GLB3030-2 2430gr NB 2253 212012.01LMW Crane 1 2 3 4

Assembly and Installation Manual
NB: 2253
IMO No.: L9576961
Shipyard
Yangfan
Crane type
GLB3030-2/2430gr
Project No.
2/12012.01LMW
To be discarded after
installation
INSTRUCTION MANUAL Project No. Page
Dept. C7250 Date: 2013-03-19 2/12012.01LMW 1(6)
TABLE OF CONTENTS
No. of manuals 3 pcs + 1 CD
Certificate for
crane issued by: LR
Certificate for
foundation issued by: LR
IMO No. L9576961
Name of ship -
Newbuilding No. 2253
Shipyard Yangfan
Owners Hongxiang Shipping
Project No. 2/12012.01LMW
Mfg. No. 62514099 Crane-1, 62514100 Crane-2, 62514101 Crane-3, 62514102 Crane-4
Type of crane GLB3030-2/2430gr
Order specification 490 9254-801 - 804 /G
Mechanical spec. 490 9255-801 - 804 /-
Hydraulic spec. 490 9257-801 - 804 /B
Electrical spec. 490 9256-801 - 804 /-
Slewing spec. 490 8453-801 /-
SAFETY DOCUMENTS
Document names written with bold letters are documents with safety aspects.
INSTRUCTION NO. REV NAME OF INSTRUCTION
GENERAL 1 1.000.4 E e 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 2/12012.01LMW - TECHNICAL DATA

2.007.91 E - TECHNICAL DESCRIPTION
FUNCTION 3 3.110.122 E - HYDRAULIC FUNCTION

3.131.29 E a STARTING AND STOPPING, ELECTRIC SAFETY FUNCTIONS, SINGLE CRANES
3.142.35 E b CRANE CONTROL SYSTEM CC3000
3.155.3 E - THERMOSTATIC CONTROLLED VENTILATION FAN
3.156.2 E b TILT WARNING SYSTEM TO PREVENT "JACK KNIFE"
OPERATION 4 PM40 1879-E00 - CREW CHECKLIST BEFORE AND AFTER OPERATION

PM40 5500-E00 b OPERATING INSTRUCTION
PM40 6491-E00 - OPERATION, START AND STOP
PM40 7609-E00 - CONTROLS AND INDICATORS
PM41 0001-E - EMERGENCY ESCAPE INSTRUCTIONS
PM41 0014-E00 a EMERGENCY ESCAPE INSTRUCTIONS, ROPE LADDER/FIXED LADDERS
4.620.26 E a PARKING THE CRANE, SEA STOWING, GENERAL INSTRUCTION
4.630 E - HANDLING HATCHES BY DECK CRANE
MAINTENANCE 5 5.005.55 E g MAINTENANCE CHART

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TABLE OF CONTENTS
MAINTENANCE 5 5.018 E c INSPECTION OF STRESSED COMPONENTS AND STRUCTURES

PM51 1709-E00 d LUBRICATING CHART, CRANE
5.150.4 E - LUBRICATING AND MAINTENANCE, CRANES TYPE GLB
5.250.1 E a SLEWING BEARING STUDS
5.301.13 E a FILTERS
5.302.24 E - HYDRAULIC OIL TANK
5.315 E b SAMPLING OF OIL TO VERIFY THE CLEANLINESS IN HYDRAULIC SYSTEM
5.421.40 E f LUBRICANTS FOR DECK MACHINERY
SERVICE 6
6.0 6.000 E e HOW TO ORDER SPARE PARTS

6.000.1 E c STATEMENT REGARDING DELIVERY OF SPARE PARTS TO SWIVELS, LIFTING B
6.000.2 E f RETURN FORM
6.004.1 E bc WORLDWIDE SERVICE NETWORK
6.005.7 E - INTRODUCTION
6.1 6.100 E b MEASURES BEFORE STARTING, DURING AND AFTER COMPLETED SERVICE/M
6.106.4 E - TROUBLE-SHOOTING CHART, OVERHEATING
6.117 E b TROUBLE SHOOTING, PUMPS
6.120.18 E b SLEWING GEAR
6.120.64 E q HYDRAULIC MOTORS, HOISTING, LUFFING, AND SLEWING CIRCUITS
6.120.107 E b WINCHES, HOISTING/LUFFING
6.121.3 E a TROUBLE SHOOTING CHART, HYDRAULIC HIGH SPEED MOTORS
6.127.51 E b HIGH PRESSURE PUMPS
6.132.18 E a REPLACEMENT OF VANE PUMP, CRANE TYPE GLB
6.142.5 E a RECOMMENDATION FOR INSPECTION AND REPLACEMENT OF HYDRAULIC HO
6.189 E f HYDRAULIC PISTON ACCUMULATORS
6.2 6.209.15 E a INSPECTION OF CLIMB PROTECTION, JIB AND CRANE HOUSE TOP
6.214 E i TIGHTENING TORQUES STUDS/SCREWS AND BOLTS
6.215.21 E b SERVICE DOOR (OPENING AND CLOSING), SERVICE AND LUBRICATION OF DO
6.216.83 E a ROPE REEVING DIAGRAM FOR CRANES TYPE GLB-2
6.222.1 E a HANDLING, INSTALLATION AND MAINTENANCE OF STEEL WIRE ROPES
6.223.20 E c REPLACEMENT OF WIRES, ONE OR TWO FALL RIGGING
625/1669 E - INDENTATION AND WEAR ON WIRE SHEAVES
625/1560 E g LIFTING BLOCK/BEAM
625/1579 E k MEASURING PROCEDURE FOR WEAR IN SLEWING BEARINGS FOR ROPE LUFF
625/1651 E a SLEWING BEARING GREASE SAMPLING PROCEDURE
6.3 6.303.49 E e TROUBLESHOOTING, CRANE CONTROL SYSTEM CC3000, GLB-CRANE

6.303.61 E d CARD FRONT MENUS CT2, CC3000
6.303.68 E - ABSOLUTE ENCODER CALIBRATION, CC3000
424 0738 e SIGNAL OVERVIEW, CRANE CONTROL SYSTEM CC3000
424 0739 g ERROR MESSAGES, CRANE CONTROL SYSTEM CC3000
6.305.16 E - ELECTRICAL EQUIPMENT, GENERAL MAINTENANCE
6.306.6 E - INSTALLATION OF POWER SUPPLY CABLE AND CABLE FOR GRAB...
6.307.14 E - SLIP-RING UNIT
6.311.12 E - OIL LEVEL FLOAT SWITCH AND OVERHEATING PROTECTOR
6.320.373 E b LIMIT SWITCHES IN HOISTING AND LUFFING WINCH SYSTEMS, CC3000
6.321.13 E a SLACK WIRE SAFETY SWITCH HOISTING AND LUFFING WINCHES
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TABLE OF CONTENTS
6.3 6.324.1 E b PREPARATION FOR OVERLOAD (OL) TEST MODE

6.324.2 E - PREPARATION FOR RIG MODE
6.990.36 E i EMERGENCY LOWERING IN CASE OF COMPLETE POWER FAILURE, OPERA
EXTRA EQUIPMENT 7 7.075.12 E - MacHEAVYVISOR RELEASE 3.6

7.076.2 E c USER MANUAL DISPLAY, CC PILOT XS
APPENDICES 8
SPARE PARTS 9 SEE SEPARATE TABLE OF CONTENTS

PARTS MANUAL Project No. Page
Dept. C7250 Date: 2013-03-19 2/12012.01LMW 4(6)
TABLE OF CONTENTS
GROUP DESCRIPTION PART NUMBER FIG
9.0 HOW TO ORDER SPARE PARTS e 6.000 E
9.1 HOISTING WINCH 189 2796-801 E/ 625-1440.047

HOISTING WINCH 189 2255-801 C/ 625-1450.055A
PRESSURE ROLLER, COMPLETE 875 13030-006 -/ 625-1451.010A
OIL PIPE, COMPLETE 875 13009-002 -/ 625-1451.224
LUFFING WINCH COMPLETE 189 1625-801 B/ 625-1440.046A
LUFFING WINCH 189 1622-801 C/ 625-1450.056A
HYDRAULIC MOTOR 188 1221-801 B/ 625-2205.009A
HYDRAULIC MOTOR 188 1223-801 B/ 625-2205.010
HYDRAULIC MOTOR 189 2418-801 A/ 625-2205.021
WINCH MOUNTING SET 289 1944-801 -/ 625-2250.008
SLEWING GEAR ASSEMBLY SET 391 0247-801 C/ 625-3254.024A
SLEWING GEAR ASSEMBLY 391 0279-801 A/ 625-3254.022A
SLEWING GEAR 289 1855-801 B/ 625-3255.034
DRIVE IN, COMPLETE 875 13004-127 -/ 625-3256.007B
9.2 PUMP UNIT 1196619 B/ 625-4935.217A

GEAR BOX 390 6453-801 B/ 625-4940.027B
HYDRAULIC PUMP 289 6004-801 A/ 625-4945.062A
HYDRAULIC PUMP 289 6005-801 A/ 625-4945.063A
SERVO VALVE 391 1550-801 -/ 625-4948.011
VANE PUMP 390 2422-801 G/ 625-4945.037
DISTANCE PIECE 390 7952-801 -/ 625-4963.012
DISTANCE PIECE 390 7953-801 -/ 625-4963.013
OIL COOLER 1198527 B/ 625-5740.040
OIL COOLER ASSEMBLY 1236187 A/ 625-5740.048A
OIL COOLER ASSEMBLY 1219505 A/ 625-5740.049
9.3 OIL TANK ASSEMBLY 189 3870-801 A/ 625-5865.033A

CRANE HOUSE ASSEMBLY 1236391 D/ 625-6102.609A
SLEWING SPECIFICATION 490 8453-801 -/ 625-6122.048A
SLEWING BEARING MOUNTING 1189942 A/ 625-6123.004A
SLEWING BEARING YARD MOUNTING 1189965 B/ 625-6124.004B
COVER MOUNTING 390 3274-801 -/ 625-6169.005A
COVER ASSEMBLY 390 3282-801 -/ 625-6169.006
JIB BEARING MOUNTING 390 6852-801 -/ 625-6170.045A
JIB BEARING HOUSING 390 6853-801 -/ 625-6170.046
JIB TOP MOUNTING 1194150 -/ 625-6244.070
LIMIT SWITCHES BOX 289 5323-801 -/ 625-6245.635B
LIMIT SWITCHES BOX 289 5449-801 -/ 625-6245.643
LIMIT SWITCHES 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
CRANE JIB MOUNTING 1194148 -/ 625-6408.112
CRANE TOP ASSEMBLY 1195411 -/ 625-6459.070
PROTECTIVE PLATE MOUNT. 390 7581-801 -/ 625-6459.051
INCLINOMETER, C 388 0176-801 B/ 625-6509A
CAB INSTALLATION 289 6807-801 -/ 625-6540.034
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TABLE OF CONTENTS
9.3 CAB ASSEMBLY 190 0115-801 A/ 625-6545.068

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 387 6227-802 F/ 625-6561.001C
VENTILATION FAN ASSEMBLY SET 1239312 -/ 625-6625.028
VENTILATION FAN 388 9464-801 A/ 625-6625.015A
LIFTING BLOCK 1205161 A/ 625-7013.126A
LOAD WIRE ROPE 1234872 Q/ -
LUFFING WIRE ROPE 1234873 R/ -
9.4 VALVE UNIT 289 1639-801 A/ 625-7207.006

VALVE UNIT 289 2557-801 -/ 625-7207.007
FLUSHING VALVE 388 3579-801 F/ 625-7287C
UNLOADING UNIT 388 3576-801 B/ 625-7291C
FILTER UNIT, INLET 189 1558-801 A/ 625-7314.007A
FILTER UNIT OUTLET 189 1559-801 B/ 625-7314.008A
DIRECTION VALVE 289 1597-801 C/ 625-7322.047
DIRECTION VALVE 289 1598-801 B/ 625-7322.048
FLUSH AND UNLOADING UNIT 388 3580-801 C/ 625-7449B
UNLOADING UNIT 388 3576-803 B/ 625-7802.004
ACCUMULATOR 388 0362-803 F/ 625-7951.005
HYDRAULIC HOSES 625-7970G
PRES. SWITCHES EXTRA OVERLOAD 288 1436-801 -/ 625-7994.001
FILTER ELEMENT 489 3104-801 C/ -
HYDRAULIC SYSTEM SPECIFICATION 1000025571 -/ 1000025571
9.5 DRIVER´S DESK 124 0827-801 B/ 625-8563.059A

EL INST. CRANE HOUSE 124 0438-801 E/ 625-8564.029
EL. INST. JIB LIGHT, CRANE 124 0647-801 B/ 625-8567.045B
EL. INST. JIB LIGHT (PACKING) 124 0648-801 C/ 625-8567.046D
EL. INST.WARN. LIGHT JIB PACK 124 0652-801 B/ 625-8567.065
EL.INST.WARN.LIGHT JIB (CRANE) 124 0651-801 B/ 625-8567.066
EL. INST. WARNING LIGHT TOP 124 0654-801 A/ 625-8567.074
CONTROLLER, HOISTING 314 2005-802 D/ 625-8591C
CONTROLLER, LUFFING/SLEWING 314 2006-802 D/ 625-8592C
CONTROLLER 414 6792-801 A/ 625-8596
CONTROL PANEL RIGHT CT3 224 0483-801 -/ 625-8597.041
EL. INST. JIB LIGHT (CABIN) 324 2043-801 A/ 625-8597.061
EL. INST. DECK LIGHT (CABIN) 324 1722-801 A/ 625-8597.062
EL. INST. FORCE LIMIT GRAB (CAB) 324 1724-801 A/ 625-8597.063
EL. INST. PMS (CABIN) 324 1723-801 A/ 625-8597.064
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. INST. WARNING LIGHT (CAB) 324 1791-801 A/ 625-8597.100
EL CABINET (C1/C2) 1236710 -/ 625-8598.170
RELAY CARD WITH LED'S 324 0089-801 A/ 625-8599.020
ASSEMBLY CT2-PLATE 324 1656-801 G/ 625-8607.010
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TABLE OF CONTENTS
9.5 EL. INST. IMPULSE RELAY 224 0116-801 A/ 625-8650.001

EL. INST. CARD RELAY (CT2) 224 0118-801 B/ 625-8650.002
EL. INST. PMS ELECTRIC CABINET 224 0119-801 E/ 625-8650.003A
EL. INST. OIL TANK HEATER (CT1) 224 0474-801 B/ 625-8650.004
EL. INST. FORCE LIMIT GRAB (CT1) 224 0547-801 A/ 625-8650.005
ELECTRICAL HEATER ASSEMBLY 1194462 -/ 625-8650.006
ELECTRICAL HEATER ASSEMBLY 1194464 -/ 625-8650.007
EL. INST. CT1 AMMETER 224 0110-801 A/ 625-8650.009
CABIN DISPLAY 424 0715-801 C/ 625-8655.001
CABIN DISPLAY ASSEMBLY 1182916 -/ 625-8655.009
SLIPRING UNIT 314 3985-801 C/ 625-8750.005D
MC-SPARE CARD 1194171 B/ 625-8760.001
CC-SPARE CARD 1194172 B/ 625-8760.002
POWER / CABLE CONNECTION 1000023803 -/ 1000023803
ELECTRICAL SYSTEM SPECIFICATION 1000026071 -/ 1000026071
9.7 MOUNTING ENCODER 390 9851-801 A/ 624-2180.014

MOUNTING ENCODER 390 9852-801 A/ 624-2180.015
ABSOLUTE ENCODER 324 1408-801 A/ 624-2180.023A
INCREMENTAL ENCODER 324 1409-801 A/ 624-2180.025A
EL. INST. LOAD STEP LIMIT 1205622 -/ 624-2195.015
EL. INST. TILT SWITCH 124 0679-801 A/ 624-2195.018
EL. INST. EMERG. STOP PEDESTAL 1202955 -/ 624-2196.008
EMERGENCY BOX 1237995 -/ 624-2460.001
HAND PUMP 189 1952-801 C/ 624-2492C
LIFE LINE 388 0962-801 -/ 624-2501
FIRE EXTINGUISHER, MOUNT 490 4074-801 A/ 624-2524A
GENERAL 1.000.4 E rev.: e 2013-01-30
Safety Instructions
Cargo Handling Equipment

The MacGREGOR crane is a cargo handling de- Our product guarantee is not valid unless MacGREGOR
vice. It is designed and manufactured to meet inter- authorized service is used.
national cargo handling standards for quality, safety
and performance within capacity specifications and
The use of proper Spares and Exchange details
outreach as per certificate.
MacGREGOR shall be contacted for ordering of ex-
change equipment and spares for this crane. Articles
The crane is designed for operation in harbour or shel-
supplied by MacGREGOR are designed and quality
tered water environments where there is no significant
tested for this application and are supplied with our
movement of the ship due to wave action.
warranty for correct function and safe working of the
crane.
Testing and examination
The crane shall be tested and thoroughly examined MacGREGOR accepts no liability for the functioning of
and certified by a competent person after any sub- the crane systems, nor for the safe use of the crane,
stantial repair. unless original spare parts are used.
Supervision, Instructions, Signs and Warnings

Safe Operating Conditions, Proper Instructions
and Precautions Proper use of this crane and its equipment is possible
as long as the owners, users and operators maintain
The responsible officer on board shall ensure that the the crane to meet full operational standards. This
crane is operated under safe conditions, by personnel includes the replacement of signs, instructions and
familiar with its functions and operating instructions. warnings as per delivery. MacGREGOR does not
All safety and precautionary issues contained in this accept responsibility for any party who fails to ensure
manual must be observed. Proper instructions and that this manual, signs, instructions, and warnings are
precautions are prerequisites for proper use. legible and easily accessible to personnel.
Preparation for Use and Operation According to

