following:
Look for:
- The software version and the hardware
specified on both handles on the replaced card.
or
- refer to the crane's mfg. no., which can be found
on the sign in crane operator's cabin.
or
- Refer to section 9.5 in the “Spare Parts Manual”.
Customers that purchase a replacement card will
receive a credit note of 40% of the sales price
when the damaged card has been returned to
Cargotec Sweden AB, MacGregor Cranes
according to section “Return Report” below.
Parameter Memory Card
The parameter Memory Card is individually for
each crane. Each parameter Memory Card needs
to be programmed with the crane's unique
parameter values. When ordering a parameter
Memory Card always specify the manufacturing
number (Mfg. no.) of the crane, which can be found
on the sign in the crane operator's cabin.
The programmed Memory Card delivered by us,
will be labelled with the crane mfg. no.
Return report
It is essential that the service department gets
information about when and why the card is
removed from the crane system. Fill out the “Return
Form”, see section 6.0 “Service”, and send it back
with the exchanged card.
Conductive transit boxes
To protect all types of electronic cards from
damages from ESD (Electro Static Discharge) it is
important to use pink anti-static plastic bags and
conductive transit boxes of the same type as used
for delivered original spare parts.
9 (10)
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10 (10)
            
   
SERVICE 6.303.61 E rev.: e 2013-06-19
   
 
Card front menus CT2, CC3000
 

General Depending of crane type there can be

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

1 

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.: e 2013-06-19
   
 
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.: e 2013-06-19

Values
Sc Ho Lu Sl Au Cl Ec LL TL TR IO

JOY Joystick % ● ● ● ● ● ● ● ● ● ● ●
AN1 Jib angle degrees (360) ● ● ● ●
AN2 Winch 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 ●
PW0 PWM0 mA ● ● ● ● ● ● ● ● ●
PW1 PWM1 mA ● ● ● ● ● ● ● ● ●
PW2 PWM2 mA ● ● ● ● ● ● ● ● ●
PW3 PWM3 mA ● ● ● ● ● ● ● ● ●
PW4 PWM4 mA ● ● ● ● ● ● ● ● ●
AI1 "Parameter" Parameter value ● ● ● ● ● ● ● ● ● ● ●
AI2 "Parameter" Parameter value ● ● ● ● ● ● ● ● ● ● ●
AI3 "Parameter" Parameter value ● ● ● ● ● ● ● ● ● ● ●
AI4 "Parameter" Parameter value ● ● ● ● ● ● ● ● ● ● ●
AI5 "Parameter" Parameter value ● ● ● ● ● ● ● ● ● ● ●
CAR Card Temperature Degrees ●

 Push Select/Info to see the MFG-

6. VER - SOFTWARE VERSION
number
Software Version makes it possible to
read the version of the software. This will
also appear at “ power on”.
 Push Select/Info to enter menu tree.
 Push Down/Exit until the display shows
VER.
 Push Select/Info to select Version
Mode

7. MFG – MANUFACTURING NUMBER

From software version CC3K H04.00 it is
possible to see the manufacturing number
of the crane.
 Push Select/Info to enter menu tree.
 Push Down/Exit until the display shows
MFG.

3 (4)
SERVICE 6.303.61 E rev.: e 2013-06-19

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4 (4)
SERVICE 6.303.67 E rev.: a 2013-08-30

Absolute Encoder Calibration, CC3000

General Preparation of minimum outreach luffing

Absolute encoders are used for position control purpo-
ses. Each encoder gives an accurate position feedback
to the control system.
The encoder calibration has to be done when the wire
or the absolute encoder has been replaced.
Absolute encoders for hoisting and luffing winches
are installed in the limit switch box or on jib bearing.
For slewing motion the absolute encoder is mounted
under the crane towards the slewing bearing.
WARNING! Always use safety belt when measuring
the MV distance.
To operate the crane in Rig mode see instruction
"Preparation for Rig Mode" in section 6.3.
WARNING!
When the crane is operated in Rig mode the crane
has no software limits.
It is not permitted to have any load in the hook.
Inappropriate use may cause severe damage to the
crane and bodily injury.

Center line of crane house

MV
(m
m)
MV distance

First jib stay

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.

1 (4)
SERVICE 6.303.67 E rev.: a 2013-08-30

- Activate Rig mode.

- Carefully position the minimum outreach until the
MV distance is achieved.
Caution! Do a visual inspection of the distance
between the front of the crane house and the first
jib stay on jib. AL
- Measure the MV distance on top of the crane
house, see Fig. 1, refer to table in Technical Data,
section 2.
- Calibration of the encoder in cabinet CT2, see
Table 1, page 4.
- Adjust the limit switch for "Min Outreach", see
instruction "Limit Switches and Software Limits
..." in section 6.3 and table "Limit switches - luffing
winch" in Technical Data, section 2. Fig. 2. Definition of "AL" hoisting winch.
- Luff out a few meters and stop.
- Exit Rig mode by stopping the crane and switch
the key switch to Normal.
- Luff in until the jib stops at "Min Outreach".
- Recheck the MV distance.

Preparation of hoisting

- Activate Rig mode.

- Start to operate the crane to definition "AL"
(hoisting winch), see Fig. 2, refer to table "Limit
switches - hoisting winch" in Technical Data, sec-
tion 2.
- Measurement to be done in front of the hoisting
winch, from the empty drum flange to the side of
the wire.
- Adjust the limit switch for empty drum. Hoist the
hoisting wire a few meters and stop. Lower the
wire until it stops at position empty drum, i.e. at
least three locking turns or tank top.
- Calibration of the encoder in cabinet CT2, see
Table 1, page 4.
- Exit Rig mode by stopping the crane and set the
key switch to Normal.

2 (4)
SERVICE 6.303.67 E rev.: a 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 cabinet CT2, see
Table 1, page 4.

0°

Fig. 3. Reference points.

3 (4)
SERVICE 6.303.67 E rev.: a 2013-08-30

Calibration of encoders in cabinet CT2

Hoisting Luffing/slewing
Operation of rig mode see instruction "Preparation To calibrate the encoder on the other cards proceed
for Rig Mode" in section 6.3. in the same way as in items 1, 2, 3, and 4 in above
paragraph except for choosing the corresponding card.
1. Push the "Select/Info" button on the front of the
MC-card which you want to calibrate, for example
Ho-card. The display on the Ho-card shows "ER-
ROR".
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 cabinet CT2. The display in the Ho-card then
flashes and shows "ANG".
4. Push the "Select/Info" button on the Ho-card.
Angle encoder is calibrated in this position.

Table 1. Encoder calibration modes

Function/ Purpose Calibration position

Mode
Ho Zero position of hoisting winch Empty drum, at least three locking turns (AL).
Lu Zero position of luffing winch Full drum, min. outreach, MV distance.
SL Zero position of slewing Aim crane jib straight ahead for 0°.

Display

ENCODER
CALIBRATION
button

Select/Info
button
Up button
Down/Exit
button

Fig. 4. Cabinet CT2, CC3000.

4 (4)
SERVICE
Installation of Power Supply Cable
and
Cable for "Grab Control Equipment", Interlock
General
Preparations for installation of the "grab control equip-
ment", are made in all cranes to get an interlock con-
nection between the external mounted "grab control
equipment" and MacGregor Cranes' safety functions.
Some preparations are done in the cabinet CT1 and
on control panel (CT3) in cabin. The two-position key
switch "Cargo/Grab Handling" which is adaptable to
the "grab control equipment", see instruction "Controls
and Indicators", section 4.
Connection of the power supply cables.
Main switch Q1
Fig. 1. Cabinet CT1.
6.306.7 E rev: a 2011-10-27
Installation of power supply cable for
"grab control equipment"
The power supply cable to the "grab control equip-
ment" needs to be connected as shown in Fig. 1. To
protect the "grab control equipment" we recommend
that the power supply cables are connected after the
main switch Q1 and fuse switch disconnector F1 in
the cabinet CT1, see Fig. 1.
K59
Fuse switch disconnector F1
1 (2)
SERVICE 6.306.7 E rev: a 2011-10-27

Contactor relay K59

To energize the contactor relay K59 in cabinet CT1,see

Fig. 1, the two-position key switch "Cargo/Grab Hand-
ling" must be in position 2, "Grab", to get reduced SWL
for operation with grab. See instruction "Controls and
Indicators", section 4.

Grab control equipment

When the cranes have a "grab control equipment"

make sure that:
- The electrical installation is done refer to the elec-
trical circuit diagram valid for the crane
- The two-position key switch "Cargo/Grab Handling"
is in position 2, "Grab", to reduce SWL for operation
with grab.

See instruction "Controls and Indicators", section 4.

2 (2)
 Page Date
SIGNAL OVERVIEW Electrical Crane 1 (2) 2013-11-18
No Revision
Crane Control System CC3000 1000037602 -

LEDs - 24V Input/Output signals are indicated with coloured LEDs

.Colour Indicating LEDs on LEDs within the COM box are external communication and
when communication with Main Processor (MP).
Green Normal inputs and outputs +24V The external communication LEDs are blinking when
Yellow 11,12 Speed reduce limits 0V transmitting data in one direction and is lit when data is
transmitted both ways.
Yellow 17,18 Speed reduction switches +24V Software
Red Limit switches, low pressure, 0V Sw before “LED No” means Software (Yellow- Speed Limit,
slack wire and overload Orange- Motion Blocked, Red- Stop).
External communication

SC – Supervisory Ho – Hoisting
CC Card MC Card
Hardware LED Signal Description Type Plinth Hardware LED Signal Description Type Plinth
324 1670-901 324 1665-901
No No No No
07 Overload test DI 107 07 Hoisting, input DI 207
08 Rigging mode DI 108 08 Lowering, input DI 208
09 Parking of jib DI 109 09 DI 209
10 Mode D (Log) DI 110 10 DI 210
11 Mode A (Container) DI 111 11 DI 211
12 Mode B (Grab) DI 112 12 DI 212
13 Mode C (Hatch C.) DI 113 14 Limit switch hoisting DI 214
16 Power Limit toggle DI 116 Sw14 Speed reduce, stop, block Sw
on/off 15
17 DI 117 15 Limit switch lowering DI 215
18 DI 118 17 Speed reduction, ext1 DI 217
19 119 18 Speed reduction, ext2 DI 218
20 120 19 DI 219
26 Run enable in DI 126 20 DI 220
27 Run enable out DO 127 Sw20 Overload load cell/pressure Sw
28 Alarm (error in CT2) DO 128 26 Run enable in DI 226
29 Ready to run DO 129 27 Run enable out DO 227
30 Twin not synch. DO 130 29 Indication Speed reduce/stop DO 229
31 131 30 Hoisting brake 1, output DO 230
32 132 31 Hoisting brake 2, output DO 231
33 ARC Cabin A Lamp DO 133 32 DI 232
34 ARC Cabin B Lamp DO 134 33 PWM 233
35 ARC 180 deg. DO 135 34 PWM 234
rotation
36 ARC Run enable out DO 136 36 PWM 236
37 137 37 PWM 237
38 Brake Failure lamp DO 138
39 139 39 PWM 239
40 140 40 PWM 240
49 149 43 PWM 243
51 151 45 PWM 245
53 153 49 Angle Check Cam DI 249
56 Twin on DI 156 51 251
57 Calibration DI 157 52 252
58 Twin reset DI 158 53 VFD Run enable out DO 253
59 Deadman Handle DI 159 54 254
60 Em. op. request DI 160 55 Indication Overload DO 255
61 Em. op. activated DO 161 56 Slack wire DI 256
24 V Power supply +24V Sw56 Slack wire from LU Sw
C1 CAN1 (ALM) Com Sc_C1 57 Brake Open Indication DI 257
C2 CAN2 (Cabin display) Com Sc_C2 58 Ext stop 1 DI 258
C3 CAN3 (PLC) Com Sc_C3 59 Ext stop 2 DI 259
El.motor high temp
C4 CAN4 (Power Com Sc_C4 C1 CAN1 (VFD) Com Ho_C1
Software
Software limitation) CC3K H01_00
CC3K H01_00 R1 RS485_1 (Remote) Com Sc_R1 Rev B C2 CAN2 Com Ho_C2
Rev B
R2 RS485_2 (Twin) Com Sc_R2 R1 RS485_1 Com Ho_R1
R3 RS485_3 (ALM) Com Sc_r3 MP Internal communication
MP Internal Com
communication
 Page Date
SIGNAL OVERVIEW Electrical Crane 2 (2) 2013-11-18
No Revision
Crane Control System CC3000 1000037602 -