Improper Use
Manual
1. Elevation of persons.
The crane operator, authorized by the responsible of- 2. Exposing persons to the risks of falling cargo.
ficer on board, must be familiar with all safety issues 3. Overloading.
contained in this Chapter and with preparation for 4. Unlocking the crane or crane jib or operating the
use and operating instructions before work is started. equipment at sea without full acceptance and con-
trol of personnel and equipment safety.
5. Unprofessional, intended or unintended, adjustment
of safety locks, hydraulic or electric settings.
Maintenance and Service
6. Disregard of occupational and safety standards of
Prerequisite for proper use is regular maintenance
work.
(see Chapter 5) and service (see Chapter 6).
MacGREGOR are available for full service of this

cargo crane. MacGREGOR will take responsibility
only for its own professional services.
1 (14)
GENERAL 1.000.4 E rev.: e 2013-01-30
Functions, Installations and Equipment Safety Functions and Equipment
Specific safety equipment is installed and delivered

General
with this crane and must be available for its intended
The MacGREGOR crane has built-in safety functions
use. The owner/operator of the ship and its equipment
and installations to allow for safe normal use, opera-
is responsible to ensure that safety functions, instal-
tion, care and control. This is applicable to instructed
lations and equipment are maintained to operational
personnel without specific professional education or
standards and are not being removed, by-passed or
certification, but working according to this manual.
worn to non-working condition.
Specific service and repair of the electrical, hydraulic
This manual features important presentations of safety
and the mechanical functions, controls and settings
functions, installations and equipment. A summary is
require professional service personnel knowledgeable
presented below.
of risks involved.
1. Safety Functions
Regular Care and Control (Maintenance)
a. Maneuvring functions:
This manual contains checklists for regular care and
1. All the crane’s working functions are stopped
control of crane equipment, wire ropes and hydraulic
and the brakes will automatically be activated
filters. These checklists routine contain inspections
when the emergency stop button is pressed.
and maintenance regularly prescribed for safe func-
The buttons are loacated in cabin and on the
tion, e.g.:
CT1-cabinet door. This action activates safety
stops and automatic lock positions.
Chapter 4 contains:
2. The crane has several fail-safe functions for
Safety Precautions Checklist for Single Cranes.
over-ruling or stopping the operator’s maneu-
vring in the event that normal hydraulic or
Chapter 5 contains, if applicable:
electrical functions fail, a sudden uncontrolled
Inspection of Stressed Components and Structures.
movement occurs or during overspeed opera-
Lubrication chart; Crane.
tion (see below).
Lubrication chart; Cable Winch and Stabilizing Equip-
3. There are limit switches for reducing speed of
ment.
or stopping all dangerous motions.
Lubrication chart; Power Swivel.
Filters. b. Hydraulic functions:
1. Hydraulic valve functions are set for exact pres-
Before maintenance and service work is started, cer- sure. Any change in the settings adversely af-
tain measures and procedures must be done. fects crane operation and must exclusively be
set by professional service personnel (see in-
Chapter 6 contains: structions Hydraulic function and High pressure
Measures before Starting, during and after completed pumps).
Service/Maintenance Work. 2. Hydraulic oil pressure sensor automatically
Handling, Installation and Maintenance of Steel Wire indicate an overload. For safe hoisting or low-
Ropes. ering, the system automatically switch from a
Electrical Equipment, General Maintenance. highspeed movement to a lowspeed movement.
Emergency Lowering in Case of Complete Power If already in lowspeed the hoisting and luffing
Failure, Operation of Crane Using a Hand Pump (Op- crane movements stop.
tional). 3. In case of a ruptured high-pressure oil pipe/
hose or other feed pressure drops, the oil feed
pressure will collapse. A feed pressure switch
stops the crane and the mechanical brakes are
automatically applied.
2 (14)
GENERAL 1.000.4 E rev.: e 2013-01-30
4. If there is a multiple-disc failure caused by worn d. Mechanical functions:

out brake discs, sticking cylinder, brake pilot 1. Automatic sensors recognize dangerous wire
valve or valve spool, hydraulic braking by pumps slacks and stop hoisting and luffing movements
and motor is still available. that threaten safe control and the equipment
5. In case of overheating oil, a temperature sensor itself.
stops the control system, locking crane opera- 2. Each working circuit has at least two independ-
tion. The electric motor continues in idling to ent brake systems.
maintain oil cooling. Dynamic braking, deceleration, is achieved by
6. Efficient oil filters protect the system from harm- the regenerative function of motor and pump
ful oil conditions. A warning light on the op- (hydraulic braking).
erator's panel indicates if the filter has to be True static braking (parking brakes) is pro-
changed. Dirty filter might cause mal function vided by multiple disc-brakes.
to the system. The mechanical brakes are automatically acti-
7. If the hydraulic oil tank oil level drops below the vated in the event of dangerous oil pressure.
minimum permissible level. Each winch is provided with one multiple disc-
A warning light on the operator’s panel is acti- brake.
vated. Each slewing gear unit is equipped with one
An indicator stops the main electric motor and multiple disc-brake.
crane functions are closed while all brake sys-
tems are automatically activated.
2. Safety Installations
a. Warning lights, measuring instruments and meters:
c. Electrical functions:
1. The operator’s panel is provided with warning
1. The crane control system protects the crane from
lights which indicate clogged filters or low oil
overload by using pressure sensors. See also
level in the oil tank.
section 3. Crane Control System ....
2. During crane start-up a warning light on the op-
2. During a complete power failure all solenoid
erator’s panel indicates that starting procedures
valves are de-energized, causing brakes to be
are still running and that working conditions
activated.
are not acceptable before the lamp goes out.
3. The electronic cabinets have power failure
Maneuvres are not to be ordered before the
indicators. This function closes the electronic
warning light goes out.
signals down which automatically activates all
3. A pushbutton siren is located in the crane
mechanical brakes.
operator’s cabinet, allowing the operator to
4. Heat sensors located in the main electric motor
alert persons in the working area (e.g. against
stop all crane operations and activate all brakes.
prohibited riding on the load or against load
5. The overcurrent protections on all electric mo-
movements).
tors prevent the electric motors from overload-
4. Measuring instruments and meters (e.g. for
ing.
checking the crane functions, adjusting valve
The main electric motor overcurrent protec-
positions, and setting functional positions) are
tion stops all crane operations and activates
supplied as per agreement with the crane buy-
all brakes.
er/owner. Tools and equipment which are elimi-
6. A separate electrical feed for the crane house
nated from the original order to MacGREGOR
lights, operator’s cab and on jib, maintains func-
are delivered at the discretion of the owner.
tion of lights even during feed disruption to the
crane operating functions. As there is not a
b. Covers and houses:
separate emergency illuminating system for the
1. Unauthorized visitors in the crane house, es-
crane (this is dependent on the ship’s systems)
pecially during crane operation, is prohibited.
the owner of the crane must provide a battery
type flash-light for the operator’s cab.
3 (14)
GENERAL 1.000.4 E rev.: e 2013-01-30
The crane is a dangerous working area, and The fire extinguisher is for emergency use inside
requires special permission to enter. Instruc- the crane.
tions given by the superintendent or responsible
officer must be followed. The equipment must be regularly inspected for
2. Covers for electric boxes must be opened only proper pressure reading at the meter and must
by authorized personnel. be serviced annually. This is to be supervised
by the responsible officer on board.
c. Alert and warning signs:
The crane is equipped with a system of danger, d. Test device:
warning, caution and notice signs. These signs At delivery, the MacGREGOR crane is equipped
are presented on pages 6 - 15. with two pressure gauges.
3. Safety Equipment
a. Locks, seals and keys:
1. Functions and equipment that are essential for
oil pressure settings, coordination of controls
and crane movements or expose dangerous
high-voltage electricity are locked. All keys to
locked positions and switches must be kept and
controlled by the responsible officer onboard
and are only to be used by qualified personnel.
2. Safety valves for hydraulic pressure settings and
switches for electric safety circuits are sealed to
secure correct position and trim. Sealed equip-
ment may be opened and positions changed
only after consulting the MacGREGOR service
organization for proper handling.
b. Safety belt, rescue line, safety chains:

1. For maintenance, service or entry to the open-
air outside the crane house, personnel must
wear a safety belt. The connector hook should
be anchored to rails and fixed position while
staying or working on crane top.
2. The rescue line and equipment for emergency
evacuation of the crane operator must always
be easily accessible on the interior wall-side
of the crane cabin. The equipment status and
completeness must be inspected regularly by
the responsible officer onboard.
3. The safety chains on the open-air crane top and
work platforms inside the crane, must be used
for attendant’s safety during stay and work.
c. Firefighting equipment:
A fire extinguisher shall be made available by
owner in the operator’s cabin.
4 (14)
GENERAL 1.000.4 E rev.: e 2013-01-30
Danger, Warning, Caution and Notice

Signs
Principles of Risk Classification

1. DANGER SIGNS are attached to equipment or are Replacement signs must follow international and
related to operations that will expose personnel to a national standards. Signs of non-MacGREGOR
life-threatening danger (e.g. high voltage electricity). design are not allowed. MacGREGOR does not
accept responsibility for unauthorized signs.
Safety installations, covers or houses prevent expo-
sure during normal working conditions, but cannot
Specific Presentation of Signs and Their Message
eliminate the imminent risk for any unprofessional/ All signs attached to the crane are illustrated on the
non-certificated person, should the danger sign not following pages. Each sign is given a specific number
be followed. to which it is referred.
Those risks classified as DANGER sign are pre-

sented and explained below with this presentation.
2. WARNING SIGNS are attached to equipment or

are related to operations that will expose personnel
to severe risk of physical injury. The injury is not
expected to be life-threatening. A warning sign is
also used to warn against misuse that risks severe
equipment and property damage.
The danger does not exist unless protection instal-

lations or devices are removed, providing proce-
dures are followed.
3. CAUTION SIGNS are attached to equipment or

related to operations that may produce a physical
risk to any person who is not cautious or aware of
the risk.
Any person should be able to avoid the danger.
4. NOTICE SIGNS are attached to equipment and

provide references to procedures, and instructions
or policies to follow to avoid danger to the function
and operation of the equipment or damage to the
equipment itself.
Responsible officers onboard must ensure that the

signs are in good condition and readable to any
person admitted to the crane area.
5 (14)
GENERAL 1.000.4 E rev.: e 2013-01-30
Alert / Warning signs
All signs used in MacGREGOR cargo handling cranes are presented below. Each sign in your specific crane has
a number on it, which can be found in the list and in the illustrations below.
PM40 7101-E00 REPORT TO SUPERINTENDENT OR OPERATOR’S ROOM FOR PERMIT TO ENTER

Any visitor to the crane must obtain a special permit from responsible officer on board.
NOTICE SIGN For authorized entry during crane operation, the operator must be fully knowledgeable of safety
precautions. The foundation, platform and crane are a dangerous working environment and
requiers that the authorized visitor understands relevant safety.
This sign is at the bottom entrance to the crane foundation.

PM40 7102-E00 DO NOT ENTER DURING CRANE OPERATION - MOVING CRANE HOUSE AND MACHINE
PARTS ...
WARNING SIGN Authorized entry requires that visitor is aware of the character of general risk and that visitor
has adequate Manual information about how to avoid the exposure.

PM40 7103-E00 HIGH NOISE LEVEL - USE EAR PROTECTION!
Motors and winches produce a noise level that is harmful to personnel after lengthy exposure.
CAUTION SIGN To eliminate the risk, adequate ear protection is required.

PM40 7104-E00 LADDER WILL ROTATE WITH CRANE - WATCH OUT!
This is specifically warn of exposure of the ladder leading up to the crane house. Upon crane
WARNING SIGN rotation, this ladder rotates and moves suddenly without warning.
This sign is at the bottom entrance to the crane (twin) platform.

PM40 7105-E00RISK OF GETTING CAUGHT BETWEEN WIRE AND DRUM - WATCH OUT!
At start of and during winch operation there is a risk of getting caught and jammed by moving
WARNING SIGN wire. A safe distance from wire and drums must be maintained and adequate caution must be
regarded.
Attached to the crane wall surfaces close to winches.

PM40 7106-E00 RISK OF GETTING CAUGHT BETWEEN DRUM AND BRACKET - WATCH OUT!
This sign warns the visitor about the risk of getting jammed during drum rotation.
Adequate caution must be regarded.
WARNING SIGN
Attached to brackets and walls of work platforms inside crane
6 (14)
GENERAL 1.000.4 E rev.: e 2013-01-30
PM40 7108-E00 RISK OF GETTING CAUGHT BETWEEN WIRES DURING CRANE OPERATION - WATCH
OUT!
This sign warns about the risk of moving wires that may catch and jam personnel.
The authorized visitor must be aware of the risk and be cautious to avoid being seriously hurt.
WARNING SIGN
This sign is attached to the steel bracket side at the open-air crane top entry.
PM40 7109-E00 RISK OF FALLING DOWN - USE SAFETY BELT!
During any visit to the crane top (e.g. for service jobs), the authorizing officer and the person
entering to the area must fully understand the risks involved.
WARNING SIGN
The safety belt must be worn during any visit to the crane top.
This sign is attached to the steel bracket side at the open-air crane top entry.
PM40 7111-E00 ROTATING FAN - KEEP HANDS OFF!
The rotating fans are protected by grids and the risk is for anyone who sticks fingers or hand
inside. This can be avoided by sign information.
CAUTION SIGN
Attached to fan houses on the open-air crane top and to wall surfaces near the top roof of the
crane.
PM40 7112-E00 RIDING ON CARGO FORBIDDEN
For the attention of the crane operator, to observe that the crane is a Cargo Handling device.
DANGER SIGN The crane operator is obliged to stop operation and to alert any person riding to keep off. The
operator’s alarm bell, in the crane operator’s cabin, may be used, preferably.
Attached on the wall side of the crane operator’s cabin.

PM40 7113-E00 HOT OIL AND SURFACES - WATCH OUT!
During crane operation, surfaces of oil heated equipment are extemely hot.
Service personnel dismounting such equipment (e.g. checking and setting valves) must be
NOTICE SIGN aware of this exposure.
Attached to surfaces inside the crane house, close to pumps, valves, pipes and manifold blocks.
Also in the foundation close to oil tank and pipes.
PM40 7114-E00 DANGEROUS OIL PRESSURE - BE CAREFUL!
The oil pressure inside oil pressure pipes is 25 - 350 bar.
Under normal working conditions, this exposes no risk for personnel because of rigorous pipe
WARNING SIGN quality control and dimensions and specifications applied to the equipment. For specific service
work, exchange of parts or equipment, the exposure may be dangerous for unqualified or
uninformed personnel.
Instructions for service must be followed and must be restricted to qualified personnel only.
Attached to surfaces close to pipes inside the crane house.
7 (14)
GENERAL 1.000.4 E rev.: e 2013-01-30
PM40 7115-E00 SLIPPERY SURFACES - WATCH OUT!

Also under normal working conditions, all walking surfaces are slippery from dirt, oil spill, etc.
The responsible officers onboard must have the crane ladders and work platform surfaces
WARNING SIGN cleaned regularly. Any person who is admitted to the area must be aware of the risk of slippery
surfaces.
This sign is attached generally to the walls of work platforms.
PM40 7116-E00 STARTS AUTOMATICALLY WITHOUT NOTICE, AT +10°C (+50°F)
Under normal working conditions, of risk is not exposed to any person near of fans. During
service or upon removal of covers, the risk must be recognized. Such operation is restricted to
NOTICE SIGN qualified personnel only.
Attached to cooling fans, at the open-air crane top, and at the inside top roof.
PM40 7117-E00 HIGH VOLTAGE INSIDE - DO NOT OPEN! AUTHORIZED PERSONNEL ONLY
High voltage equipment, couplings and boxes are covered and do not expose risk unless covers
or hoses are removed. Access is restricted to qualified and authorized personnel only.
DANGER SIGN
Attached to electrical equipment and boxes where 110 V or 440 V is exposed after covers are
removed.
PM40 7118-E00 RISK OF FALLING DOWN - APPLY SAFETY CHAIN!
During any visit to the work platforms, the authorizing officer and the person entering the area
must fully understand the risks involved.
WARNING SIGN The safety chains (at work platforms) must be used to prevent personnel from falling.
Attached to the steel bracket side at the open-air crane top platform, and at the crane
work platforms inside the crane house.
PM40 7119-E00 HIGH VOLTAGE INSIDE - DO NOT OPEN BEFORE MAIN SWITCH (Q1) IS SWITCHED OFF!
AUTHORIZED PERSONNEL ONLY
High voltage equipment, couplings and boxes are covered and do not expose risk unless covers
or hoses are removed. Access is restricted to qualified and authorized personnel only.
DANGER SIGN
Attached to electrical equipment e. g. electric main motor.

PM40 7122-E00 RISK OF BODILY INJURY - SUSPENDED LOAD - WATCH OUT!
The crane operator must ensure that the suspended load does not expose personnel below to
risks of falling material. The crane operator must stop operation and alert personnel.
DANGER SIGN The operator’s alarm bell in the crane operator’s cabin is preferably used.
Applied on the wall side of the crane operator’s cabin.

PM40 7123-E00 RISK OF GETTING CAUGHT BETWEEN WIRE AND WIRE SHEAVES - WATCH OUT!
This sign warns of the risk of moving wires that may catch and jam personnel.
The authorized visitor must be aware of the risk and be cautious to avoid being seriously hurt.
WARNING SIGN
This sign is attached to the steel bracket side of the open-air crane top entry.
8 (14)
GENERAL 1.000.4 E rev.: e 2013-01-30
PM40 7124-E00 RISK OF BODILY INJURY. EMERGENCY OPERATION, AUTHORIZED PERSONNEL ONLY
OPERATE WITH UTMOST CARE, SEE INSTRUCTION
Emergency operation of luffing and slewing, in the event of complete power failure or main
DANGER SIGN pump unit failure, is extremely difficult and dangerous.
This operation must be undertaken with great care and only by skilled personnel. Instructions
must be observed at all times.
Attached to the wall side of the crane operator’s cabin.
PM40 7125-E00 DANGER - KEEP OUT OF WORKING AREA!
The working area of the crane, over deck as well as over the deck-sides, is dangerous for
personnel, equipment or property. Items lifted or articles dropped may cause death, injury or
DANGER SIGN severe damage.
The crane operator must stop operation and alert personnel.
The operator’s alarm bell must also be used for attention.
Attached on both sides of the crane jib. (Optional, attached above Pedestal access opening.)
PM40 7127-E00 220V INSIDE. DO NOT OPEN! AUTHORIZED PERSONNEL ONLY
This high voltage equipment is covered and does not expose risk unless cover is removed.
The electrical equipment inside cover is powered even if the main switch has shut off other
DANGER SIGN electrical supply.
Access is restricted to qualified and authorized personnel only.
Attached outside and inside the cabin.