LEDs - 24V Input/Output signals are indicated with coloured LEDs

.Colour Indicating LEDs on LEDs within the COM box are external communication and
when communication with Main Processor (MP).
Green normal inputs and outputs +24V The external communication LEDs are blinking when
Yellow 11,12 speed reduce limits 0V transmitting data in one direction and is lit when data is
transmitted both ways.
Yellow 17,18 Speed reduction switches +24V Software
Red limit switches, low pressure, 0V Sw before “LED No” means Software (Yellow- Speed Limit,
slack wire and overload Orange- Motion Blocked, Red- Stop).
External communication

Lu - Luffing Sl - Slewing
MC Card MC Card
Hardware Type Plinth Hardware Type Plinth
324 1665-901 LED Signal Description 324 1665-901
LED Signal Description
No No No No
07 Luffing in, input DI 307 07 Left, input DI 407
08 Luffing out, input DI 308 08 Right, input DI 408
11 DI 311 11 DI 411
12 DI 312 12 DI 412
14 Limit switch luffing in DI 314 14 Limit switch left DI 414
Sw14 Speed reduce, stop, Sw Sw14 Speed reduce, stop, block Sw
15 block 15
15 Limit switch luffing out DI 315 15 Limit switch right DI 415
17 Speed reduction, ext1 DI 317 17 Speed reduction, ext1 DI 417
18 Speed reduction, ext2 DI 318 18 Speed reduction, ext2 DI 418
19 DI 319 19 DI 419
20 DI 320 20 DI 320
26 Run enable in DI 326 26 Run enable in DI 326
27 Run enable out DO 327 27 Run enable out DO 327
29 Indication Speed DO 329 29 DO 329
reduce/stop
30 Luffing brake 1,output DO 330 30 Slewing brake 1, output DO 430
31 Luffing brake 2,output DO 331 31 Slewing brake 2, output DO 431
32 32 432
33 PWM 333 33 PWM 433
34 PWM 334 34 PWM 434
36 PWM 336 36 PWM 436
37 PWM 337 37 PWM 437
39 PWM 339 39 PWM 439
40 PWM 340 40 PWM 440
43 PWM 343 43 PWM 443
45 PWM 345 45 PWM 445
49 Angle Check Cam DI 349 49 Angle Check Cam DI 449
51 Jack-knife DI 351 51 Remote on DI 451
52 352 52 Brake low oil level warning DI 452
53 VFD Run enable out DO 353 53 VFD Run enable out DO 453
54 Cooling fan #1 DO 354 54 Cooling fan #2 DO 454
55 Indication Overload DO 355 55 DO 455
56 Slack wire DI 356 56 Brake low oil level stop DI 456
57 Brake Open DI 357 57 Brake Open Indication DI 457
Indication
58 Ext stop 1 (Deadman DI 358 58 Ext stop 1 DI 458
Handle, Winch Temp) (Luffing Slewing limit off)
59 Ext stop 2 DI 359 59 Ext stop 1 DI 459
(El.motor high temp (Luffing Slewing limit off)
Software Klixon) (El.motor high temp Klixon)
CC3K H01_00 Com Com Sl_C1
Rev B C1 CAN1 (VFD) Lu_C C1 CAN1 (VFD)
1 Software
CC3K H01_00
C2 CAN2 (ARC angle Com Lu_C Rev B C2 CAN2 (ARC Angle Cabin) Com Sl_C2
swivel) 2
R1 RS485_1 (ARC gyro) Com Lu_R R1 RS485_1(Outdoor display) Com Sl_R1
1
MP Internal Com MP Internal communication Com
communication
 ERROR MESSAGES Page Date
1(2) 2014-03-25
Crane Control System CC3000 No Revision
424 0739 K

Error message codes from CC3000 Abbreviations: VFD = Variable Frequency Drive
With the crane still running, the following steps are necessary to obtain ALM = Active Line Module
the error code(s). Error code Description
Important!!! 01 S ys t e m E r r o r s
Before reporting error to nearest MacGregor Service 01_01 to 01_15  Contact nearest MacGregor Service Station
Station, please look for the error code in the display of 01_12 System Software version mismatch
the MC or CC card.  Check the software version in the cards
1. Open the control system cabinet and look for the 02 MC or CC Card
card with the flashing LED “error MP” or “error SP” 02_01 to 02_61  Restart system or replace the card
on top of the cards.  Contact Cargotec in Örnsköldsvik
2. Push the “Select/Info” button once on the card with 03 Safety processor
error LED flashing. An error code (e.g. E51_11) is 03_01 to 03_91  Contact Cargotec in Örnsköldsvik
shown on the display on the card. 10 MEM card
3. Hold on pressing “Select/Info” button, the 10_10  Replace the MEM card
description of this error will be rolling on the  Contact Cargotec in Örnsköldsvik
display. Release the button, the description 11 Parameters
disappears and the error code is shown. 11_01 to 11_30  Contact Cargotec in Örnsköldsvik
24 24V Supply Voltage
24_01 to 24_04  Check 24V supply
Hardware Hardware
30 J o ys t i c k
Hardware Hardware
324 1665-901 324 1665-901
30_01 Joystick level, normally 1.25 V to 11.75 V.
324 1670-901 324 1665-901

Item 1.
Encoder  Check connection to joystick
Error MP/SP
Calibration  Check switches/cam in joystick
 Measure potentiometers in joystick
30_02 Joystick logic error for “Lowering”, “Luffing Out” or
“Slewing Right” movement.
30_03 Joystick logic error for “Hoisting”, “Luffing In” or
“Slewing Left” movement.
30_04 Joystick is not in zero position when system starts.
31 An g l e E n c o d e r
Display 31_01 Angle encoder communication error
 Check angle encoder connection
 Replace the angle encoder
Item 2,3,4 & 5
31_02 Angle shaft coupling
Buttons
 Check angle encoder connection
Select/Info
Up  Replace the angle encoder
Down/Exit 31_03 Angle encoder or speed encoder error
Software
CC3K H01_00
Rev B
Software
CC3K H01_00
Rev B
Software
CC3K H01_00
Rev B
Software
CC3K H01_00
Rev B
 Replace the angle encoder or speed encoder
 Contact Cargotec in Örnsköldsvik
31_04 Angles at CAM control place mismatch.
4. Continue to press “Select/Info” or “Down/Exit” button once to  Check angle encoder cable and connection
see the next error and so on.  Replace the angle encoder
5. Pressing “Up” button once to show the previous error and so  Calibrate encoder again.
on.
 Contact MacGREGOR Cranes in Örnsköldsvik
6. When there are no more error messages, the display shows
31_05 Shaft not connected
three hyphens “---”. When all errors have been shown on the
display, the error LED is either on or off. 31_11 Different angle values when more than one
31_12 encoder for luffing.
31_13 (Only on Sc-card).
31_51 to 31_53 Power Swivel angle encoder
31_54 to 31_57 ARC angle encoder in cabin
32 Speed Encoder
32_01 No data from speed encoder
 Check speed encoder cable and connection
 Replace a new speed encoder
 Exchange cards
32_02 VFD or CC3000 encoder
32_03 Wrong speed direction
 Change speed encoder direction or shift cable
connection (switch A and B)
 Replace the speed encoder
 Exchange cards
 Contact Cargotec (MacGregor) in Örnsköldsvik
32_04 VFD encoder
32_05, 32_06 Encoder error
32_10 No data from speed encoder