PM40 7129-E00 STARTS AUTOMATICALLY WITHOUT NOTICE AT +25°C (+80°F)
Under normal working conditions, of risk is not exposed to any person near of fans. During
service or upon removal of covers, the risk must be recognized. Such operation is restricted to
NOTICE SIGN qualified personnel only.
Attached to cooling fans, at the open-air crane top, and at the inside top roof.
PM40 7130-E00DANGEROUS OIL PRESSURE. BE CAREFUL!
The oil pressure inside oil pressure pipes is 25 - 350 bar.
Under normal working conditions, this exposes no risk for personnel because of rigorous pipe
quality control and dimensions and specifications applied to the equipment. For specific ser-
WARNING SIGN vice work, exchange of parts or equipment, the exposure may be dangerous for unqualified or
uninformed personnel.
Instructions for service must be followed and must be restricted to qualified personnel only.
Attached to surfaces close to pipes inside the crane house.

PM40 7131-E00 RISK OF GETTING CAUGHT BETWEEN DRUM AND BRACKET - WATCH OUT!
This sign warns the visitor about the risk of getting jammed when the drum is rotating.
WARNING SIGN Adequate caution must be exercised.
Attached to brackets and walls of work platforms inside the crane.

PM40 7132-E00 HOT OIL AND SURFACES - WATCH OUT!
Surfaces of equipment in which there is hot oil can be extremely hot when the crane is in opera-
tion. When service personnel are working on such equipment (e.g. checking and setting valves)
NOTICE SIGN they must be aware of the danger.
Attached to surfaces inside the crane housing, close to pumps, valves, pipes, and manifold
blocks. Also in the foundation, close to oil tank and pipes.
9 (14)
GENERAL 1.000.4 E rev.: e 2013-01-30
PM40 7134-E00 RISK OF GETTING CAUGHT BETWEEN WIRE AND DRUM. WATCH OUT!
When the winch is started and during operation, there is a risk of getting caught and jammed by
moving wire. A safe distance from wires and drums must be maintained and adequate caution
WARNING SIGN must be exercised.
Attached to the crane wall surfaces close to winches.

PM40 7135-E00RISK OF GETTING CAUGHT BETWEEN DRUM AND BRACKET - WATCH OUT!
This sign warns the visitor about the risk of getting jammed when the drum is rotating.
WARNING SIGN Adequate caution must be exercised.
Attached to brackets and walls of work platforms inside the crane.

PM40 7136-E00 RISK OF GETTING CAUGHT BETWEEN WIRES DURING CRANE OPERATION - WATCH
OUT!
This sign warns about the risk of moving wires, that may catch and jam personnel.
Authorized visitors must be aware of the risk and be very cautious to avoid serious injury.
WARNING SIGN
This sign is attached to the steel bracket at the open-air crane top entry.
PM40 7140-E00 HIGH VOLTAGE, SEPARATE FEED, EVEN WHEN MAIN SWITCH (Q1) IS SWITCHED OFF.
AUTHORIZED PERSONNEL ONLY.
High voltage equipment, couplings and boxes are covered and do not expose risk unless co-vers
DANGER SIGN or hoses are removed.
Boxes with this sign are powered even if main switch has shut off other electrical power. Access
is restricted to qualified and authorized personnel only.
Attached to electric cabinet CT1.
PM40 7142-E00 HIGH VOLTAGE INSIDE. DO NOT OPEN! AUTHORIZED PERSONNEL ONLY
This high voltage equipment is covered and does not expose risk unless cover is removed.
The electrical equipment inside cover is powered even if the main switch has shut off other
DANGER SIGN electrical supply.
Access is restricted to qualified and authorized personnel only.
Attached to the cover of slipring device in the foundation.
10 (14)
GENERAL 1.000.4 E rev.: e 2013-01-30
Fig. 1. PM40 7101-E00 Fig. 2. PM40 7102-E00
Fig. 3. PM40 7103-E00 Fig. 4. PM40 7104-E00
Fig. 5. PM40 7105-E00 Fig. 6. PM40 7106-E00
Fig. 7. PM40 7108-E00 Fig. 8. PM40 7109-E00
11 (14)
GENERAL 1.000.4 E rev.: e 2013-01-30
Fig. 9. PM40 7111-E00 Fig. 10. PM40 7112-E00
Fig. 11. PM40 7113-E00 Fig. 12. PM40 7114-E00
Fig. 13. PM40 7115-E00 Fig. 14. PM40 7116-E00
Fig. 15. PM40 7117-E00 Fig. 16. PM40 7118-E00
12 (14)
GENERAL 1.000.4 E rev.: e 2013-01-30
Fig. 17. PM40 7119-E00. Fig. 18. PM40 7122-E00
Fig. 19. PM40 7123-E00 Fig. 20. PM40 7124-E00
Fig. 21. PM40 7125-E00 Fig. 22. PM40 7127-E00
Fig. 23. PM40 7129-E00 Fig. 24. PM40 7130-E00
13 (14)
GENERAL 1.000.4 E rev.: e 2013-01-30
Fig. 25. PM40 7131-E00 Fig. 26. PM40 7132-E00
Fig. 27. PM40 7134-E00 Fig. 28. PM40 7135-E00
Fig. 29. PM40 7136-E00 Fig. 30. PM40 7140-E00
Fig. 31. PM40 7142-E00
14 (14)
GENERAL 1.005 E rev.: f 2012-11-28
Preface
This instruction manual covers a MacGREGOR deck Spare parts

crane. We hope that it will prove a valuable companion General advice how to order spare parts; spare parts
to everyone concerned with the operation of the crane lists and illustrations.
or otherwise in a responsible position.
Every manual belongs to a specific crane or piece of

equipment. The identification can be found on the label
on the manual’s back.
The manual contains nine sections. The various sec-

tions cover the following subjects:
General
Contents list; Safety; Conversion tables; Hydraulic and
electric symbols.
Technical description
Technical data; description of crane design.
Function
Electric and hydraulic functions of the crane.
Operation
Operating instructions; crane operator’s checklist.
Maintenance
Lubricating chart and maintenance instructions.
Service
General service instructions for the hydraulic system,
mechanical, control system and electrical equipment.
Extra equipment
Extra equipment, if any; e.g. cargo handling equipment.
Appendices
Other information, which cannot be referred to any of
the above mentioned sections.
1 (2)
GENERAL 1.005 E rev.: f 2012-11-28
THIS PAGE IS INTENTIONALLY LEFT BLANK
2 (2)
GENERAL 1.009 E rev.: a 1996-05-20
General Instructions
Cleanliness in Hydraulic Systems
General
The fundamental and foremost rule in all work with Use a brush for cleaning, wipe off with a non-
hydraulic systems and components is absolute linting rag, repeat the cleaning if necessary. Fin-
cleanliness. ish by spraying the area of operations - hose con-
nections etc. - with the solvent.
Many components, e.g. valves and pumps, have 4. Mount protective covers immediately after remov-
very narrow tolerances, therefore microscopic im- ing a component, a pipe or a hose. Components,
purities, invisible to the human eye, may have dis- shall also be fitted with covers and plugs in order
astrous effect on the function of a hydraulic sys- to prevent ingress of dirt.
tem. These covers must be kept in clean and closed
packages. After use, covers are to be cleaned in
The hydraulic system installation contains a cleaner the workshop.
with a cartridge designed to stop impurities pro- 5. Observe minute cleanliness when handling all
duced within the hydraulic system during operation. types of quick-release connectors. Spray both
Every care must be taken to prevent external im- connectors with solvent before making up a con-
purities from entering the system when servicing or nection. Clean all covers before reinstallation.
repairing it.
Storing and filling up of hydraulic oil
This also applies for components that have been
1. Store barrels, hoses and pump as clean as pos-
removed and or to be reinstalled. Sooner or later, a
sible and best of all in a warm room. The oil vis-
component that has been replaced will be inspected
cosity will then be considerably lower, which
in a test equipment somewhere. It is important that
make the filling through filter easier.
the component stays in the same condition as it was
2. Barrels, hoses and pump must be carefully han-
when it was removed, as it may otherwise be
dled and cleaned when necessary.
impossible to decide the real cause of a malfunction.
3. Store barrels horizontally, so plugs (or cocks) are
It may also be possible that a component sent in
below the liquid level and impurities (e.g., damped
for inspection is not defective at all, and will be
air) does not penetrate the barrels.
returned.
4. Observe minute cleanliness when filling up oil -
carelessness is one of the greatest sources when
Rules when working on the hydraulic system impurities penetrates the hydraulic system.
The following fast rules shall be observed during 5. Fill up hydraulic oil. See separate instruction.
working on the hydraulic system: 6. Never use the last drop in the barrel, as it often
consists of water and other impurities depend-
1. Carry out a rough general clean-up. ent on how many times the barrel has been
2. Protect the area where work shall be done. Use opened.
a sheet of plastic material or similar.
3. Clean well with white spirit or a similar solvent.
Remember that it is not enough to clean only the
parts immediately concerned, but also their sur-
roundings from where accumulated dirt may be
transferred in to the repair area. Do not forget to
clean the tools to be used.
1 (2)
GENERAL 1.009 E rev.: a 1996-05-20
2 (2)
GENERAL 1.102 E rev.: c 1999-09-14
Conversion Factors
Length Pressure
1 mm = 0,0393701 in (tum) 1 atm = 14,6959 lbf/in2 (psi)
1 m = 3,28084 ft (fot) 1 atm = 1,01325 bar
1 in = 25,4 mm 1 atm = 1,03323 at
1 ft (fot) = 304,8 mm 1 bar = 0,986923 atm
1 at = 14,2233 lbf/in2 (psi)
Volume 1 at = 0,980665 bar
10 lbf/in2 = 0,689476 bar
1 dm3 = 1 litre = 0,219969 gallon (UK)
10 lbf/in2 = 0,70307 at
1 dm3 = 1 litre = 0,264172 gallon (US)
1 bar = 1,01972 at
1 gallon (UK)= 4,54609 dm3
1 bar = 14,5038 lbf/in2 (psi)
1 gallon (US)= 3,78541 dm3 2
1 kp/cm = 14,2233 lbf/in2
1 bar = 100 kPa = 0,1 MPa
Mass 1 Pa = 1 N/m2
1 kg = 2,20463 lb 1 Pa = 10,2 · 10-6 kp/cm 2
1 lb = 0,45359 kg 1 Pa = 0,145 · 10 -6 lbf/in2
1 ton (metric) = 1000 kg 1 Pa = 7,5 · 10-3 mm Hg
1 ton (UK) = 1 longton (US) 1 kp/cm2 = 98,07 ·103 Pa
1 ton (UK) = 1016,05 kg
Power
Force 1 kW = 1,35962 hk
1 kp = 2,20462 lbf 1 kW = 1,34102 hp (UK, US)
1 kp = 9,80665 N 1 hk = 0,986320 hp (UK, US)
1 lbf = 4,44822 N 1 hp (UK, US) = 1,01387 hk
1 lbf = 0,453592 kp 1 hk = 0,735499 kW
1N = 0,101972 kp 1 hp (UK, US) = 0,745700 kW
1N = 0,224809 lbf
Temperature
Moment of force 0°C = 32°F
1 kpm= 9,80665 Nm 0°C = 273,15 K
1 kpm= 7,23301 lbf · ft 0°F = -17,7778°C
1 Nm = 0,737562 lbf · ft 0°F = 255,3722 K
1 lbf · ft = 0,135582 daNm 0K = -273,15°C
1 lbf · ft = 1,35582 Nm 0K = -459,67°F
1 lbf · ft = 0,13825 kpm
1 daNm = 1,01972 kpm 1
°C = (°F - 32) °F = 1,8 (K - 273,15) + 32
1 daNm = 7,37562 lbf · ft 1,8
1
°F = °C · 1,8 + 32 K= (°F - 32) + 273,15
1,8
Moment of inertia
°C = K - 273,15
1 kg · m 2 = 3417,17 lb · in2
1 lb · in 2 = 0,00029264 kg · m2 K = °C + 273,15
1 (2)
1.102 E rev.: c 1999-09-14
2 (2)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
Hydraulic and Electric Symbols
Hydraulische und elektrische Bildzeichen
This section covers a part of the symbols and port markings commonly
used in MacGREGOR (SWE) AB, Service Division hydraulic and electric
circuits, divided into three parts:
Diese Sammlung umfaßt einen Teil der allgemeinen Bild- und

Anschlußzeichen, die in MacGREGOR (SWE) AB, Service Division,
hydraulischen und elektrischen Schemas vorkommen, unterteilt in drei
Gruppen:
1. Hydraulic symbols, basic.
Hydraulische Bildzeichen, einfach.
2. Hydraulic symbols, composite.
Hydraulische Bildzeichen, kombiniert.
3. Electric symbols.
Elektrische Schaltzeichen.
1 (30)
Hydraulic symbols and valve assemblies
Hydraulische Bildzeichen und Ventil-

Baugruppen
1. Hydraulic Symbols
Hydraulische Bildzeichen
Working oil line.

Arbeitsdruckleitung.
Pilot line.
Steuerdruckleitung.
Drain line.
Leckölleitung .
Plug, plugged connection (alternative symbols).

Verschlußchraube, Sperrung (wahlweise).
Fixed restriction.
Feste Blende, feste Drosselung.
Variable restriction.
Regelblende, regelbare Drosselung.
Restriction unaffected by viscosity.

Temperaturunabhängige Drosselung.
Flexible hose.
Schlauch, biegsame Leitung.
2 (30)
Pipe junction.
Leitungsverbindung.
Crossed pipes, no connection.

Kreuzende Leitungen, ohne Verbindung.
Rotary connection.
Dreh-Verbindung.
Tank line, tank.

Tankleitung, Tank.
Regulation or variability.
Regelbar oder nachstellbar.
Enclosure of component assembly.

Umriß eines Mehrkomponentenblocks.
Mechanical connection.
Mechanische Verbindung.
Pump, fixed displacement, 1 direction of flow.

Pumpe, konstantes Deplacement, 1 Stromrichtung.
Pump, variable displacement, 2 directions of flow.

Pumpe, variables Deplacement, 2 Stromrichtungen.
3 (30)
Motor, fixed displacement, 2 directions of flow, exter-

nal drain.
Motor, konstantes Deplacement, 2 Stromrichtungen,
extern Drainierung.
Motor, 2 displacement, 2 directions of flow.

Motor, 2 Deplacement, 2 Stromrichtungen.
Motor, variable displacement, 2 directions of flow.

Motor, variables Deplacement, 2 Stromrichtungen.
Electric motor.
Elektromotor.
M
Filter.
Filter.
Filter with contamination indicator.

Filter mit Anzeiger.
Filter with by-pass valve.

Filter mit Rückschlagventil.
4 (30)
Air breather.
Luftreiniger.
Pressure electric switch, normally open.

Druckschalter, druckgesteuert, normal offen.
Pressure electric switch, normally closed, adjustable.

Druckschalter, druckgesteuert, normal geschlossen,
regelbar.
Non-return valve.
Rückschlagventil.
Non-return valve, spring loaded with certain opening

pressure difference.
Rückschlagventil, federvorbelastet mit gewisser
Öffnungsdruckdifferenz.
Non-return valve, spring loaded with certain closing

pressure difference.
Rückschlagventil, federvorbelastet mit gewisser
Schließungsdruckdifferenz.
5 (30)
Quick coupling or gauge connection.

Schnellkupplung oder Meßanschluß.
Gauge connection.
1
Meßanschluß.
Ventilation valve.
Entlüftungsventil.
Non-return valve with variable restriction.

Drosselrückschlagventil, regelbar.
Shuttle valve.
Wechselventil.
Brake cylinder.
Bremszylinder.
Cylinder, double-acting with fixed cushion at one side.

Zylinder, doppelt wirkend mit konstanter Dämpfung
auf einer Seite.
Pressure gauge.
Manometer.
Thermometer.
Thermometer.
6 (30)
Oli cooler.
Ölkühler.
Accumulator.
Druckspeicher.
Shut-off valve.
Absperrventil.
Valve, basic symbol.

Schieber, Grundzeichen.
Electrically controlled valve.

Schieber, elektromagnetisch gesteuert.
Pressure controlled valve.

Schieber, druckgesteuert.
Pilot controlled valve, internal pressure supply.

Schieber, vorgesteuert, interner Steuerdruck.
Pilot controlled valve, external pressure supply.

Schieber, vorgesteuert, externer Steuerdruck.
Lever controlled valve.

Schieber, knüppelgesteuert.
7 (30)
Mechanically controlled valve.

Schieber, mechanisch gesteuert.
Valve with spring return.

Schieber mit Feder-Rückführung.
Valve with detent.

Schieber mit Lagehalter.
4/2 direction valve

A B
Electrically controlled four-way, two-position valve,
spring return to neutral position.
4/2-Wegeventil
4-Wegeschieber mit 2 Arbeitsstellungen, Feder-
P T
Rückführung in die Nullstellung.
4/3 direction valve

Electrically controlled four-way, three-position valve,
spring centred.
4/3-Wegeventil
4-Wegeschieber mit 3 Arbeitsstellungen, feder-
zentriert.
Proportional valve.
Proportionalventil.
Servo valve.
Servoventil.
8 (30)
Balance valve (GP- and HH-cranes)

Ausgleichsventil(GP- und HH-Kräne)
Flow regulator, adjustable.

Fluß Regulator, regelbar.
Flow regulator with non-return valve.

Fluß Regulator mit Rückschlagventil.
Cartridge valve.
Patronenventil.
Pressure limiting valve, adjustable.

Druckbegrenzungsventil, regelbar.
9 (30)
Pressure limiting valve with remote opening or clos-

ing.
Druckbegrenzungsventil mit ferngesteuerter Öffnung
oder Schließung.
Pressure reducing valve.