33 Weight
 ERROR MESSAGES Page Date
2(2) 2014-03-25
Crane Control System CC3000 No Revision
424 0739 K

33_01 Loadcell 49_01 to 49_07 A1, A2, A3, A4, A5, A6, A7
 Check loadcell cable and connection  Check cable, connection
 Replace the loadcell  Check sensor
 Contact Cargotec in Örnsköldsvik  Replace the MC or CC card
33_02 Pressure
33_03 Loadcell Check 50 Displacement
33_04 Torque 50_11, 50_21 Open circuit (Low speed, high speed, unloading,
33_07 Load system, in EO 50_31, 50_41 plussing valve [LC])
33_11 Difference Loadcell  Check cable and connection
33_12 Difference Pressure 50_12 Short circuit (Low speed, high speed, unloading,
33_13 Difference Loadcell check 50_22, 50_32 plussing valve [LC]))
33_14 Diffeerence Torque 50_42  Check output cable is not connected to
0V(ground)
33_31 Outreach, angle Lu
 Replace the MC or CC card
33_32 Outreach, angle Sc
50_13, 50_23 Transistor (Low speed, high speed, unloading,
33_33 Outreach, angle Sc speed
50_33, 50_43 plussing valve [LC]))
33_37 Outreach, in EO
 Check cable and connection
33_41 Change to Main not possible
 Replace the MC or CC card
33_42 Change to Whip not possible
50_24 High speed valve
35 Temperature
50_34 No plussing pressure
35_01, 35_02 MC card temperature is too high
 Power off system 51 Brake
 Contact Cargotec in Örnsköldsvik 51_11, 51_21 Open circuit
35_11 ALM high temp  Check cable and connection
35_12 VFD high temp 51_12, 51_22 Short circuit
35_13, 35_41 Electric motor high temp  Check output cable is not connected to
35_14, 35_42 Hydraulic oil high temp 0V(ground)
35_15, 35_43 High temp  Replace the MC card
35_16 Air intake high temp 51_13, 51_23 Transistor
35_44 Winch oil high temp  Check cable and connection
35_45 Braking resistors overheated  Replace the MC card
36 Power 51_14, 51_24 Control Circuit
36_01, 36_02 High current 51_15, 51_ 25 VFD Brake output
36_03 No data from power sensor 51_31 Read back (pressure or switch)
37 Limit 51_32 Closed (pressure or switch)
37_01 to 37_06 Limit error at stop cam 51_33 Closing failure
 Check stop cam connection or switch 51_34 Slip
37_10 Limit: Software limits 51_50 to 51_52 Low oil level or temp error
37_21 Limit: Luffing Slewing 51_60 Low pressure
37_22 Limit: Anticollision 52 Pump
38 Run Enable 52_01 to 52_05 Pump PWM current
38_01 Run enable: No input on terminal X26 52_11 to 52_14  Check that PWM output is not connected to
38_02 Run enable: Terminal X26 is always set 0V(ground)
38_03 Run enable: No run enable in  Check that cable is not broken
38_04 Run enable: Team  Replace the MC card
39 Feed pressure 53 VFD
39_01, 39_02 Low feed pressure 53_01 to 53_50 VFD
39_03 High feed pressure 54 AL M
40 Lubrication 54_01 to 54_06 ALM
40_01, 40_02 Lubrication 55 Stab Winch
41 Power limitation 55_01 to 55_04 Stab winch
and 55_40
41_01 to 41_04 Power limitation
56 Power Swivel
45 External IO
56_01 to 56_23 Power Swivel
45_01 to 45_36 External IO
and 56_40
48 Motion Sensor
62 Twin
48_01, 48_02 Power swivel
62_01 No data from Slave
48_11, 48_12 Swing
62_02 Error in Slave
48_21, 48_22 Ship
62_10 to 62_14 Angle error Master Ho, Lu, Ll, Tr
62_20 to 62_24 Angle error Slave Ho, Lu, Ll, Tr
63 Team
63_01 to 63_05 Team
70 Speed
70_10 Speed control deviation
70_20 Variable Frequency Drive zero speed timeout

49 External analogue in
 INSTRUCTION
INSULATION TEST
ELECTRICAL CRANE

1 PREPARATION LIST
Before applying high voltage anywhere in the electric system, all electronic systems need to be
prepared according to the preparation list below.
1.1 CT1 Cabinet
 Switch off all circuit breakers.
 Transformers (T1, T2, T3 a.s.o.)
Disconnect all kind of fuses.
Disconnect all earthing cables.
 Power supplies (U1, U2, U3 a.s.o.)
Disconnect all contacts on power supply.
 Safety relay (K99)
Disconnect earthing cable.
1.2 CT2 Cabinet
Disconnect (pull out) all MC- and CC-cards on the CC3000 19" rack.
Disconnect the cables from terminal X10:48 & 50 (internal side) up to backplane card (Two red and
2
two black 2,5 mm ).
Disconnect all cables connected on the backplane card (used for different encoders).
Disconnect (pull out plinth, Se picture 1) X122, X132 and X124 from UZ1, UZ2, UZ3 a.s.o)
Disconnect (pull out plinth, Se picture 2) X521, X531 and X524 from BU1, BU2, BU31 a.s.o)
Check that there is no connection between terminal X10:42 and X10:48.
Check that there are no short circuit between X10:42 and X10:50.
Check that there are no short circuit between X10:48 and X10:50.
Disconnect the small capacitor connected between terminal X10:50 and X10:PE.
If applicable: Disconnect all cables from CAN-bus repeater AZ7 by loosen contact.

Picture 1. Remove X122, X132 and X124. Picture 2. Remove X524, X521 and X531

1.3 CT13/16 Cabinet

Verify that motor cables from frequency converters are not connected to converter.
1.4 CT14/17 Cabinet
Verify that motor cables from frequency converters are not connected to converter.

This document remains our property. It must not be reproduced or made accessible to our competitors or others who could make undue use of it, without our written permission.

Rev ind Revision Appd Year Week

Description (English) Drawn by Year Week
Insulation test (megger) Electrical crane C Hörnfeldt 10 40
Deescription (own language) Drawing No Rev ind Sheet
Isolationstest (megger) Elkran 1000004064 D 1(2)
 INSTRUCTION
INSULATION TEST
ELECTRICAL CRANE
1.5 CT19 Cabinet (if applicable)
 Verify that no Power Swivel is connected.
 Disconnect cable W1693 from terminal X19: 331-333. (KTY-input to UF11-inverter in CT17)
1.6 Cabin
 Cabin Display – Disconnect all cables (M12-contacts).
 If applicable: ARC-box (CT24) – Disconnect cable W1645 (M12-contact).

2 PROCEDURE
2.1 Resistance check after preparation
Check with an Ohm-meter that there is no connection between following terminals:
 In CT1 cabinet:
X2:127 and earth
X2:274 and earth
 In CT2 cabinet:
X10:50 and earth
X11:50 and earth
2.2 Megger test 500 V
Test all cables in the 24V circuits on X10 plinth with 500 VAC. Apply test probes between mounting
plate and X10 plinth. IT IS ABSOLUTELY FORBIDDEN TO USE THE MEGGER ON TERMINAL
STRIP X11.
2.3 Megger test 1000 V
CT1. Test electric motors and cables. Apply test probes between mounting plate and X2 plinth.
IT IS ABSOLUTELY FORBIDDEN TO USE THE MEGGER ON TERMINAL STRIP X3.
Test motor circuits by applying test probes between mounting plate and contactor.
CT9 (If applicable) Test electric motors and cables. Apply test probes on contactors.
CT13/16. Test electric motors and cables. Apply test probes on motor cables.
CT14/17. Test electric motors and cables. Apply test probes on motor cables.
IT IS ABSOLUTELY FORBIDDEN TO USE THE MEGGER IN CT10-CABINET.
2.4 Test results
Results to be higher than 5 MOhm. Note! If the humidity in the air is high a result between 1 and 4
MOhm is acceptable.

This document remains our property. It must not be reproduced or made accessible to our competitors or others who could make undue use of it, without our written permission.

Rev ind Revision Appd Year Week

Description (English) Drawn by Year Week
Insulation test (megger) Electrical crane C Hörnfeldt 10 40
Deescription (own language) Drawing No Rev ind Sheet
Isolationstest (megger) Elkran 1000004064 D 2(2)
SERVICE 6.305.19 E rev.: a 2013-06-17

Electrical Equipment, General Maintenance

Introduction Portable control boxes

General maintenance of the electric equipment of
the crane is important in order to prevent unexpected
breakdowns. The following general advice may be
useful. Relevant electrical system is placed in section
9, SPARE PARTS.
Start the crane and try out all combinations of move-
ments that are practicable. This will show if the electric
functions are satisfactory.
Control panels and remote control boxes may be sub-
jected to abuse an abnormal wear, and should be
inspected after every use. The control boxes must be
stored in a compartment that is well protected against
moisture. Remove moisture that may have collected
in the boxes, and find out how it entered.

Inspect all electrical equipment cabinets, and com-

ponents. Any defective component must be repaired
or replaced without delay. A detailed inspection and
overhaul at two-year intervals is recommended. Check
that all screws and nuts are securely tightened in the
contactor cabinets, that all switches and pushbuttons
operate correctly, and that cable connections are per-
fectly tight and all insulating parts intact. Make sure
that inspection door gaskets seal perfectly.

Dangerous voltage, 700V DC, can remain charged in

the DC-bus up to 5 min. after the power switch Q1 is
switched off.
C-00108

Danger!
Fig.1. Electric Cabinet CT1/CT2
Electrical equipment can be alive unless the main
switch and the separate supply is disconnected in
cabinet CT1 and CT2.

Earth connection, hull

Verify that the protective earth connection of the crane
is made to the ship’s hull.
Clean contact surfaces, when required.

Earth connection, crane

Check crane system earth connections, and clean
contact surfaces as required.

1 (2)
SERVICE 6.305.19 E rev.: a 2013-06-17

General maintenance
- Change filter to the ventilation fan in cabinet CT1,
if necessary, see Fig. 1.
- Clean contacts, insulating parts, cams, contact rolls,
and rotary potentiometers.
- Make sure that all cable connnections are clean
and securely tightened.
- Clean the control levers, and grease their sliding
surfaces.
- Examine the return springs and grease lightly so
that no grease transfers to the contacts.
- Replace the filters of the airflow fans in cabinets
CT2, CT10, CT13 and CT14. See instruction "Hea-
ting and Cooling of Cabinets in Electric Cranes" in
section 3.

Jib flood light

Make sure that connections in the junction box are
clean and well tightened.

- Remove moisture and dirt.

- When necessary, clean contact surfaces of terminal
strips and of lamp holder.
- Make sure that lamp holder gasket seals correctly.
- Make sure that the work light can be rotated.

Oil level/temp

See instruction "Control and Indicators" in section 4.

2 (2)
SERVICE 6.307.19 E rev.: - 2013-01-28

Slip-Ring Unit
General Removal

DANGER! - Park the jib in a suitable manner.