Druckreduzierventil.
Pressure reducing valve with T-port.

Druckreduzierventil mit T-Anschluß.
10 (30)
2. Valve Assemblies
Ventil-Baugruppen
Filter unit with by-pass valve.

Filtereinheit mit Shuntventil.
Filter unit with by-pass valve and electric filter indica-

tion.
Filtereinheit mit Shuntventil und Zustandsanzeige.
Filter unit with pressure limiting valve.

Filtereinheit mit Druckbegrenzungsventil.
11 (30)
Filter unit with pressure limiting valve.

Filtereinheit mit Druckbegrenzungsventil.
Filter unit with by-pass valve and electric filter indica-

tion.
Filtereinheit mit Shuntventil und Zustandsanzeige.
12 (30)
Pump for hoisting winch.

Pumpe für Lastwinde.

13 (30)

Pump for luffing winch.

Pumpe für Einziehwinde.
14 (30)
Pump for luffing winch.

Pumpe für Einziehwinde.
Pump for luffing or slewing.

Pumpe für Einziehwinde oder Schwenkantrieb.
15 (30)
Pump for slewing or luffing.

Pumpe für Schwenkantrieb oder Einziehwinde.
Pump for slewing.

Pumpe für Schwenkantrieb.
16 (30)
Hoisting winch with 84-series motor and motor valve.

Lastwinde mit Motor Typ 84 und Motor-
Umschaltventil.
Hoisting winch with 63/64-series motor and motor

valve.
Lastwinde mit Motor Typ 63/64 und Motor-Umschalt-
ventil.
17 (30)
Hoisting winch with variable high speed hydraulic mo-

tor.
Lastwinde mit variabel schnellaufendem hydrau-
lischem Motor.
Luffing winch with 63/64-series motor and motor valve.

Einziehwinde mit Motor Typ 63/64 und Motor-
Umschaltventil.
18 (30)
Unloading and flushing valve, slewing.

Entlastungs- und Spülventil, Schwenkantrieb.
Unloading and flushing unit, hoisting and slewing.

Entlastungs- und Spülventil, Lastwinde und Schwenk-
antrieb.
Flushing valve.
Spülventil.
19 (30)
Valve unit for stabilizing winch.

Ventileinheit für Stabilisierungswinde.
Unloading unit for feed pump.

Entlastungsventil für Speisepumpe.
20 (30)
Valve unit, cylinder luffing.

Ventileinheit, Zylinder-Einziehung.
Valve unit, cylinder luffing.

Ventileinheit, Zylinder-Einziehung.
21 (30)
3. Electric Symbols
Elektrische Schaltzeichen
Conductor junction, permanent.

Leitungsverbindung, fest.
Conductor junction, separable.

Leitungsverbindung, trennbar.
Crossed conductor, no connection.

Kreuzende Leitungen, ohne Verbindung.
Slip ring with brush.

Schleifring mit Bürste.
Fuse, supply side indicated.

Sicherung, Zuführungsseite markiert.
Magnetic relay, contactor.

Steuergerät, elektromagnetische Erregerwicklung.
Make contact.
Arbeitskontakt.
Break contact.
Schaltkontakt.
22 (30)
Main contact.
Hauptkontakt.
Contact, manually operated.

Kontakt, von Hand betätigt.
Contact, manually operated without automatic return.

Kontakt, von Hand betätigt, nicht selbstrückstellend.
Emergency stop.
Notschalter.
Contact with delayed opening.

Kontakt mit Ausschalt-Verzögerung.
Contact with delayed closing.

Kontakt mit Einschalt-Verzögerung.
Contact with delayed opening/closing.

Kontakt mit Ein- und Ausschalt-Verzögerung.
Limit switch.
Endschalter.
Contact, thermal controlled.

Kontakt, thermisch gesteuert.
23 (30)
Pressostat.
Pressostat. P
Level switch.
Ölstandswächter.
Temperature switch, thermostat.

Temperaturwächter, Thermostat.
Touch free contact.

Berührungsfreier Geber.
Inductive contact.
Induktiver Geber.
Ammeter.
Strommesser.
A
Voltmeter.
Voltmesser. V
Hour counter.
Stundenzähler. h
Earth (hull) connection.

Massenverbindung (Rumpf).
24 (30)
Rectifier.
Gleichrichter.
Transformer with two windings.

Transformator mit zwei Wicklungen.
Transformer with several secondary windings, with

screen between primary and secondary windings.
Transformator mit mehreren Sekundärwicklungen, mit
Schirm zwischen den Primär- und Sekundär-Wicklungen.
Triple-pole thermal relay (overcurrent) circuit breaker.

Dreipoliges thermisches Relais (Überstrom-Aus-
lösung).
Frequency converter.
Frequenzumformer.
25 (30)
Diode.
Diode.

Light emitting diode.
Leuchtdiode.
Pilot lamp.
Meldeleuchte.
Light.
Beleuchtung.
Flood light.
Scheinwerfer.
Alarm signal.
Alarmsignal.
Alarmsiren.
Alarmhupe.
Single-phase outlet.
Steckdose, einphasig.
26 (30)
Position encoder.
Drehfeldgeber.
Puls/speed encoder
Geschwindigkeitsgeber
Flexible lead connector.

Steckverbindung.
Resistor.
Widerstand.
Resistor, non-linear.
Widerstand, spannungsabhängig.
Variable resistor.
Widerstand, regelbar.
Potentiometer with slider and a fixed tap.

Potentiometer mit Schleifer und einer Festanzapfung.
Heater.
Heizkörper.
Motor.
Motor. M
27 (30)
Condenser.
Kondensator.
Heater, cabin.
Heizkörper in der Fahrerkabine.
Air condition.
Klimaanlageapparat.
VL . . . .
Solenoid valve.
Magnetventil.
Oil tank heater.

Ölbehälterheizer.
28 (30)
Controller, hoisting.
Steuerknüppel, Lastwinde.
Controller, luffing and slewing.

Steuerknüppel, Einziehwinde und Schwenkantrieb.
29 (30)
30 (30)
TECHNICAL DATA Project No.: 2/12012.01LMW rev: - 2013-03-15
TECHNICAL DATA
GENERAL
Type of crane GLB3030-2/2430gr
Work order 2/12012.01LMW
Serial number 62514099 - CRANE No. 1

62514100 - CRANE No. 2
62514101 - CRANE No. 3
62514102 - CRANE No. 4
Ambient temp range -25 to + 45° C
BASIC DATA
Lifting height H 10.5 m
Lifting height K 29.5 m
Hoisting Hoisting Hoisting Hoisting Luffing time Slewing speed Jib radius, Jib radius,
capacity, capacity, speed, speed, Max – min Minimum Maximum
Low speed High speed Low High radius
(ton) (ton) (m/min) (m/min) (sec) (rev/min) (m) (m)

30 13.3 25 45 65 0.8 4.7 30
24 10.5 25 45 65 0.8 4.7 30
1 (6)
MAIN SUPPLY
Rated voltage 440 V
Type of frequency 3 - 60 Hz
Control voltage 220 V
ELECTRIC MOTOR, Pump unit
Rated power, continous 127 kW
Starting current 530 A
WIRE ROPE
Load wire rope Ø 30 mm × 288 m

No. 1234872
Luffing wire rope Ø 28 mm x 226.5 m

No. 1234873
OIL VOLUME / OIL FILLING (per unit)
Hydraulic oil tank 450 liters
Slewing gear 14.0 liters
Hoisting winch 11.0 liters
Luffing winch 6.5 liters
2 (6)
Limit Switches in Hoisting and Luffing Winch Systems
3 (6)
Limit switches - hoisting winch
4 (6)
LOAD STEP DIAGRAM
Fig. 1. Load diagram
5 (6)
6 (6)
TECHNICAL DESCRIPTION 2.007.91 E rev.: - 2008-08-08
Technical Description
Jib top
Protective plate
Lifting block
Main electric motor
Pump unit
Crane operator's cab

Oil tank
Slack wire device
Luffing winch
Crane jib
Hoisting winch
Slewing gear
Fig. 1. Crane type GLB.
1 (4)
MacGREGOR hydraulic deck cranes are self- The hydraulic system is designed for start at a
contained units with all machinery enclosed in the temperature range of from high to lowest ambient
crane house and, thus, well protected against external working temperature for world wide trading according
abuse. to classification societies. For cranes operating in cold
environment an optional oil heater should be installed
When delivered, the cranes are mechanically, in the oil tank. The oil heater is started by using the
hydraulically, and electrically complete in every pushbutton in the CT1 cabinet.
respect and ready to be installed on a suitable
foundation fixed in the ship’s deck or on a crane An oil cooler removes heat developed in the oil during
carriage travelling on deck. its work cycle. If the oil temperature exceeds a certain
level, a thermostat operates a contactor to stop the
main drive electric motor.
Construction
All crane movements - hoisting, luffing, and slewing -
Filters on outlet and inlet to the oil tank ensure
are driven by hydraulic motors. These are supplied
continous cleaning of the oil flow. Two filter indicators,
with high pressure oil by a pump unit comprising
one electric activates a warning lamp in cabin and
separate pumps for each hydraulic circuit and a
one visual indicates when elements need to be
separate feed and control pressure pump. The high
changed.
pressure pumps are mounted in the same pump unit
and are geardriven by a flange mounted electric motor.
Various pressure limits are provided to protect the
Starting of the electric motor is affected by an Y/D
crane against overload. All moving parts in the
starter, giving low starting current.
hydraulic system are lubricated by the hydraulic oil
which minimises mechanical wear and ensures the
The hoisting winch is driven by a hydraulic motor via
added advantage of silent operation.
a planetary gear box. A brake is integrated in the winch
gear set. When the winch is running, the brake is
The crane house is an all-welded structure on a rigid
automatically released by a hydraulic unit. The
baseplate, and encloses all mechanical and
hoisting winch is also provided with a pressure roller
hydraulical machinery and associated electrical
and one layer of wire on the drum.
equipment for adequate protection against rain, sleet,
and waves breaking over the ship. Catwalks, ladders,
Limit switches operate if the wire slackens and to
platforms, and handrails facilitate maintenance of the
preclude the complete unwinding of the wire from the
crane.
wire drums.
The tops of the crane house and of the jib head are
The crane jib is raised and lowered by the luffing winch
fitted with sheaves for the hoisting and luffing wire
whose general design is similar to that of the hoisting
ropes. All sheaves have sealed roller bearings
winch.
mounted on shafts and secured by locking plates.
The slewing drive of the crane uses a high-speed

Various limit switches on slewing and luffing motions
hydraulic motor, installed onto a planetary gearbox
are provided.
and fitted with a drive pinion. The pinion meshes with
the internal gear teeth of the slewing ring which
The cranes are supplied with test certificates to the
supports the crane house. On customer’s order limit
requirements of National Swedish Board of Shipping
switches can be provided to define the slewing range
and Navigation. The design meets the requirements
of the crane.
of ILO and the relevant classification societies whose
certificates will be furnished if specially ordered.
2 (4)
Crane operator’s cabin Deck lights

The crane operator’s cabin, with a tilted front window Two deck lights are installed in front under the cabin
located on the service door, affords an allround view and are controlled from cabin and bridge. Optional extra
of the entire work area. The cabincontains crane deck lights can be fitted upon request.
operator's seat, ready access to the two control
levers, one controlling the hoisting winch, and the Crane control system CC3000
other, the luffing and slewing movements.
Control of the hydraulic equipment is servo assisted
with the electronic crane control system CC3000.
The cabin also contains control panels with various
Speed regulation is infinitely variable and involves no
switches, pushbuttons, and signal lamps. Electric
loss of energy. The regulating system employs spring-
windscreen wiper, heater and ventilator are provided
loaded units which automatically return to neutral
as standard. Air conditioning is available as an
position when the hydraulic pressure drops.The main
optional feature.
movements of the crane, hoisting, luffing and slewing
- can be operated simultaneously without any speed
Emergency exit is via the cabin's side window.
reduction as well as independent of each other.
Jib
Hydraulic hoses
The jib is made of two box girders, joined by transverse
The hydraulic hoses are high-pressure tested and
tubular steel struts. The foot of the jib mounts on two
carefully cleaned and inspected before assembly.
trunnion journals at the sides of the crane house skirt.
A halogen floodlight is mounted on the jib.
Cargo handling gear
Electrical equipment The swivel, hook, shackles, rings, and chains all have
Certain electric cables outside of the crane house, ample safety margins for the maximum load to be
e.g. on the jib, are carried in steel conduit. All cables handled by the crane. The non-rotatory, langs lay wire
and electrical accessories are specifically designed ropes are galvanised and oiled.
for marine use.
Surface treatment
The slip-ring unit linking the crane network with the
All surfaces of the crane are carefully prepared by
shipboard network is placed under the platform inside
sandblasting before being given a coat of Primer. As
the crane house.
standard the crane is painted with an anticorrosive
system basically based on two-component epoxy
The electric cabinet is placed on the inside wall of the
paint and an acrylic finishing coat.
crane house. The cabinet contains contactors, relays,
motor switch and various other components of the
electric installation. The main power switch (Q1) is
placed on the CT1-cabinet.
Lighting
Lighting is installed in both crane house and cabin.
Can also be installed in foundation and pedestal if
required.
3 (4)
4 (4)
FUNCTION 3.110.122 E rev.: - 2009-02-02
Hydraulic Function
General Component identification
The following description refers to the standard The main components are identified by four-digit
hydraulic system of MacGREGOR hydraulic deck numbers in the diagram and on the actual components
cranes, GLB version. in the crane. The first digit of each number signifies
the circuit to which the component belongs:
Minor variations in the hydraulic system may occur in
individual cranes of the same type, and the objective of 1... Hoisting circuit
this description is only to provide a general orientation 2... Luffing circuit
concerning the arrangement of the hydraulic system. 3... Slewing circuit
4... Feed and control pressure circuit
Note! 5... Additional programming equipment *)
For reference see hydraulic circuit diagram in section 9.4 6... Twin crane hydraulic equipment
in the parts manual. All hydraulic components mentioned 7... Other additional hydraulic equipment *)
in this instruction can be found in the diagram.
*) Equipment installed at request of customer
The crane drive system consists of three separate
hydraulic work circuits, i.e. hoisting, luffing, and Legend
slewing respectively. There is also a feed and control
pressure circuit, to assist the hydraulic work circuit. MHO Hydraulic motor, hoisting circuit
MLU Hydraulic motor, luffing circuit
Each of the work circuits may have one or more pumps MSL Hydraulic motor, slewing circuit
located in the pump unit, in Figure 1 marked PHO, PLU, PHO Pump, hoisting circuit
PSL. Pump PF for the feed and control pressure system PLU Pump, luffing circuit
is also located in the pump unit. PSL Pump, slewing circuit
PF Pump, feed circuit
Identifying circuits in the hydraulic

HOISTING LUFFING SLEWING
diagram CIRCUIT CIRCUIT CIRCUIT
Figure 1 shows the arrangement of the three work

MHO MLU MSL
circuits, hoisting, luffing, and slewing circuits, together
with the feed and control pressure circuit. The circuits
appear in the same order in the hydraulic diagram.
Symbols PHO PLU PSL
Every hydraulic component is represented by a

special symbol in the circuit diagram. The meaning
of the symbols is explained in section “General” in
the Manual. The symbol for the reservoir is shown in PF
several places in the diagram for greater simplicity of
drawing; but there is naturally only one reservoir in
FEED AND CONTROL CIRCUIT
actual fact.
Fig. 1. Identifying hydraulic circuits.
1 (6)
FUNCTION 3.110.122 E rev.: - 2009-02-02
Feed and control circuits
Feed pressure circuit

The function of this circuit is mainly to replace the hot
fluid leaking from the closed work circuits. The feed
fluid is introduced through non-return valves into the
low-pressure side of the system. The feed circuit
operates at a pressure (inlet/outlet) of approx. 3.0/
2.5 MPa (30/25 bar), which is set at valve 4148 and
is measured at test point 1 and 16 respectively. Test
point 1 is feed pressure inlet and 16 is feed pressure
outlet.
Control pressure circuit

The function of this circuit is to supply fluid to the brakes
and to the pump servos, that controls winch speed,
slewing speed and working direction. The system
operates at the same pressure as the feed pressure
and is measured at test point 1.
Note!
For exact pressure settings, see pressure list in the
hydraulic diagram.
2 (6)
FUNCTION 3.110.122 E rev.: - 2009-02-02
Hoisting winch circuit Lowering
Introduction
Low speed High speed
The hydrualic circuit diagram shows the following main
hoisting components:
Pumps 1111, 1112 Hoisting Control lever

Hydraulic motor 1141
Brake 1211 Fig. 2. Control lever in neutral, hoisting
The brake is mounted inside the winch gearbox.
Function Lowering
With the control lever in neutral, Figure 2 or 5, and
the pump running, the hoisting circuit performs no
actual work. A continuous supply of fluid from the
feed circuit, flushes the circuit.
Low-speed range, brake release Control lever Hoisting

When the control lever is moved to the left for low-
speed operation of the winch, Figure 3, valve 1221 Fig. 3. Control lever, hoisting, brake release position
and 1226 in the actuated mode, "b", (1226 slightly
delayed in relation to 1221) and connects full control
pressure to the brake valve 1226 which releases the
brake, and also to valve 1128-1 which shifts from its
unloading mode. Lowering
With no load on the cargo hook and the control lever

in brake release position, Figure 3, the hoisting winch Low speed High speed
should produce a slow hoisting movement, so called
plussing. See instruction "High pressure pumps" in
section 6.1.
Control lever Hoisting
Fig. 4. Control lever, hoisting, low-speed hoisting
3 (6)
FUNCTION 3.110.122 E rev.: - 2009-02-02
High speed range, brake release Safety functions