Before opening the slip-ring unit, make sure that
power supplied by separate transformers is switched
off in the ship's engine room. Also check by means
of a voltmeter that the slip-ring unit is not alive. Make
sure that the current can not be switched on again
during the maintenance operation.
Work on a slip-ring assembly may only be carried out
by a qualified electrician or by persons under the su-
pervision of a qualified electrician and only according
to accepted electrical safety procedures.
The function of the slip-ring assembly may not be
changed in any way. Especially safety devices must
not be made ineffective. Other than during mainte-
nance and inspection work the housing must always
remain closed.
Use only insulated tools and original spare parts.
- Disconnect the ship's power supply at all points of
feed.
- Disconnect all the cables connection from crane
and ship supply.
- Remove the driver connecting the slip-ring unit and
the foundation. Note the cables mounting sequence.
- Remove cover on absolute encoder inside the foun-
dation.
- Loosen the absolute encoder from shaft on slip-ring
unit.
- Remove mounting screw holding the slip-ring unit
on the bottom of the foundation, see Fig. 1.
- Remove the slip-ring unit.
- Remove shaft from slip-ring unit.
Any extra equipment such as extra limit switches fitted
on top of the slip-ring unit are removed prior to removal
of the entire slip-ring unit.

No responsibility will be assumed for damage to prop-

erty or injury to persons caused by improper use of
the slip-ring assembly.

2 3

1 4

1. Connections to crane
5
2. Mounting screws to crane
3. Absolute encoder 6
4. Slip-ring unit
5. Connection box, ship power
6. Guide pins
8
7. Driver
8. Rubber protection
Note! Must be tightened.
7

Fig. 1. Slip-ring unit inside the foundation.

1 (2)
SERVICE 6.307.19 E rev.: - 2013-01-28

Installation Maintenance

Clean all contact surfaces between slip-ring unit and

crane bottom plate. Tighten all screws properly. See DANGER!
instruction "Tightening torque". Before opening the slip-ring unit, make sure that
power supplied by separate transformers is switched
off in the ship's engine room. Also check by means
- Assemble the shaft on the slip-ring unit.
of a voltmeter that the slip-ring unit is not alive. Make
- Assemble the slip-ring unit under crane bottom
sure that the current can not be switched on again
plate.
during the maintenance operation.
- Assemble the driver to the bottom of the foundation.
- Remove the cover around the slip-ring unit.
- Fit the slip-ring unit guide pins to the driver's slot-
ted holes by pulling apart the driver and lock it with
General
help of the through bolt.
See "Maintenance Chart" for maintenance intervals.
- Install the cables against the driving bar.
- Connect the electrical cables from the crane on
Check collector for damaged parts.
correct mounting sequence.
Check contact pressure of brushes.
- Remove the connection box plates.
Check brush holders.
- Connect the cables to the plinths.
Check tightness of electric and mechanical fasteners.
- Install the absolute encoder. See spare part pic-
Check gaskets and cable glands for tightness.
tures for assembly of the absolute encoder in sec-
Keep grease and oil products away from the plastic
tion 9.7.
insulating parts in the collector.

After installation
Carbon brushes
- Check tightness of all electric and mechanical
The carbon brushes must never wear down so far that
fasteners regularly for the first working period.
metal parts of the brush holder come into contact with
- Check alignment. The slip-ring unit must not be
the slip-ring. Replace carbon brushes or entire slip-ring
allowed to slope in relation to the driver.
assemblies before they are worn out.
- Rotate the crane and make sure that no mechanical
Remove carbon dust with dry, oil free, compressed air
side forces are transferred to the unit.
or with a vacuum cleaner.
- Tighten the rubber protection, see Fig. 1.
No substance containing oil or grease may come into
- Calibrate the absolute encoder according to instruc-
contact with the brushes or the slip-rings.
tion "Absolute Encoder Calibration...", section 6.3.

Wire brushes
Check wire brushes.
Remove debris caused by wear with dry, oil free,
compressed air or with a vacuum cleaner.
Lightly apply "Cramolin Protection" or equivalent con-
tact spray on the slip-ring ways and wire brushes.

2 (2)
SERVICE 6.311.14 E rev.: b 2013-06-13

Oil Level/Temperature Sensor, Brake unit

General

To prevent operation of the crane with too little oil in an 1

oil level/temperature sensor is installed in the brake
unit, see Fig. 1. Apperence of brake unit may vary.
The sensor controls an indicator lamp on the control
panel in the cabin, see fig. 2.

1 1. Indicator light "BRAKE, LOW OIL LEVEL"

Fig. 2. Control panel in cabin

Sensor display

The display on the sensor shows the oil level in cm.

The display can also show oil temperature. If you push
the arrow to the right the display shows, in this order:
1. Max value for oil level
2. Min value for oil level
3. Oil temperature
4. Max value for oil temperature
5. Min value for oil temperature
6. Oil level

If no arrow is pushed for five seconds the display will

show the oil level again.

C
1. Oil level/temperature sensor

Fig. 1. Brake unit (Example) cm

mode
C-00257

Fig. 3. oil level/temperature sensor with display

If the oil level is under or above measureable area for

the sensor the display will flash.

1 (2)
SERVICE 6.311.14 E rev.: b 2013-06-13

THIS PAGE IS INTENTIONALLY LEFT BLANK

2 (2)
SERVICE 6.320.409 rev.: b 2014-11-10

Limits for Hoisting and Luffing

Index

Section Page
General 1
Sensors and switches 1
Measure limits 2
How to set cams 2 1
3
How to measure limit values on winch drum 4
2
3
Luffing winch limits 5 4
2
Hoisting winch limits 8
Safety functions at large outreaches 10 3
1

C-00214
High hook function 10
Tilt warning system, "Jack knife" 12

General
1. Cam
The movement and outreaches of the jib and lifting 2. Angle encoder (absolute)
block are controlled by software limits in the crane 3. Limit switch
control system, with limit switches as a safety system. 4. Speed encoder (incremental)
The system makes sure that the crane operates with
correct speed and outreach for the load. Fig. 1. Limit switch box

You must read the instruction "Technical Data" in

section 2 together with this instruction, all values for
outreaches and hook travel are there.
Sensors and Switches
Limit switch boxes
The limit switch boxes are connected to the winches
and contains cams, limit switches and encoders. The
winches operate the cams and encoders through the
limit switch gearbox, see Fig. 1.
Limit switches and cams
A limit switch is a microswitch that is operated by a
rotating cam. They are set with values from instruction
"Technical data".
The cams in the hoisting winch limit box are marked
"BH" followed by the number of the cam in instruction
"Technical Data".
The cams in the luffing winch limit box are marked "BL"
followed by the number of the cam in "Technical Data".