When the control lever is moved to the right, Figure 6, The hoisting winch circuit embodies three safety
valves 1221 (a) and 1226 (b) are actuated, (1226 features:
slightly delayed in relation to 1221). Control pressure
is connected to the brake valve 1226 which releases - Main pressure limiting valves 1111-2; 1111-3, 1112-
the brake, and also to valve 1128-1 which shifts from 2, 1112-3.
its unloading mode. - Pressure switch 1311 (overload valve) stops the
crane in the event of overloading at low speed.
The brakes are released and the motor assumes the Shifts to low-speed when running in the high-speed
high-speed position (min. displacement). The motor mode.
rotates at double speed, and the lifting capacity of - Pressure switch 1381 stops the crane in the event
the winch is reduced to approximately 50 - 60 % of of insufficient feed pressure.
its maximum rate.
Note! It is not allowed to adjust sealed safety valves
With no load on the cargo hook and the control lever without contacting MacGREGOR Cranes, Service
in brake release position, Figure 6, the hoisting winch Department.
should produce a slow hoisting movement in the same
way as in low speed operation. Lowering
High-speed range overload

If the load on the cargo hook is too heavy for handling
in the high-speed range, the pressure switch 1311
will cause valve 1221 to shift to low-speed range. Full
displacement on the hydraulic motor.
Hoisting Control lever
Hoisting and lowering, high speed or low speed Fig. 5. Control lever in neutral, hoisting.
Pulling the control lever backwards from the brake

Lowering
release position will start the winch to lift the load,
Figure 4 low speed and Figure 7 high speed. The servo
valves 1111-6 ,1111-7, 1112-6 and 1112-7 affect the
servo cylinders and thus the pump displacement. The
pumps 1111 and 1112 thereby produce a flow of fluid
that is proportional to deflection of the control lever.
If, instead, the control lever is moved forward, the load
will be lowered, ie, the function is the same as for hoisting, Fig. 6. Control lever, hoisting, brake release position.
except for the direction of flow.
Lowering
High speed lowering (optional)
If the crane is designed for high speed lowering the
motor will automatically assume high-speed position
when the control lever is moved forward for lowering,
even if the control lever is to the left, for low speed.
Valve 1221 (a) will be actuated.
Fig. 7. Control lever, hoisting, high-speed hoisting.
4 (6)
FUNCTION 3.110.122 E rev.: - 2009-02-02
Luffing winch circuit
Introduction
The hydrualic circuit diagram shows the following main Note!
luffing components: It is not allowed to adjust sealed safety valves without
contacting MacGREGOR Cranes, Service Department.
Variable displacement pump 2111
Hydraulic motor 2141
Brake 2211
The luffing and slewing movements are generally Luffing-out (lowering jib)
operated by a common control lever, Figure 8.
Brake release
Moving the control lever from neutral, eg. backwards
to raise the jib, causes the valves 2221 and 2226 (2226
slightly delayed in relation to 2221) to shift position
and control pressure is admitted to the brake 2211 Luffing-in (raising jib)
and to valve 2127 which shifts position from the
unloading mode.
Fig. 8. Control lever, luffing/slewing.
With the control lever in the brake release position,
the luffing winch should produce a slow movement of
the crane jib, so called plussing. See instruction "High
pressure pumps" in section 6.1.
Raising and lowering the jib

Moving the control lever further backwards starts
operation of the luffing winch. The servo valves 2111-
6 and 2111-7 affect the servo cylinder and thus the
pump displacement. The pump 2111 thereby produces
a flow of fluid at a rate that is proportional to the lever
deflection.
To lower the jib, move the lever forward from neutral.

The function is the same as for luffing-in, except for
the direction of the fluid flow.
Safety functions
The luffing winch circuit embodies two safety features:
- Pressure limiting valves 2111-2, 2111-3.

- Pressure switch 2481; stops the crane in the event
of insufficient feed pressure.
5 (6)
FUNCTION 3.110.122 E rev.: - 2009-02-02
Slewing circuit
Introduction
The hydrualic circuit diagram shows the following main
slewing components: Slewing left Slewing right
(Anti-clockwise) (Clockwise)
Variable displacement pump 3111
Hydraulic motors 3141, 3142
Flush unloading unit 3127
Brakes 3211, 3212
Fig. 9. Control lever, luffing/slewing.
The luffing and slewing movements are generally

operated by a common control lever, Figure 9.
Brake release
Moving the control lever, eg. to the left for slewing left
(anti-clockwise), will affect valve 3221. The brakes will
be released and the unloading valve 3127-1 will be
blocked.
Slewing left and right

By moving the control lever further to the side, the crane
will start to slew in the direction chosen. The servo
valves 3111-6 and 3111-7 affect the servo cylinder
and thus the pump displacement. The pump 3111
thereby produces a flow of fluid at a rate that is
proportional to lever deflection.
To slew to the right (clockwise), move the lever to the

right instead. The function is the same as for slewing
left, except for the direction of the fluid flow.
Safety functions
The slewing circuit embodies one safety feature:
- Main pressure limiting valves 3111-2 and 3111-3.
6 (6)
FUNCTION 3.131.29 E rev.: a 2009-02-13
Starting and Stopping, Electric Safety Functions

Single Cranes
Introduction
The following description refers to the starting and Note! If crane is equipped with PMS a starting per-
stopping, and electric safety functions, of a standard- mission is required. Read "OPERATING
type single crane. A complete electric circuit diagram INSTRUCTION START - STOP" and "Controls and
relating specifically to the particular crane will be found Indicators" to operate crane with PMS.
in the section SPARE PARTS of the Manual.
The purpose of the present description is to furnish a Start sequence

general idea of the design and function of the electric - Press button S13 "1" (start).
system. The crane is supplied with electric power via - Pilot light H1 "DO NOT OPERATE" goes on.
the slip-ring unit and the main switch in the crane
house. Cables lead from the main switch to: a trans- The feed circuit pressure build up its operating pres-
former supplying power for all control circuits; a switch sure. Pressostats BP1 - hoisting circuit, BP2 - luffing
for the oil cooler fan motor; a Y/D switch for the main circuit, close and start a delayed closing 8s time relay
electric motor; and a thermostat switch for the venti- K71.
lation fan in crane house.
- After 8s, Y contactor K2 switches on N contactor
All components are marked by symbols in the dia- K1; the main motor M1 starts in Y connection.
gram, making it easier to follow the various stages of - At the same time as the Y contactor was switched
the starting sequence, e.g. on, an 8s delayed-opening double relay K9 was
started.
- Contactors: K1 (N); K3 (D); K2 (Y). - After 8s, the Y contactor drops, and D contactor
- Time relays: K9; K71. K3 is switched on by double time relay K9 closing
after 0.1s.
The D contactor and self-holding N contactor switch
Before start main motor M1 to delta configuration.
- Push button "1" (start) closing prepares the ener-
Verify that the ambient temperature is not below -15°C. gizing of motor switch Q5 of oil COOL FAN MO-
If the crane is operated in temperatures below -15°C a TOR M3.
heater has to be installed in the oil tank. Motor M3 is started by thermostat BLT1 if the tem-
perature of the hydraulic oil exceeds +10oC.
- Warning light H1 goes out. The crane is operatio-
Starting and stopping the crane nal.
Note! Joysticks for hoisting or luffing/slewing motions Stop sequence

must be in neutral position when starting the crane. If - Press button S13 "0" (stop).
the joysticks have been moved in any direction when - All contactors of Y/D switches and all other motor
pressing the start button the motion is blocked. Move contactors are de-energized. All motors stop.
the joysticks to neutral position then operation is - The ventilation fan motor stops only when the main
possible. switch Q1 is switched OFF.
1 (2)
FUNCTION 3.131.29 E rev.: a 2009-02-13
Other electric functions

Overheating protection Control system error
A thermostat BT2 in the hydraulic system of the crane If an error is detected by the crane control system in
opens the control circuits of the main electric motor the CT2-cabinet pilot light H4 illuminates. Check the
and the oil cooler fan motor when the oil temperature CT2-cabinet according to instruction "Crane Control
exceeds +85oC. Pilot light (H5) "High oil temperature" System CC3000" under Section 6.3.
illuminates.
Restart the crane by use of pushbutton S13 "1/0"

(start/stop). Pilot light H1 "DO NOT OPERATE"
illuminates. Crane and cooler fans start, but the crane
control system CC3000 is still blocked.
Pilot light H5 goes out when the crane's working oil

temperature is back below +85°C. The crane control
system CC3000 returns to normal and pilot light H1
goes out.
Oil level switch

If the oil level in the hydraulic oil tank drops below the
minimum permissible level, an alarm system is swit-
ched on by a float type oil level switch BLT1. Warning
light H2 goes on.
If the oil level sinks further, level switch BLT1 opens

the control circuit of main motor M1.
Siren
A pushbutton "SIREN" in the cabin allows the opera-
tor to warn people on deck.
Ventilation fan
For all cranes a ventilation fan is fitted in the crane
house. This is controlled by a +25°C thermostat BT1
which is located in the CT1-cabinet.
Lighting and heating

Electric power is supplied by separate slip-rings for
lighting in the crane house, in the operator’s cabin,
and on the jib and heating in the cabin.
The crane house lighting is operated by a switch un-

der the bottom plate. The cabin lighting is operated by
a switch and the jib light is operated by a pushbutton
in the cabin.
2 (2)
FUNCTION 3.142.35 E rev.: b 2009-07-10
Crane Control System CC3000
General
The following description refers to the microcomputer For detailed information about the control system a
based crane control system CC3000 for complete electric circuit diagram, relating specifically
MacGREGOR Cranes hydraulic deck cranes, single to your crane, will be found in the instruction manual,
crane versions. section "Spare Parts", Group 9.5. Also for detailed
information about the hydraulic system a complete
Minor variations in the use of control system input hydraulic circuit diagram can be found in section
and output signals due to differences in hydraulic and "Spare Parts", Group 9.4.
electric system may occur. The objective of this
description is only to provide a general orientation
concerning the principles of the control system.
Control lever Unloading/displacement

hoisting winch Cabinet CT2 shift valve
Brake valve
HOISTING
Limit switch box
Hoisting winch
MC
"Ho" Hydraulic Hydr.
pump motor
CC
"Sc"
Unloading valve
Unloading Brake valve Pressure switch
valve
Memory card
LUFFING
Luffing winch
MC
Control lever "Lu" Hydraulic Hydr.
luffing/slewing pump motor
MEM
Unloading valve Limit switch box

Brake valve
Slewing gear
SLEWING
MC Hydraulic Hydr.
"SL" pump motor
Unloading valve Limit switch box
Fig. 1. Crane control system with interfaces to control levers and hydraulic system.
1 (4)
FUNCTION 3.142.35 E rev.: b 2009-07-10
Crane control system - interfaces and

principle of operation
Control levers (joysticks)

The right control lever controls the hoisting winch. The
signals from the control lever are connected to the
MC card, "Ho" for hoisting winch.
The left joystick controls the luffing and slewing
movements. Both digital and analouge signals are
connected to MC card "Lu" for luffing and "SL" for
slewing.
The joystick linear potentiometers are fed with 0V,

+6V, and +12V. The output level is approximately +6V
with the joystick in neutral. The output signal is
controlled by the joystick and is decreased to
approximately +1.5V and increased to approximately
+10.5V, depending on the joystick movement.
The joystick for hoisting also gives 24V signals for

selection of low speed/high speed and hoisting/
lowering. The joystick for luffing/slewing also gives Fig. 2. Crane control system CC3000 in CT2
24V signals for selecting luffing in/luffing out and cabinet.
slewing left/slewing right. The voltage to current amplifier feeds the hydraulic
pump solenoids.
Crane control system

The Crane control system consists mainly of four CT2 cabinet
micro processor cards. One Communication Card CT2-cabinet containing the crane control system is
(CC) is used for internal communication between the protected against humidity by a casing with protection
cards and a parameter memory card. Three Motion class IP54 (dust and splash water proof).
Control cards (MC) are controlling all input and out-
put signals for each crane movement hoisting, luffing 19" subrack with electronic cards
and slewing. Each MC card feeds a potentiometer in All electronic cards are mounted in a standard 19"
the control lever for the crane movement in control.
aluminium subrack. A backplane card is used for
Potentiometer and control lever direction signals go
connecting power, 24V to the CC and MC cards. It
to a microprocessor with a software control program also provides communication lines between CC and
that handles brake release logic, overload logic and
MC cards and between CC card and the parameter
rampforming. The output from the microprocessor is
memory card.
fed to a voltage to current amplifier on the card.
The rampformer gives smooth acceleration and re- Hydraulic pumps

tardation to the crane movements.
The hydraulic pumps are variable displacement
pumps (e.g., the flow is steplessly variable from zero
The brake release logic circuit releases and applies
to max. rated flow). The pump oil flow is controlled by
the brake in the correct sequence with the displace-
a 24V pulse width modulated (PWM) current signal.
ment/unloading signals when the hydraulic motor is
The direction of the oil flow is dependent on which
started and stopped.
one of the two solenoid valves is activated.
2 (4)
FUNCTION 3.142.35 E rev.: b 2009-07-10
The speed of the winch, the pump displacement, the Micro Processor Cards - CC and MC
current through the solenoid coil and the lever
movement are proportional to each other.
Hardware
The control system consists mainly of one CC card
Hydraulic motors
and three MC cards. All MC cards are identical and
The hydraulic motors may be reversed by changing interchangeable.
the direction of the hydraulic pump oil flow. Each mo-
tor also having a low and a high speed range selected Each MC card is a complete stand-alone
by the operator's control lever. microprocessor system with processors, several types
of memories and communication channels, analogue
Overload protection and digital inputs as well as analogue and digital out-
To prevent the crane from being overloaded, i.e. lifting put current drivers. Each card can fully handle all in-
a too heavy load, the hydraulic system is equipped put and output signals needed for one hydraulic circuit,
with an electro-hydraulic overload system. Pressure i.e. one crane movement.
sensing switches, which normally enable the opera-
tion, stop the hoisting movement if a too heavy load A safety system consists of a secondary micro pro-
is lifted at the current jib outreach. The pressure switch cessor, which monitors the behavior of the primary
gives a signal to the control system overload logic, processor in critical situations such as hazardous ope-
which senses the overload input signal and switches ration at low feed pressure and overload pressure.
over from high speed to low speed or from low speed This system will stop the crane movement due to
to stop. activated limit.
Limit switch box, hoisting winch Software
The limit switch box contains cams with limit switches All cards, CC and MC are programmed with the same
and encoders. It controls the movements of the crane control software. Each card senses which rack-
hoisting block. position and therefore which function/crane movement
it is controlling.
Limit switch box, luffing winch

All cards identify themselves by showing a two-
The limit switch box contains cams, limit switches and character abbreviation of the function/movement
encoders. It controls the movements and outreaches name on the front panel display:
of the jib. - Sc - supervisor
- Ho - hoisting
Limit switches, slackwire - Lu - luffing
The limit switch for hoisting slackwire stops the - Sl - slewing.
lowering movement, and the limit switch luffing slack-
wire stops the luffing out movement when a wire is The leftmost card, the CC "Sc", is only used for
slack. supervisory functions such as communication with
other cards and distribution of control system para-
meters from the parameter memory card.
Luffing / slewing limits
If installed, luffing/slewing limits prevent collisions New versions of the crane control software can be
between the jib and other cranes, or other objects on loaded/programmed into the cards by using a stan-
the vessel. For more information about luffing/slewing dard notebook PC.
limits see section 4 and 6.3.
3 (4)
FUNCTION 3.142.35 E rev.: b 2009-07-10
Parameter memory card The system checks itself and external input and out-
All parameter values are stored in the parameter put signals. Internal problems such as loss of
memory card. The information is stored in electronic communications are continuously checked. Loose
memories on the card. Stored parameter values are connections to pumps and valves are detected when
not dependent on power supply or battery. There is, the output is activated. Signal levels that do not
however, a battery on the card used for a calendar, correspond to normal levels, i. e. the potentiometer
giving all cards date and time information. The card is input from the operator's handle, are also detected.
located inside the rack and is mounted on the
backplane card that also holds all the card connectors. When any type of malfunction is detected, the card
The lifetime of the battery is 10 years. flashes with its error LED, no. 28. All card error LEDs
are wired together to an error lamp in the operator's
cabin, the "control system error" lamp. To get the
Anti-condensation heating
corresponding error message number, push the
To avoid condensation on the electronic cards, the Select/Info push-button on the card with the flashing
temperature inside the cabinet is more then the LED.
temperature outside. Heating elements are therefore
mounted behind the row of plinths. They are powered If there are several errors, they are shown one at a
with 24V AC when the control system is switched off time for each push on the Select/Info push-button.
or when the crane is not operational. When there are no more error messages to read, the
display shows two hyphens "- -". The error LED is
now either on or off.
Signal overview CC3000
- If it is on, the error is still present but has been
Coloured LEDs acknowledged.
Signals to and from each card are indicated by green,
yellow and red LEDs (Light-Emitting Diodes) on the - If it is off, the errors are no longer present.
front panel of each card. When a new error is detected the error LED starts
flashing again to indicate that a new error exists.
Green LEDs are used for normal input and outputs.
Yellow LEDs indicate that the crane motion concerned Error message sign
is driven with slower speed. The corresponding error message text can be found
Red LEDs indicate that the motion is stopped. on the ERROR MESSAGES sign in the cabinet, see
section "Service", Group 6.3.
Signal overview sign
All signals indicated with LEDs are listed on the SIG-
NAL OVERVIEW sign inside the cabinet, see section
"Service", Group 6.3.
Error messages
Built-in diagnostics system

The CC3000 control system has its own built-in
diagnostics system. The system is capable of
detecting several types of malfunctions.
4 (4)
FUNCTION 3.155.3 E rev.: - 2001-08-23
Thermostatic Controlled Ventilation Fan
General
The ventilation fan is thermostatic controlled and

situated inside the crane house top, see Fig. 1.
Function
With the main switch in position "1" (on-position)
the ventialtion fan starts via a thermostat, positioned
in the CT1-cabinet, see Fig. 2. The thermostat bulb
is situated outside the cabinet.
The thermostat is activated at +25°C. The thermo-

stat can be adjusted, see Fig. 3.
Thermostat
Fig. 2. Thermostat installed in CT1-cabinet

Fan
Fig. 1. Crane house Fig. 3. Thermostat
1 (2)
FUNCTION 3.155.3 E rev.: - 2001-08-23
2 (2)
FUNCTION 3.156.2 E rev.: b 2012-08-28
Tilt Warning System to Prevent "Jack Knife"
General
The tilt warning system is a safety function to prevent

"jack knife", i.e. the jib and load falls into the crane
house. "Jack knife" can occur if:
- The crane house tilts rearward
- The jib is in a short outreach position
- Wind blows at high speed toward the front of the 3
crane. See Fig. 1.
The tilt warning system has a tilt switch on the jib

bearing flange to sense the tilt of the crane house. The
outreach for tilt warning system is sensed by either
a safety cam in the the luffing winch limit box or by a
software limit in the crane control system.
2
Function
1
When the crane house tilts rearward more than 3° 1. Crane house tilts rearward, 3° (or 3.5°)
(or 3.5°), see Fig. 1, pos. 1, and the jib is in the extra 2. Short jib outreach
3. High wind speed toward the front of the crane
minimun "jack knife" outreach, see Fig. 1, pos. 2, the
luffing-in motion gets blocked. The "Tilt Warning" pilot
lamp, see Fig. 2, comes on. The crane must be luffed- Fig. 1. Causes of "jack knife".
out and/or slewed until the "Tilt Warning" pilot lamp
goes off to luff in again.
Note!
The "jack knife" outreach is noted in the instruction The Pilot lamp on the control panel are optional.
"Technical Data" in section 2 in the Instruction and
Parts Manual.
Fig. 2. "Tilt Warning" pilot lamp in cabin.

To set the safety cam values, read instruction "Techni-
cal Data".
The tilt switch is calibrated and does not need to be set.
Read also instruction "Controls & Indicators" in sec-

tion 4 in the Instruction and Parts Manual for more
information.
1 (2)
FUNCTION 3.156.2 E rev.: b 2012-08-28
2 (2)
OPERATION PM40 1879-E00 rev.: - 2011-04-01
Crew Checklist Before and After Operation
Before operation Heater fans in crane house

Start the heater fans up to 24 hours before operation.
General
To start the heater fans, set switch Heater Fan S49
Read sections 4 "Operation" and 5 "Maintenance" in
on the CT1 cabinet to "1" and turn main switch Q1 to
the instruction manual.
"1". The fans automatically goes off when the crane
Make sure that maintenance is done.
house temperature is +25°C. Refer to "Controls and
Make sure that control levers are in neutral. If not, tell
Indicators" in section 4. See Fig. 1.
responsible officer.
Refer to Technical Data in section 2 for operating
temperature for your crane.
Oil level S50

Make sure that the oil level in tank is sufficient.
Make sure that the oil level in winches and slewing HOUR
METER
gears are sufficient.
S49
Oil temperature
The oil temperature in the oil tank must be at least
+10°C before operation.
Start oil heater and heater fans to increase the oil

temperature before operation. Q1
If the oil is colder than +10°C, you can start the crane S51
and let it idle to increase the temperature of the hy-
draulic oil until it is +10°C.
Oil heater
Start the oil heater up to 24 hours before operation. Fig 1. CT1 cabinet
To start the oil heater, set switch Summer/Winter
switch S50 on the CT1 cabinet to "2", winter. Turn
main switch Q1 to "1". The heater automatically goes
off at oil temperature +10°C. Refer to "Controls and
Indicators" in section 4.
1 (2)
Release jib and lifting gear After operation

Release jib and loose gear from its parking position.
Park the crane
Refer to “Parking the crane”in section 4. See Fig 2.
Park the crane, refer to “Parking the crane”in section 4.
Anti-condensation heating
Make sure that the heating elements in the electric
cabinet CT2 are warm. Refer to “Crane control system
CC3000” in section 3. See Fig 4.
Fig. 2. Lifting gear
Wires and sheaves

Make sure that the wires run correctly in the sheaves
and that the wire ends are securely clamped.
Fig. 4. Heating elements in CT2 cabinet
Fig. 3. Wires and sheaves
2 (2)
OPERATION PM40 5500-E00 rev.: b 1996-08-08
OPERATING INSTRUCTION
Handling of dangerous cargo

- Dangerous substances shall be handled in accordance with the
relevant requirements of National or Local Regulations and ap-
plicable National and International standard, only under the su-
pervision of a competent person who is familiar with the risks
and the precautions to be taken.
- Further requirements are stated in ILO Codes of Practice, Safety

and health in dock work.
The crane is not designed for transport of passengers.
1 (2)
OPERATION PM40 5500-E00 rev.: b 1996-08-08
2 (2)
Operation, Start and Stop
Operation
Safety precautions for crane operation Max. 2
MacGregor cranes are designed for operation in har-
bour or sheltered water environments where there is
no significant movement of the ship due to wave action.
Fig. 2. Trim
Only ship's crew is allowed to operate key switches.

When the crane is rigged for operation, all keys must Control lever slewing and luffing
be stored in a safe place by responsible officer. With the slewing/luffing control lever in neutral, the
brakes are engaged. Move the lever a short distance
Tell responsible officer onboard before you operate from neutral to release the brakes. Move the lever left
the crane. or right to slew in that direction. Move the lever forward
or backward to operate the luffing winch.
Do not operate crane if someone is in the crane house When the luffing winch operates, the hoisting winch
without permission. brake is released and it can hoist slowly. Refer to
"Controls and Indicators".
When operating with grab or magnet, handling log or
palletized cargo the lifting capacity must be reduced
to 80% of SWL if there is no “GRAB” switch in cabin.
It is not permitted to drag loads, you must lift them.
List and trim

Make sure that the ship does not list more than five
degrees. See Fig. 1.
Max 5
Fig. 3. Control lever slewing and luffing
Control lever Hoisting and lowering

With the hoisting winch control lever in neutral, the
winch brake is engaged. Move the hoisting winch lever
to high or low speed position to release the winch brake.
Maximum lifting capacity at high speed is approximately
40% of maximum SWL. The winch starts hoisting at a
slow speed when the brake is released if there is no
load in the hook. Move the lever forward to lower or
Fig. 1. List backward to hoist. Refer to "Controls and Indicators".
Make sure the ship does not trim more than two de-
grees. See Fig. 2.
Fig. 4. Control lever hoisting and lowering
1 (2)
Start and stop Trouble shooting if the crane stops

If the "HIGH OIL TEMP" pilot lamp is on:
Start
1. Push the start button "1" (S13, start/stop) to start
Joysticks for hoisting or luffing/slewing motions must
the main motor and oil cooler fan. The crane cannot
be in neutral position when starting the crane.
be operated.
Press pushbutton START PERMISSION CRANE to ask
2. Pilot lamp "HIGH OIL TEMP" goes out when the oil
for start permission. The crane is ready to start when
temperature is less than +85°C.
the green pilot light comes on. Press pushbutton “1”
3. Pilot lamp "DO NOT OPERATE" goes out when the
(START) to start the crane. The crane will start within
crane is ready for operation.
20 seconds and is operational when the red warning
light goes out. Do not operate on red light.
If the "LOW OIL LEVEL" pilot lamp is on:
1. Make sure that the hydraulic oil level is sufficient.
Note!
If the "CHECK OIL FILTER" pilot lamp is on
If the joysticks have been moved in any direction when
1. Replace filter and make sure that the hydraulic
pressing the start button the motion is blocked. Move the
system operates correctly.
joysticks to neutral position then operation is possible.
Broken circuit in cabinet CT1
1. Make sure that the motor switches and overcurrent
relays are not opened. Refer to the settings list inside
the cabinet.
STOP
Fig. 5. Start and stop
Stop
Press pushbutton “0” (STOP). See Fig 5.
Short stop in operation

When you take a short stop in operation or in case of
technical problems:
1.Raise swivel to approx. 1.5 m below jib head, if pos-
sible.
2.Return control levers to neutral.
3.Press STOP button.
Emergency stop
If the crane gets out of control:
- Let go of both control levers; they will return automati-
cally to their neutral positions.
- Press Emergency Stop button on the control panel!
2 (2)
Controls and Indicators

CT3 Display CT3
31 Lowering
Luffing out 32
Low High
Slew Slew
left right
speed speed
Luffing in Hoisting
Fig. 1. Controls and indicators in the crane cabin.
WARNING! H3 CHECK OIL FILTER

Only ship's crew is allowed to operate key switches. Indicator light. Comes on when the oil pressure over
the oil filter is more than five bar. The crane will stop
five minutes after the light has come on. Note! Replace
WARNING!
the oil filter or do a check of the hydraulic system.
Store Keys Safely
When the crane is rigged ready for operation, all !
keys for all lockable switches must be stored in a H4 CONTROL SYSTEM ERROR
safe place by the responsible officer on board. Indicator light. Comes on when an error is sensed by
the crane control system in the electronic cabinet CT2.
H1 DO NOT OPERATE H5 HIGH OIL TEMP

Indicator light. Comes on during starting sequence Indicator light. Comes on when the oil tempe-
of the crane (main electric motor and supply to elec- rature in the hydraulic system is more than 85°C.
tronics). Note! The crane stops when the oil temperature is
more than 85°C.
H2 LOW OIL LEVEL
!
Indicator light. Comes on as a pre-warning for low oil H6 OVERLOAD
level in crane and the siren, which is installed under Indicator light. Comes on at overload.
the crane cabin, will sound. The indicator light and the
siren can be switched off by selecting the key "FLOAT
SWITCH" in position "1". Note! Refill oil tank.
1 (6)
D
H8 MAIN MOTOR OVERHEATED S16 DECK LIGHT
Indicator light. Comes on when the main motor (M1) Pushbutton. Switches on/off the deck light placed
temperature exceeds 150°. under the cabin.
Note! The crane stops when the motor temperature
is more than 150°C.
S17 SIREN
H9 TILT WARNING Pushbutton. Starts the siren.
Indicator light. Comes on when the crane house is
tilting more than the preadjusted value, 3° or 3.5°.
Read instruction about "Tilt Warning" in section 3 for J
S18 JIB LIGHT
more information.
Pushbutton. Switches on/off the jib light.
?
H12 START PERMISSION CRANE 0
1 2
Pushbutton/Indicator light. Before starting the crane
push the pushbutton to ask for start permission. The
crane is ready to start when the green indicator light S19 FLOAT SWITCH
comes on. Key switch with three positions, 0/1/2. Normal oil level
is between MIN and MAX. If the oil level drops the
indicator light ”LOW OIL LEVEL” comes on and the
alarm will sound. Select position "1" or "2". Examine
1 why oil level has dropped!
0
S13 START / STOP 0 - Normal position
Pushbutton with two positions, 1 / 0. 1 - Siren off
Use the Siren off position in an emergency. The siren
1 - Start will be silent and the indicator light ”LOW OIL LEVEL”
Position “1” starts the complete crane. During the goes off. The operation of the crane may be continued
starting sequence the ”DO NOT OPERATE” indicator for a short time.
light comes on.
2 - By-pass
0 - Stop
The by-pass position is used in extreme emer-
Position “0” stops the complete crane.The power supply
gency to lower a load which is hanging on
to the main electric motor and electronics will be
the hook. The ”LOW OIL LEVEL” light conti-
broken.
nues to illuminate and the crane siren sounds.
See separate instruction "Oil level float switch and
overheating protector".
F14 RESET WIPER
Pushbutton. Resets the wiper motor (automatic fuse),
when the wiper motor has stopped due to a surge in P
current. 0
1
RGENC
S20 PARKING OF JIB
ME Y
Key switch with two positions, 0/1.

E
S15 EMERGENCY STOP

Pushbutton. Stops the complete crane in case of 0 - Normal position
emergency. The pushbutton has to be reset, otherwise 1 - Parking
the crane cannot be started again. The parking position is used when maximum outreach
is reached for the jib. Further lowering is possible for
parking of the jib when switch is in parking position "1".
2 (6)
S31 CONTROL LEVER, HOISTING/LOWERING

0
1
Note! Joystick for hoisting/lowering motion must be in

S22 WIPER neutral position when starting the crane. If the joystick
Switch. 0/1. Starts and stops the window wiper. has been moved in any direction when pressing the
start button the motion is blocked.
Move the joystick to neutral position then operation is

0
1 possible. When the control lever is in neutral position
the brake is engaged and holds the load.
S23 CAB LIGHT Moving control lever in low speed or high speed posi-
Switch. 0/1. Operates the cabin light. tion releases the winch brake.
Moving control lever in hoisting or lowering direction
means continued speed increase from zero to maxi-
mum speed.
0
1 To give a smooth acceleration and retardation to the
winch movement the control system is fitted with a
S24 CAB HEATER ramp former with a special ramp time.
Switch. 0/1. Starts and stops the cabin heater. The ramp time is the time it takes to increase the winch
speed from standstill to maximum speed, when the
control lever is moved rapidly from zero to maximum
speed position. In the same way it also takes the cor-
responding ramp time to decrease the winch speed
0
1 from maximum speed to standstill, if the control lever
will be dropped.
S25 FAN 0/1 The ramp time for the hoisting system is 2 seconds.
Switch. 0/1. Starts and stops the ventilation fan in the See Fig. 2
cabin.
PUSHBUTTON
Pushbutton on top of the control lever to be used only
when operating extra equipment e. g. grab.
1 2
S26 CARGO / GRAB HANDLING

Control lever movement
Key switch with two positions,1 / 2.
1 - Cargo
Normal SWL.
2 - Grab
- Reduced SWL for operation with grab. Start - acceleration Retardation - stop
- Interlock connection of "grab control equipment".
See instruction "Installation of Power Supply Cable Speed
…", section 6.3. max.
H
Time
0
1 2 sec. 2 sec.
Acceleration Retardation
S27 WARNING LIGHT
Switch. 0/1. Fig. 2. Hoisting/lowering.
0 - Warning light is off
1 - Warning light is on.
3 (6)
S32 CONTROL LEVER, LUFFING/SLEWING
Note! Joystick for luffing/slewing motion must be in Control lever movement

neutral position when starting the crane. If the joystick
has been moved in any direction when pressing the
start button the motion is blocked.
Move the joystick to neutral position then operation is Start - acceleration Retardation - stop
possible. With the control lever in neutral position the
brakes are engaged.
Speed
Moving the control lever short distance from neutral max.
releases the brake for luffing winch or/and slewing
machinery.
Moving the control lever furthermore in luffing or sle-
wing direction means continued speed increase from Time
zero to maximum speed. 4 sec. 4 sec.
To give a smooth acceleration and retardation to the
luffing winch movement and the slewing movement Acceleration Retardation
the control system is fitted with a ramp former with a
special ramp time. Fig. 4. Slewing.
The ramp time is the same as it takes the luffing winch
speed or the slewing machinery to increase from
standstill to maximum speed when the control lever
is moved rapidly from zero to maximum speed posi-
tion. In the same way it also takes the corresponding
ramp time to decrease the winch speed from max. to
standstill if the control lever will be dropped.
The ramp time for luffing is 2 seconds and for slewing
4 seconds. See Fig. 3 and 4.
PUSHBUTTON
Pushbutton on top of the control lever to be used only
when operating extra equipment e. g. grab.
Control lever movement
Start - acceleration Retardation - stop
Speed
max.
Time
2 sec. 2 sec.
Acceleration Retardation
Fig. 3. Luffing.
4 (6)
Cabin Display
The display gives information about the status of the
crane during its operation. What information that can
be presented depends of the crane's configuration. CONTROL LEVER INDICATOR, (S31)
The information on the display is supplied by the soft- The right circle with four green arrows and a small
ware Macheavyvisor, refer to section 7 of this manual. white ball represents the right control lever and the
four motions it controls.
Note! If there is no communication with the CC3000 (Hoisting/lowering in both high/low speed)
system, the message "Disconnected" shows on the
screen. During operation of the hoisting winch, the white ball
will move along the circle to indicate the direction and
In case of overload indicated by CC3000 an audible speed during hoisting and lowering. Clockwise rota-
alarm and a text warning come on. tion means hoisting and counterclockwise rotation
means lowering.
LOAD DIAGRAM
Note! If an arrow goes yellow the motion is speed
reduced by CC3000. If an arrow is crossed with a
The default view includes a load diagram with a white
white cross, the motion is not permitted by CC3000.
marker, that shows the current load and outreach.
The specific diagram for this crane can be found in

Technical Data in section 2 of this manual.
CONTROL LEVER INDICATOR, (S32)

LOAD
The current load in the hook in ton. If the value equals The left circle with four green arrows represents the
or exceeds the limit, the box flashes in red. left control lever and the four motions it controls.
(Luffing in/out and slewing left/right)
Note! If an arrow goes yellow the motion is speed

reduced by CC3000. If an arrow is crossed with a
JIB RADIUS
white cross, the motion is not permitted by CC3000.
The current jib radius in meter. If the value gets close
to the limit, the box goes yellow.
HOISTING/LOWERING SPEED
The current hoisting/lowering speed in m/min.
JACK-KNIFE
This icon appears on the screen when the Jack-knife
limit is reached.
5 (6)
Electric Cabinet CT1
1 2
S50
S49 HEATER FAN
Switch. 1/2. Starts and stops the heater fans in the
crane house. They go off automatically when the S49
temperature is more then +25°C. Main switch (Q1)
must be in position "1" to operate them. o
1 2 Hour meter
S50 SUMMER/WINTER
Switch with two positions, 1/2, that controls the oil
heater in the oil tank.
1 - Summer
When the crane house temperature is more than +10°C
set switch to "1" - summer position. Set main switch
(Q1) to position "1".
2 - Winter
When the crane house temperature is less than +10°C
set switch to "2" - winter position. Set main switch (Q1)
to position "1" approximately 24 hours before operation. Q1 S51 Emergency stop
Fig. 5. Electric cabinet CT1/CT2.

RGENC
ME Y
E
S51 EMERGENCY STOP

Pushbutton. Stops the complete crane in case of
emergency. The pushbutton has to be reset, otherwise
the crane cannot be started again. 0
Q1 MAIN POWER SWITCH S52 CRANE HOUSE LIGHT

Switch with two positions 0/1 (OFF/ON). Switch. Turns on and off the crane house light.
Switch is installed on the roof of the pedestal.
0 - OFF
Stops the power supply to the electric cabinet CT1.
RGENC
ME Y
1 - ON
E
Starts the power supply to the electric cabinet CT1.