1 (12)
SERVICE 6.320.409 rev.: b 2014-11-10

Encoders How to set cams

The encoders gives a position of the lifting block and
the jib to the crane control system and to be viewed on
Set cam degrees operating area
the display. Encoders are of two types, angle (abso-
Open the adjustment screw to adjust the cam
lute) and speed (incremental). They are installed in the
degrees. Use the cam end as a measure line when
limit switch box, and also at the jib bearing connected
you adjust the cam as on Figs. 2, 3 and 4. It is 5°
directly to the jib.
between each hole. The figures are only examples
of cams.
The angle encoders must be calibrated when replaced.
When a wire rope has been replaced the encoder for
that winch system must be calibrated.

Measure limits

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 4
the winch.
The jib outreach values refer to the crane house slew- 3
ing centre, not to the jib bearing centre.

C-00150
The values for hook travel refer to the jib bearing centre. 2

1. Lock screw
2. Maximum cam degree 55°
3. Minimum cam degree 30°
4. Adjustment screw
5. Measure line

Fig. 2. Cam 30°-55° set to 45° operating area

2 (12)
SERVICE 6.320.409 rev.: b 2014-11-10

Set cam to operate limit switches

Open the lockscrew of the cam with a 10 mm wrench,
3 and rotate the cam to correct position. The cam oper-
ates the limit switch when it "clicks", see Figs. 5 and
6. Tighten the lock screw when the cam is in correct
position.

2 CLICK!

C-00151

C-00153
1. Lock screw
2. Adjustment screw
3. Measure line Fig. 5. Limit switch activated

Fig. 3. Cam 110°-270° set to 170° operating area

CLICK!

C-00154
C-00152

Fig. 6. Limit switch deactivated

Fig. 4. Cam 110°-270° set to minimum 110°

operating area

3 (12)
SERVICE 6.320.409 rev.: b 2014-11-10

How to measure limit values on winch

.
drum to make sure limits are set cor-
rectly

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.

First layer wire

Values AT and AL are measured from the wire lock

C-00160
side (empty drum flange side) to the side of the wire,
see Figs. 7 and 8.
Fig. 9. Luffing winch second layer BT
C-00157

C-00159
Fig. 7. Luffing winch first layer AT

Fig. 10. Hoisting winch second layer BL

Luffing winch limits

Refer to instruction"Technical Data" for values of luff-

ing limits. To operate in Rig mode refer to instruction
"Preparation for Rig Mode", section 6.3.
Jib outreach is measured from crane house slewing
center.
C-00158

Fig. 8. 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. 9 and 10.
WARNING!
When the crane is operated in Rig mode the crane
has no software limits.
It is not permitted to have any load in the hook.
Inappropriate use may cause severe damage to the
crane and bodily injury.

4 (12)
SERVICE 6.320.409 rev.: b 2014-11-10

12. Stop the crane and start in Rig mode, refer to

WARNING!
Use a safety belt when you are on the crane top.
A fall from the crane top can cause death or injury.
CAUTION!
Keep a distance between the front of the cranehouse
and the first jib stay. If you luff in to much the jib can
cause damage to the crane house.
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.
"Preparation for Rig Mode".
13. Move the jib to SW limit "Max outreach Lu, Stop"
position, refer to Fig. 12.
14. Set the "Safety Cam, Max Outreach Lu, Stop", refer
to Fig. 5 and 12. Move the cam backwards until
there is a click to deactivate the cam, refer to Fig 6.
15. Luff in from "Max outreach Lu".
16. Luff out to make sure that cam stops the jib.
17. Stop the crane and exit Rig mode, refer to "Prepa-
ration for Rig Mode", and start crane in Normal
mode.
18. Luff in from Max outreach area and then luff out,
to make sure that the SW limit "Max outreach Lu,
Stop" stops the luffing out movement.

Safety Cam, empty Drum Lu, Stop

Safety Cam, Min outreach Lu, Stop
19. Luff out to "Max outreach, Lu, Stop", refer to Fig. 12.
1. Start the crane in Rig mode, refer to "Preparation
20. Stop the crane and start in Rig mode, refer to
for Rig Mode".
Preparation for Rig Mode.
2. Hoist the lifting block close to the jib top and move
21. Turn the key switch "Parking of Jib" to position
the jib to SW limit "Min Outreach Lu, Stop", refer
"1", and move the jib to SW limit "Empty drum Lu,
to Fig. 11 and "Technical Data".
Stop" position, refer to Fig. 12. Do not put the jib
3. Calibrate the luffing angle encoder. Refer to instruc-
in the parking support. Make sure that there is at
tion "Absolute Encoder Calibration".
least three locking turns of the wire on the drum.
4. Set the "Safety cam, Min Outreach Lu, Stop", refer
22. Set the "Safety Cam, Empty drum Lu, Stop", refer
to Fig. 5 and 12. Move the cam backwards until
to Fig. 5 and 12. Move the cam backwards until
there is a click to deactivate the cam, refer to Fig 6.
there is a click to deactivate the cam, refer to Fig
5. Luff out from minimum outreach area and then luff
6.
in, to make sure that the cam stops the luffing in
23. Luff in from the parking area.
movement. Make sure that the jib does not touch
24. Turn the key switch "Parking of Jib" to position
the crane house.
"1"and luff out to make sure that cam stops the
6. Stop the crane and exit Rig mode, refer to "Prepara-
jib. Make sure that there is at least three locking
tion for Rig Mode", and start crane in Normal mode.
turns of the wire on the drum.
7. Luff out from minimum outreach area and then luff
25. Stop the crane and exit Rig mode, refer to "Prepara-
in, to make sure that the SW limit "Min Outreach
tion for Rig Mode", and start crane in Normal mode.
Lu, Stop" stops the luffing in movement. Make
26. Luff in from empy drum outreach area and then
sure that the jib does not touch the crane house.
luff out, to make sure that the SW limit "Empty
8. Measure the MV distance again to make sure it
drum Lu, Stop" stops the luffing out movement.
is correct.

Make sure limits are set correctly

Check Cam Lu
After the cam adjustments are done, do a control
9. Luff out to "Check Cam Lu", refer to Fig. 12.
measure the AT (and BT if second layer wire) on the
10. Set the cam for "Check Cam Lu", refer to Fig. 5.
luffing winch. Start at minimum outreach and luff out
to maximum outreach.
Safety Cam, Max outreach Lu, Stop
11. Luff out to "Max Outreach Lu, Stop", refer to Fig. 12.