S71 EMERGENCY STOP
Pushbutton. Stops the complete crane in case of
WARNING! emergency. Positioned inside the pedestal at deck
Some components in the crane are still energized level near the access door. The pushbutton has to be
when the main power switch is off. Refer to electric reset, otherwise the crane cannot be started again.
diagram for information about energized components.
6 (6)
OPERATION PM41 0001-E rev.: - 1994-06-16
EMERGENCY ESCAPE INSTRUCTIONS

Leaving Crane Operator's Cabin
Using Escape Line and Safety Belt
1. Make sure that the loop at the upper end of the
escape rope is securely fastened in the dee-eye
on the cranehouse wall.
2. Put on the safety belt and pull tight.
3. Drop the reel out of the cabin window so that the

rope uncoils and hangs down.
Take care that the reel does not hit anybody or

cause other damage.
4. Exit through the window on the escape ladder on

the outside of the cabin and grip the rope firmly
just below the brake buckle. Adjust the speed of
descent by alternately holding the rope tight and
letting go by degrees.
Braking of the lowering speed may also be con-

trolled by a person on deck by alternately tight-
ening and slackening the rope.
If more than one person is to descend by the rope,

reverse it after each lowering operation.
1 (2)
OPERATION PM41 0001-E rev.: - 1994-06-16
2 (2)
OPERATION PM41 0014-E00 rev.: a 2010-02-03
EMERGENCY ESCAPE INSTRUCTIONS

Rope Ladder / Fixed Ladders
Leaving Crane Operator's Cabin Using
Rope Ladder 1
1. Exit through the window to the escape ladder on

the outside of the cabin. See Fig.1 pos.1.
2. Release the rope ladder from the bracket by remo- Rotating
ladder
ving the straps and pull the rope ladder out and let Emergency
it fall towards the deck. See Fig.1 pos. 2. ladder
Hand rail
1
Fixed ladder Foot rail
Deck level
Strops
Fig. 2. Fixed emergency ladders.
Emergency rope ladder attached to bracket

After the emergency rope ladder has been used it is
important that the emergency rope ladder is put back
correctly, see Fig. 3.
Fig. 1. Emergency rope ladder.
Leaving Crane Operator's Cabin Using

Emergency Ladders
1. Exit through the window to the emergency ladder

on the outside of the cabin. See Fig. 2 pos. 1. Fig. 3. Emergency rope ladder attachment.
1 (2)
OPERATION PM41 0014-E00 rev.: a 2010-02-03
2 (2)
OPERATION 4.620.26 E rev.: a 2008-08-20
Parking the Crane, Sea Stowing

General Instruction
Introduction
Prior to sea voyage, the jib/jib extension should be put When the jib enters the parking area the function "Force
on its parking support, see Fig. 2. The hook is to be Limitation" is automatically activated. This function
stowed to deck, fibrestrops with low ultimate load or limits the pull in the hoisting wire rope to reduce stress
manual stretching screw must be used. If the hook is in the steel structure of the crane and parking
not secured to deck a jib safety lock is recommended to arrangement. See also instruction "Limit Switches in
lock the crane jib in the parking support. See Fig. 3. ..." in section 6.3.
Parking the crane Sea stowing with cargo hook secured

to deck
When parking, the jib is driven to maximum outreach
and then the key switch "PARKING OF JIB" is put in 1. Lower the jib into parking support, using the key
position "1", see Fig. 1. The key switch must be switch "PARKING OF JIB", see Fig. 1.
held in this position until the jib reaches its parking 2. Run the block up to suitable height.
position. 3. Secure hook to deck as shown in Fig. 2.
PARKING OF JIB
0 0
1 1
Fig. 1. Switch in cabin, Parking of jib.
Rope connection
Stretching screw
Notice! Hand-tighten
turnbuckle
only to the extent that
Deck the tightening gear is
not slack.
Fig. 2. Jib/jib extension on parking support, hook secured to deck.
1 (4)
OPERATION 4.620.26 E rev.: a 2008-08-20
Sea stowing with cargo hook/block Prior to cargo handling

hoisted to jib top
1. Release the hook from sea stowing position.
1. Lower the jib into parking support, using the key 2. Release the crane jib from parking parking
switch "PARKING OF JIB". See Fig. 1. support.
2. Run the block up against the jib. Do NOT tighten 3. Luff the crane in to working area (e.g. within max.
too hard. (The jib must still be resting on the support). outreach).
3. We recommend to secure the hook to the deck with
a rope otherwise the hook will be swinging during Note! Release the hook manually from sea stowing
sea voyage. See Fig. 4. position before starting the crane since the hook will
start hoisting when the brake is released.
When parking the jib with the hook block hoisted to jib Crane jib
top it is important that the parking support is provided Locking bar
with an arrangement to lock the crane jib/jib extension.
See Fig. 3.
Important!
The wire ropes must not be tightened too hard. The Chain
crane structure, wire ropes, sheaves, and winches
are subject to heavy stress during sea voyage.
Jib
support
Locking bar position with

crane in operation
Fig. 3. Locking arrangement on parking support.
Rope
Fig. 4. Block secured to deck by using a rope.
2 (4)
OPERATION 4.620.26 E rev.: a 2008-08-20
Crane jib parked on next crane

housing or foundation (If no electrical
interlocking.)
Example:
Before operating crane No. 1 carefully check that crane
No. 2's jib has been removed from its parking support,
see Fig. 5.
Crane No. 2 Crane No. 1
Fig. 5. Jib parked on crane housing.
Example:
Jibs parked in their jib supports on the foundation Before operating the crane carefully check that the
towards each other. Hook secured to deck, see crane jib has been removed from its parking
Fig. 6. support.
Crane No. 2 Crane No. 3
Fig. 6. Jib parked on foundation, hook secured to deck.
3 (4)
OPERATION 4.620.26 E rev.: a 2008-08-20
Parking suggestions of extra equipment
Example: Important!
The grab should be lowered to the deck when the Power cable and stabilizing cable should be parked
crane is parked, this to avoid load on the wires. on jib top during sea voyage. Parking on hook block
is for temporary use only.
Turnbuckle
Support Support
SIDE VIEW TOP VIEW
Fig. 7. Grab lowered to deck, fixed with suitable tightening equipment.
Example: Example:
Fix block
with wire
ropes
Deck Deck
Angle bar Angle bar
Fig. 8. Power swivel with lifting block secured to deck. Fig. 9. Power swivel secured to deck.
4 (4)
OPERATION 4.630 E rev.: - 1994-02-04
Handling Hatches by Deck Crane
Handling hatches
When pulling hatch covers by means of deck Always check that the pulley blocks are correctly
cranes, it is very important that the pulley blocks are positioned, so that the hoisting ropes cannot deviate
so placed that the hoisting wire can be maintained more than 5°, at the most, from the crane house
very nearly vertical during operation. The crane jib centre line.
should be set at an angle where it will not require
any subsequent shifting in order to achieve the N.B. The capacity of the wire pulling the hatch cover
required lifting height. may limit the force which can be applied by the
crane.
The included angle between the hoisting wire and
the vertical centre line of the crane house must not
exceed 5°.
Fig. 1. Fig. 2.
1 (2)
OPERATION 4.630 E rev.: - 1994-02-04
2 (2)
MAINTENANCE 5.005.55 E rev.:g 2010-07-08
Maintenance Chart
Lubricate crane according to LUBRICATING Loose gear

CHART. - Check that block, beam, hook, swivel and shackle
are intact. Check according to instruction "Lifting
Daily or before taking crane into Block/Beam", section 6.2.
operation
Hydraulic oil tank

- Check oil level.
After 50 operating hours (running-in
Slewing gear case period)
- Check oil level. See instruction in section 6.1. The
oil quantity is marked on the name plate and in Power swivel oil tank (optional)
instruction "Technical Data", section 2. - The first oil change see instruction in section 7.
Winches, hoisting and luffing

- Check oil level. See instruction in section 6.1. The
oil quantity is marked on the name plate and in Every month
instruction "Technical Data", section 2.
Escape device
Filter service indicator - Visual inspections should be carried out with
- Check filter service indicator particular attention being paid to the condition of
- If necessary change filter cartridges, see instruction the rope.
"Filters", section 5.
Filter guard (CT1)

- When the pilot light "Check Oil Filter" illuminates
Every 200 operating hours or every two
red the filter guard will stop the crane within 5
months
minutes.
- Replace oil filter. See instruction "Filters", section 5. Pumps
- Check for leaks.
Limit switches; compare section 6.3 instruction
for stop position
Multiple-disc brake, slewing gearset/winches
- Testrun all functions and check that they are - The drain plug shall be taken out every 200 hours
working properly. of operation, to drain off oil that may have been
collected.
Slack wire switch

- Function test, see instruction in section 6.3.
1 (4)
Slewing bearing studs/screws - Wire ropes are inspected according to stipulations

- Inspect visually the slewing bearing studs/screws issued by Classification Associations and National
from deck and inside pedestal. If any stud/screw Bodies.
shows a tendency to slacken, tighten all studs/ - Check that wire rope clamps on wire drums are
screws. Tightening torque, see drawing "Slewing safely secured.
bearing, yard mounting" and "Slewing bearing,
mounting", section 9.3. Wire sheaves
- Inspect for wear
Wire rope sockets (thimbles) - Check that shafts are safely secured.
- Make sure that wire rope thimbles are safely
secured Climb protection, jib top
- Inspect for wear and damage. - Inspect climb protection for wear and damage
- Check play between wire sheave and climb
Ventilation filter unit (optional) protection. See instruction in section 6.2.
- Make sure the coarse filter is clean.
- Clean or replace if necessary. See separate Slack wire device
instruction. - Inspect rollers for wear or damage.
Pressure roller (hoisting winch)

After 200 operating hours - Check roller and springs for wear and damage
- Check function.
Slewing gear case Electrical equipment including slip-ring unit

- The first oil change. (Running-in period 200 hours.) - Inspect according to “Electrical Equipment, General
See instruction in section 6.1. Maintenance” in section 6.3.
Winches, hoisting and luffing Heating elements, cabinet CT2

- The first oil change (Running-in period 200 hours). - Check that the elements in cabinet CT2 is working
See instruction in section 6.1. i.e. get warm.
Crane house, foundation and jib welding joints
Every 500 operating hours or every six - Inspect for any sign of crack
months See "Inspection of Stressed Components and
Structures", section 5.
Oil cooler Hydraulic system

- Inspect oil cooler externally. Clean when required. - Check the following pressures:
- Feed pressure inlet, at guage connection 1
Wire ropes, wire rope clamps - Control pressure, at guage connection 2
- Pressure cut-off (overload) valve/valves 1311,

- Inspect for wear. See instruction "Handling,
1312 etc., at connection 3.1
Installation, and Maintenance of Steel Wire Ropes"
in section 6.2 Pressures should be according to the Hydraulic
Component Specification, part of Hydraulic Circuit
diagram in section 9.4.
- Adjust if required.
2 (4)
Oil analysis (oil tank) Winches

- Sample oil and analyse every six months. - Oil analysis. See instruction "Winch", section 6.1
- Change oil. See instruction in section 6.1.
Pump servo
- Check plussing Air breather, hydraulic oil tank
- If necessary adjust. - Check and replace air breather on top of the tank.
Slewing gear, pinion Hydraulic accumulators

- Check backlash. - Check pressure, re-charge as required. See
instruction “Hydraulic Accumulators”, section 6.1.
Slewing bearing
- Measurement to be taken according to instruction Cable winch (optional)
"Measuring Procedure for Wear in Slewing - V-belt, check tension
Bearings for Rope Luffing Cranes" in section 6.2 - Slipring unit, check
- Check seals. - Brake discs, check
- Brush holders, check.
Filter service indicator See instruction in section 7.
- Replace filter cartridge. See instruction "Filters",

section 5. Service door
- Open service door, see instruction in section 6,
Slip-ring unit and check hinges for damage and corrosion.
- Check brush holders, wire brushes and slip-rings

according to instruction in section 6.3. Slewing bearing studs/screws/nuts
- Inspect visually and by hammer test.
External access ways
- Inspect for wear and damage.
Every 2000 operating hours or every two

Emergency escape ladder (optional) years
- Inspect for wear or damage.
Hydraulic oil tank

Ventilation filter unit (optional) - Take out the drain plug
- Make sure the filter bags are clean. - Drain oil and clean the reservoir. (See “Hydraulic
- Replace if necessary. See separate instruction. Oil Tank”, section 5.)
- Verify that the oil level float switch is working
properly. This inspection is verified when changing
oil or cleaning of oil tank
Every 1000 operating hours or at least - Check air breather cap
every year - Top up with fresh oil according to “Lubricants for
Deck Machinery”, section 5
- Change all oil filter cartridges.
Slewing gear case
- Change oil. See instruction in section 6.1.
3 (4)
Multiple-disc brake, winch Every ten years

- Check for leaks
- Check braking torque - Replace all hydraulic hoses. See instruction in
- Check according to instruction "Winch" in section 6.1. section 6.1.
Multiple-disc brake, slewing gearset

- Check for leaks
- Check braking torque
- Check discs
- Check according to instruction "Slewing Gearset,
section 6.1.
Oil tank in cable winch (optional)

- Drain oil, turbo coupling
- Drain oil, spur gear.
See instruction in section 7.
Oil tank in power swivel (optional)

- Drain oil and clean the reservoir. See instruction,
in section 7.
At dry docking or at maximum 5 years

interval
Slewing bearing studs/screws

- Tighten all studs or screws. Tightening torque, see
separate drawing, "Slewing bearing, yard
mounting" and "Slewing bearing, mounting", section
9.3
- Consult MacGREGOR before replacing studs or
screws with any other specifications than
recommended.
Every five years
Hydraulic hoses inside crane house

- Check hydraulic hoses for damage. See
instruction in section 6.1.
4 (4)
MAINTENANCE 5.018 E rev.: c 2013-01-29
Inspection of Stressed Components and Structures
Visual inspection
Refer to the "Maintenance Chart" for maintenance
intervals.
Inspect for signs of cracks and other damage. Do a

thorough visual inspection of all of the crane structure,
the jib, the pedestal and the foundation, see Fig. 1.
Carefully inspect stressed parts that are subjected

to high loads.
C-00305
Fig. 2. Parking support and jib, example
Inspect for cracks

Cracks will usually show by cracking or flaking of the
1 paint followed by a brownish discolouration by rust.
Inspect welds and surrounding material when rust
2 is found.
3 Note!
Rust on a painted surface does not necessarily
C-00307
mean that there is a crack in the underlying material.
1. Crane structure and jib When rust is found on top of or near a weld, grind
2. Foundation the topmost surface layer away to expose the crack
3. Pedestal clearly. Cracks can be too small to see, use Magnaflux
to identify the crack if needed.
Fig. 1. Crane
Detected cracks must be inspected and repaired.
Inspect the parking support for wear and cracks, see Before repairing of a crack in a stressed part, always
Fig. 2. contact MacGregor Service Organisation for recom-
mendations.
1 (2)
MAINTENANCE 5.018 E rev.: c 2013-01-29
2 (2)
LUBRICATING CHART PM51 1709-E00 rev.: d 2011-11-07
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 (4-6 nipples) *
2 Wire sheaves, Jib top: 1 nipple/sheave (4-7 nipples) *
3 Wire sheaves, Lifting block: 1 nipple
4 Wire rope thimbles,**Crane house top: 1-2 pcs, Jib top: 1 nipple (If installed) *
5 Swivel, Lifting Block: 1 nipple (If installed)
6 All wire ropes
7 Electric main motor: 2 nipples
8 Door hinges: 3 nipples, see Instruction manual section 6.2.
9 Jib bearings: 2 nipples
10 Oil tank
11 Air breather cap, oil tank
12 Oil filters
13 Slewing gear, gearbox
14 Slewing bearing teeth
15 Slewing bearing (10 or 20 nipples, see section 9.3 Slewing specification/Slewing Bearing)*
16 Hoisting and Luffing winches, journal bearing: 1 nipple/winch *
17 Hoisting and Luffing winches, gearbox
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! If the crane is not operated for a longer period of time it must be lubricated before storage.
Note! If the crane has not been used for an extended period of time it must be lubricated before use.
* 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)
Jib top with lifting block Example: Wire sheaves crane top and wire rope
thimble, manual greased.
1 1, 4
6. Wire ropes 1, 4
1
3. Wire sheave
5. Swivel
1. Wire sheaves
Filter service
indicator
8. Door hinges
12
Filter 7. Electric motor

4135
12. Oil filters
12 Oil filling 10. Oil tank

11. Air breather cap
Filter
4136
16, 17. Luffing winch
13. Slewing gear case

16, 17. Hoisting winch
15. Slewing bearing 9. Jib bearings
14. Slewing bearing teeth
2 (4)
Example: Wire sheaves jib top and wire rope Red lamp on right control panel in operator’s cab
thimble, central greased.
CHECK
OIL FILTER
CAUTION!
Replace all filter cartridges if this lamp comes on.
16 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 an example of a bearing, and may not be the same as in your crane.
Grease
1 nipple
C-00231
3 (4)
4 (4)
MAINTENANCE 5.150.4 E rev.: - 2003-02-19
Lubricating and Maintenance

Cranes type GLB
Contents
Door hinges ................................................................. 2

Electric motor .............................................................. 3
Slewing bearing ........................................................... 4
Jib bearing ................................................................... 5
Wire sheaves Jib and Wire rope socket ....................... 6
Wire sheaves Crane house ......................................... 7
Wire rope socket Crane top ......................................... 8
Slewing gear case ....................................................... 9
Lifting equipment ....................................................... 10
Oil tank ..................................................................... 11
Oil filter ...................................................................... 12
Oil filter change .......................................................... 13
Wire ropes ................................................................. 14
Winch with high speed motors ................................... 15
Cable winch (optional) ............................................... 16
Power swivel (optional) .............................................. 17
1 (18)
Door hinges
Grease nipple;
Service door
2 (18)
Electric motor
Grease nipple;
Upper bearing
Grease nipple;
Lower bearing
3 (18)
Slewing bearing
Grease nipple; Grease;