5 (12)
SERVICE 6.320.409 rev.: b 2014-11-10

306

306

2
C-00222

Fig. 11. Jib at Minimum outreach, to measure MV distance

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)

6 (12)
SERVICE 6.320.409 rev.: b 2014-11-10

1
2

4
5

C-00330
7

Fig. 12. Luffing limits

Fig. pos. Luffing limit Controlled by

1 Safety Cam, Min Outreach Lu, Stop BL5
2 Min Outreach Lu, Stop SW
3 Check Cam Lu BL(x)
4 Max Outreach Lu, Stop SW
5 Safety Cam, Max Outreach Lu, Stop BL3
6 Empty Drum Lu, Stop SW
7 Safety Cam, Empty drum Lu, Stop BL1
*For BL(x) see "Technical Data" Basic limit switches luffing winch
Table 1. Luffing limits

7 (12)
SERVICE 6.320.409 rev.: b 2014-11-10

Hoisting Winch Limits
Refer to instruction "Technical Data" for values of hoist-
ing limits. To operate in Rig mode refer to instruction
"Preparation for Rig Mode", section 6.3.
Lifting height is measured from jib bearing center.
7. Stop the crane and exit Rig mode, refer to "Prepa-
ration for Rig Mode", and start crane in Normal
mode.
8. Hoist a few meters and stop. Lower until it stops
to make sure that the SW limit "Empty Drum Ho,
Stop" stops the lowering movement.

Check Cam Ho
WARNING!
9. Hoist the lifting block to "Check Cam Ho", refer to
When the crane is operated in Rig mode the crane
Fig. 13 and Technical Data.
has no software limits.
10. Set the cam for "Check Cam Ho", refer to Fig. 6.
It is not permitted to have any load in the hook.
Inappropriate use may cause severe damage to the
crane and bodily injury. Safety Cam, Full Drum Ho, Stop
11. Start the crane in Rig mode, refer to Preparation
for Rig Mode.
WARNING!
12. Move the jib to "Min Outreach Lu, Stop" position,
Use a safety belt when you are on the crane top.
refer to Figs. 11.
A fall from the crane top can cause death or injury.
13. Hoist the lifting block to "Full Drum Ho, Stop", refer
to Fig. 13.
CAUTION! 14. Set the "Safety Cam, Full Drum Ho, Stop", refer to
Keep a distance between the front of the cranehouse Fig. 5 and 13. Move the cam backwards until there
and the first jib stay. If you luff in to much the jib can is a click to deactivate the cam, refer to Fig 6.
cause damage to the crane house. 15. Lower a few meters and stop. Hoist until it stops to
make sure that the cam stops the hoisting move-
ment.
CAUTION! 16. Stop the crane and exit Rig mode, refer to "Prepa-
Hoist the lifting block close to the jib top before you ration for Rig Mode", and start crane in Normal
luff in to minimum outreach. The lifting block can mode.
start to swing and hit the cabin. 17. Lower a few meters and stop. Hoist until it stops to
make sure that the SW limit "Full Drum Ho, Stop"
Safety Cam, Empty Drum Ho, Stop stops the hoisting movement.
1. Start the crane in Rig mode, refer to "Preparation
for Rig Mode".
2. Move the jib to "Min Outreach Lu, Stop" position,
refer to Fig. 11.
3. Lower the lifting block to "Empty drum Ho, Stop",
refer to Fig. 9 and "Technical Data". Make sure the
winch has at least three locking turns.
4. To calibrate the hoisting angle encoder, refer to
instruction "Absolute encoder calibration".
5. Set the "Safety Cam, Empty Drum Ho, Stop", refer
to Fig. 5 and 13. Move the cam backwards until
there is a click to deactivate the cam, refer to Fig
6.
6. Hoist a few meters and stop. Lower until it stops to
make sure that the cam stops the lowering move-
ment.

8 (12)
SERVICE 6.320.409 rev.: b 2014-11-10

1
2

H
C-00433

4
5
Fig. 13. Hoisting limits

Fig. pos. Hoisting limit Controlled by

1 Safety Cam, Full Drum Ho, Stop BH4
2 Full Drum Ho, Stop SW
3 Check Cam Ho BH(x)
4 Empty Drum Ho, Stop SW
5 Safety Cam, Empty Drum Ho, Stop BH1

*For BH(x) see "Technical Data" Basic limit switches luffing winch

Table 2. Hoisting limits

9 (12)
SERVICE
Safety functions close to max outreach
At large outreaches there is a possibility that the lift-
ing block and jib top will touch. This will not cause any
damage to the crane, the crane is designed for that.
At outreaches from min outreach to near max out-
reach the hoisting limit "Full Drum Ho, Stop" will stop
the lifting block from touching the jib top, see Fig 14.
The luffing wire rope will slack if the lifting block lifts
the jib or the jib is lowered to the block. Then the slack
wire safety switch will engage and hoisting and luffing
movement stops.
To be able to operate the crane you must lower the lift-
ing block or raise the jib until the wire rope is tightened.
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-
gether will cause an overload alarm.
Refer to instruction "Slack Wire Safety Switch Hoist-
ing and Luffing Winches" in section 6.3 for more
information.
C-00137
Fig. 14. Safety function at large outreaches
10 (12)
6.320.409 rev.: b 2014-11-10
"High Hook" function
"High Hook" function prevents the lifting block to collide
with the jib top when the crane operates near maximum
outreach. When the crane is operated in this area, the
system will set the motion in speed reduce before it
stops, see Fig. 15.
It is only possible to luff in the jib or lower the hook
when the crane is stopped by "High Hook". "High
Hook" function is operated by software limits and the
control system.
Calibration of "High Hook"
"High hook" must be calibrated when the wires have
been replaced. When the crane’s all encoders are
calibrated, calibrate the "High Hook" function.
WARNING!
When the crane is operated in Rig Mode the crane
has no software limits.
It is not permitted to have any load in the hook.
Inappropriate use may cause severe damage to the
crane and bodily injury.
1. Lower the jib to Max jib outreach, see Fig 12. 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
jib top.
4. Push the "Select/Info" button on the front of the
hoisting MC-card, refer to instruction "Card front
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.
SERVICE 6.320.409 rev.: b 2014-11-10

C-00224
1. High Hook Ho, Stop
2. "High Hook" area

Fig. 15. "High Hook" area

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