Slewing bearing Slewing bearing teeth
4 (18)
Jib bearing
Grease nipple;
Inside crane house
5 (18)
Wire sheaves Jib and Wire rope socket
Grease nipples; Jib top, Central lubricating
6 (18)
Wire sheaves Crane house
Grease nipple
7 (18)
Wire rope socket Crane top
The wire rope sockets can also be located on jib top

or lifting block.
Grease nipple
8 (18)
Slewing gear case
Oil change Air breather
Check oil level
Oil drain plug
9 (18)
Lifting equipment
Grease nipple, Lifting block
Grease nipple, Swivel
10 (18)
Oil tank
Check air breather

Check oil level (dipstick)
Drain oil tank
11 (18)
Oil filter
Filter unit, outlet Filter unit, inlet

Oil filling Electrical indicator, visual indicator
12 (18)
Oil filter change

Necessary equipment when changing filter cartridges:
- 2 new filter cartridges with O-rings.
- Spanner.
- Bucket.
Put the bucket Remove the

1 under the filter
2 drain-plug by
unit. hand and let the
Loosen the oil run into the
drain-plug at bucket. Make
the bottom sure not to lose
of the filter the
unit using the O-ring.
spanner.
(size 9/16"
or 15 mm)
Loosen the Unscrew the

3 filter cap using
4 filter cap by
the spanner. hand.
(size 1" or Be careful
26 mm) not to drop it.
Remove the old
O-ring between
the filter cap
and the filter
head.
Remove the Mount the filter cap and tighten it using

5 old filter cart-
6 the spanner.
ridge.
Install the new
O-ring between Mount the drain-plug and the O-ring on the
7 filter cap and tighten it using the spanner.
the filter cap
and the filter
head.
Install the new
filter cartridge.
13 (18)
Wire ropes
Relubricating of steel wire ropes, see instruction

6.222.1 E.
Grease
14 (18)
Winch with high speed motors
Grease nipple
Oil filler inlet

Oil dipstick
Oil outlet
15 (18)
Cable winch (optional)
Oil change; Spur gear

Grease nipples; Electric motor
Oil drain plug;

Spur gear
Oil change; Turbo coupling
16 (18)
Power swivel (optional)
Check oil level (dipstick)
Grease nipples, ball bearing
Drain oil tank (seen from below)
17 (18)
18 (18)
MAINTENANCE 5.250.1 E rev.: a 2012-11-04
Slewing Bearing Studs
General Yard Mounting for inner studs and Slewing Bearing

Mounting for outer studs.
The slewing bearing studs are screwed in to correct
depth and stretched with a special tensioning tool 1. Make sure the studs are screwed in at the correct
before the nut is tightened. depth.
2. Stretch the studs with a hydraulic tensioner. Stretch
the stud two times to get correct prestressing force.
Inspection of studs 3. Stretch the studs in correct order, see Fig 2.
4. Repeat the process on the first tightened nuts, until
Hit the nuts with a hammer to make sure that the all studs have the correct prestressing force. The
studs are tight. If one stud is not tight, all studs must tightening of other nuts reduces the load on the first
be stretched to the correct tension. tightened nuts.
Contact Cargotec Services if you remove/install the

Tighten slewing bearing studs complete crane for the correct assembly and tension-
ing at the slewing bearing studs.
This instruction is valid for both inner and outer studs
on the slewing bearing, see Fig 1. Make sure you use a Note!
correct tensioning tool and that you know how to use it. The drawings are examples for guidance only, type
of bearing and number of studs may be different on
Refer to the spare part pictures for correct assembly of your crane.
studs and correct prestressing force, Slewing Bearing
2 1
X
3 4
C-00227
C-00228
1. Inner studs
2. Outer studs
3. Install depth of studs Fig. 2. Tightening sequence
4. Prestressing force
Fig. 1. Slewing bearing studs
1 (2)
2 (2)
Filters
Introduction
For cleaning hydraulic oil, the hydraulic system is The other indicator is visual (see Fig. 1) and should
equipped with two filters. The two filters are marked be read when the oil temperature is approximately
4135 and 4136. 45°C. Upon reaching a certain degree of clogging, a
red indication can be seen on the top of the filter
Filter indicators indicator. Replace both filter cartridges in the system
when the red indication shows.
The filter indicators operate only when the crane
starts.
Replacement filter cartridges
Filter 4135 has two filter indicators. One indicator is You must replace both cartridges (see Fig. 3) in the
electric and operates a warning lamp placed on the crane at the same time. Flush all other parts of the
control panel in the cabin (see Fig. 4a and 4b). filters with white spirit when you replace the cartridges.
Use new seals. Reassemble the filters.
4101 4102
Electric indicator
Visual
indicator
Oil filling
Filter Filter
4135 4136
Fig. 1. Filter inlet. Fig. 2. Filter outlet.
Fig. 4a. Control panel.
Filter cartridge
Fig. 3. Filter cartridge. Fig. 4b. Control panel.
1 (2)
2 (2)
Hydraulic Oil Tank
The hydraulic oil tank is placed on the wall inside the Oil level MIN
crane house. If the oil level drops to MIN, the oil and temperature
guard activates the lamp LOW OIL LEVEL on the
Checking oil level control panel in the operator's cab. At the same time
the siren sounds.
Check oil level by use of the dipstick. Check that oil
level is between min. and max on the dipstick.
Verify that the guard is working properly by starting the
crane. Loosen the nut that holds the guard and lift it up
slowly.
1
Oil filling
1. Outlet filter
2. Inlet filter
3. Air filter with dipstick
4. Oil level and temperature guard
2 5. Thermometer
6. Vedge valve (oil drain)
3
7. Quick coupling
8. Heater
4
Fig. 1. Hydraulic oil tank.
1 (2)
Filling oil
Oil is filled at an ”aero-quip” type quick-release coupling,
placed on the filter unit, see Fig. 2. When filling oil the
hydraulic system must be at rest and the electric
power switched off.
Fill oil to just under the MAX mark on the dipstick. Use
oil according to the ”Lubricating Chart”.
NOTE! Oil must not be filled directly into the tank.
Cleaning the oil tank

Oil filling
Before cleaning the oil tank, immobilise the crane jib
in a suitable manner, push the stop button and switch
off the power. Drain off the oil into clean empty barrels Fig. 2. Oil filter unit with filling.
or drums.
Remove the tank cover. Scrape off sediment, if any,

from the tank bottom and sides using a rubber scraper.
Flush the tank with white spirit.
Wipe the tank dry with clean rags. DO NOT USE

COTTON WASTE, or other linting material. Apply new
sealing compound and reinstall the tank cover.
If the drained oil is in good condition and can be used

anew, it should be filtered before refilling.
Pump and hoses used for filling must be perfectly

clean.
Fill oil to just under the MAX mark on the dipstick. Use
oil according to the ”Lubricating chart”.
2 (2)
MAINTENANCE 5.315 E rev.: b 2010-09-03
Sampling of Oil to Verify the Cleanliness in Hydraulic System
General Procedure for oil sampling

- Oil temperature in the system should be 40-50oC.
This instruction describes sampling oil from a hy- - Special oil sampling bottles should be used and
draulic crane system. can be purchased from oil companies.
- Connect a pressure gauge hose to gauge outlet
This procedure is general and there can be some 3.1 (hoisting circuit), see Fig. 1.
differences depending of crane type. - Start the crane and run the hosting winch in maxi-
mum speed hoisting.
Type of oil to be used in the system can be found - Bleed out 0.5 litre of oil in a bucket. This oil to be
in Section 5. disposed.
- Fill the oil sample bottle.
When to sample oil - Send the oil sample to an oil company for
analysis.
To verify the oil condition, an oil sample should be
The oil company will be able to recommend if the
taken every six months and sent for analysis. This
oil can be further used.
analysis is done by the oil companies and can be
Feedback on the oil analysis can also be obtained
of different levels. When the result is received, a
from MacGregor Cranes.
recommendation is normally given if the oil is ap-
proved or has to be changed.
For maximum practical contamination in the sys-

tem, see Table 1.
Pump Hose
Gauge outlet 3.1

Bottle
Fig. 1. Sampling hydraulic oil.
1 (2)
MAINTENANCE 5.315 E rev.: b 2010-09-03
Analysis using automatic particle counter

ISO 4406
We recommend cleanliness code 19/17/14 or better,
according to ISO 4406:1999. Scale no. Number of particles per millilitre fluid
Number of particles equal to or larger than 4 µm(c), ISO code More than Up to and including
not to exceed code 19. 26 320 000 640 000
Number of particles equal to or larger than 6 µm(c), 25 160 000 320 000
Number of particles equal to or larger than 14 µm(c), 23 40 000 80 000
21 10 000 20 000
Analysis using microscope sizing 20 5 000 10 000
We recommend cleanliness code -/17/14 or better, 19 2 500 5 000
according to ISO 4406:1999. 18 1 300 2 500
17 640 1 300
Number of particles equal to or larger than 5 µm, 16 320 640
not to exceed code 17. 15 160 320
Number of particles equal to or larger than 15 µm, 14 80 160
not to exceed code 14.
13 40 80
12 20 40
Procedure if oil sample is showing too high 11 10 20
contamination 10 5 10
9 2,5 5
If the oil analysis shows too high contamination, the 8 1,3 2,5
oil and the filters should be changed. The crane
7 0,64 1,3
should be driven for approximately 1 hr and a new
6 0,32 0,64
oil sample should be taken and sent for analysis.
Table 1. Cleanliness level correlation table.
2 (2)
MAINTENANCE 5.421.40 E rev.: f 2012-05-21
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 Tivela S220 or similar.
Stabilizing winch, turbo coupling (if appli-

Hoisting and luffing 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 Tivela S220 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 T68.
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 T46.
1 (2)
MAINTENANCE 5.421.40 E rev.: f 2012-05-21
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: MOBILGREASE Special 530303.
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 Alvania EP (LF) 2 (-20 to +130°C).
Arctic climate: SHELL Albida PPS2.
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 MALLEUS GL95 (-15 to +150°C).
SHELL MALLEUS GL65 (-30 to +150°C).
Slip-ring unit, signal slip-rings

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

lubricants for extreme temperatures.
2 (2)
Cargotec Sweden AB How to order
MacGregor Cranes 6.0
Sjögatan 4G
spare parts
SE-891 85 ÖRNSKÖLDSVIK, Sweden
Telephone: 46 - 660 - 29 40 00
Telefax: 46 - 660 - 139 77
www.cargotec.com
SERVICE
Hydraulic system 6.1
Mechanical
6.2
equipment
Electrical
6.3
equipment
SERVICE 6.000 E rev.: e 2010-09-08
How to Order Spare Parts
Important details when enquiring or ordering spare parts
Please send your inquiry or order to closest MacGregor global service station, see instruction "MacGregor Global
Services", 6.004.1 E.
To speed up the process we request you to provide us with below information:
State name of company as well as your name
Vessel's name and IMO number (and/or Lloyd's number)
Crane type (see manual or name plate in operator's cabin)
Crane place on the vessel. No. 1 counted from the fore
Crane serial number (see manual or name plate in operator's cabin)
Spare part figure or drawing number. To be found in section 9 in the manual
Part description
Item number from spare part figure or drawing respectively
Part number, if available, from spare part figure or drawing respectively
Quantity required
When you order a wire rope or lifting block, please specify which certificate is needed.
Deadline - when or where in the world do you need the parts?
Delivery details such as: consignee as well as phone and fax numbers
Terms of delivery: by DHL, air freight direct or consignment, by truck or shipping freight
The more you can provide us with above details the faster and more reliable replies and deliveries will be made.
Address:
Cargotec Sweden AB
MacGregor Cranes
Phone: 46 - 660 - 29 40 00
Telefax: 46 - 660 - 139 77
www.macgregor-group.com
1 (2)
6.000 E rev.: e 2010-09-08 page 2 (2)
Tel: 46 - 660 - 29 40 00
Direct: Fax: 46 - 660 - 139 77
Date: ................................................
Spare parts/Service specification

Please use this form whenever assistance is needed. Service request
Confirmation of
phone call/conv.
From: .. ............................................................. E-mail address: ................................................
.............................................................. Phone no.: ......................................................
.............................................................. Telefax no.: ......................................................
Re: M/V ........................................................ IMO /Lloyd's no.: ..............................................
Crane type: ............................................. Serial no: .........................................................
Crane place: ........................................... Our ref.: ..........................................................
For following spares we would like to: have your quotation
place order, deadline for arrival :................................
Part no. Qty Description Fig./Drwg. Item
1. .......................................... ..... ............................................ .............................. ..............
2. ........................................... ..... ............................................ .............................. ..............
3. ........................................... ..... ............................................ .............................. ..............
4. ........................................... ..... ............................................ .............................. ..............
5. ........................................... ..... ............................................ .............................. ..............
6. See enclosure
Delivery/Agent's address: ............................................................................................................
............................................................................................................
............................................................................................................
...................................................................................................................
Name/ Title/
SERVICE 6.000.1 E rev.: c 2007-01-08
Statement Regarding Delivery of Spare Parts to Swivels, Lifting

Block, Lifting Beams etc.
Reference is made to ILO regulations, SAFETY AND Section D

HEALTH IN DOCK WORK, section A, B and D.
Section D stipulates the Test loading is needed.
Section A
Due to the difficulties for the shipowner to perform
Paragraph A.1.1 stipulates that every lifting adequate proof load test certified by a competent
appliance should be with the provisions of section person, in general MacGREGOR (SWE) AB,
D.1: Örnsköldsvik, cannot supply separate spare parts
to hook blocks, swivels, lifting beams etc. to the
(a) before taking in to use the first time owner or managers. However, it is possible to
(b) after the renewal or repair of any stress bearing deliver such parts to the MacGREGOR service
part; and organization, if they can guarantee that the proof
(c) at regular four-year intervals, after the date on load test and appreciate inspection according to ILO
which the appliance was first taken in to use. will be performed under their responsibility.
Paragraph A.1.2 stipulates that the following MacGREGOR (SWE) AB, Örnsköldsvik
exceptions to the requirements of paragraph A.1.1 Quality Department
may nevertheless be allowed:
(a) where any part is renewed or repaired, it should

be considered sufficient to subject that part, Gunnar Tjärnström
by separate means, to the same stress as Quality Manager
would have been imposed on if it had been
tested in-situ during the testing of the
complete appliance.
Section B
Paragraph B.1.2 stipulates that every item of loose

gear, including cargo blocks, lifting beams and lifting
frames, should be tested:
(a) before it is taken in to use the first time

(b) after any renewal or repair of a stress-bearing
part.
1 (2)
SERVICE 6.000.1 E rev.: c 2007-01-08
2 (2)
SERVICE 6.000.2 E rev.: f 2012-11-08
RETURN FORM
How to return parts from deck crane manufacturing,
installation or guarantee exchange
Delivery address: MacGregor Cranes

Cargotec Sweden AB
Att.: Mr Peter Sjölund
Björnavägen 2
SE-891 41 ÖRNSKÖLDSVIK
SWEDEN
Transport means, if necessary: Advised by us on request.

Phone no.: 46-660-29 40 00
Fax no.: 46-660-124 55
E-mail: peter.sjolund@cargotec.com
Identification: Absolutly necessary is a paper inside the return

shipment, shortly describing:
1) the part
2) from where it has been taken and
3) why it is returned.
Claim: Detailed claim can be sent separately and does not

have to be enclosed.
The above refers only to the return shipment as such.
1 (2)
SERVICE 6.000.2 E rev.: f 2012-11-08
RETURN FORM
To be packed inside return box or parcel
Date:
Sent by:
Newbuilding no.:
Ship’s name:
IMO no.:
Crane place on board:

Crane serial no.:
Returned part’s
drawing or article
no, serial no.:
Part description:
Serial no. of unit

from which the part
is taken:
Unit description:
Reason for return: *
*) Please note: To be filled in with short but specific details. “Faulty“ is not enough, a much better description is
“leaking“, “not adjustable“, “cracked“, “earthing fault“, “short circuit“ if the reason is obvious, or, a circumstantial
evidence pointing to the returned part as the reason for malfunction, like “luffing movement too slow in one di-
rection“.
(Service/guarantee: 662 5000-706)
2 (2)
SERVICE & PARTS 6.004.1 E rev.: bc 2011-06-21
Worldwide Service Network

Marine Service: Worldwide Service Network
AUSTRALIA DENMARK INDIA
Sydney Office Copenhagen Office Mumbai Office

Tel: +61-2-464 741 49 Tel: +45-44-538 484 Tel: +91-22-2758 2222
Fax: +61-2-464 770 03 Fax: +45-44-538 410 Fax: +91-22-2758 2227
24 hrs: +61-408-494 777 24 hrs: +45-44-538 484
Esbjerg Office INDONESIA
BELGIUM Tel: +45-44-538 484
Fax: +45-44-538 410 Batam Office
Antwerpen Office 24 hrs: +45-44-538 484 Tel: +62-778-737 2207
Tel: +32-3-546 4640 Fax: +30-778-737 2210
Fax: +32-3-542 4772 ESTONIA
24 hrs: +32-3-546 4640 ITALY
Zeebrugge Office Tallinn Office
Tel: +32-50-84 05 50 Tel: +372-6 102 200 Genoa Office
Fax: +32-50-84 09 50 Fax: +372-6 102 400 Tel: +39-010-254 631
24 hrs: +372-53-018 716 Fax: +39-010-246 1194
BRAZIL 24 hrs: +39-335-139 4779
FINLAND
Rio de Janeiro Office JAPAN
Tel: +55-21-2516 1790 Turku Office
Fax: +55-21-2516 1743 Tel: +358-2-412 11 Kobe Office
24 hrs: +55-21-9121 1986 Fax: +358-2-412 1517 Tel: +81-78-846 3220
24 hrs: +358-400-824 414 Fax: +81-78-846 3221
CHINA 24 hrs: +81-90-4387 9992
FRANCE Kumozu Office
Hong Kong Office Tel: +81-59-234 4114
Tel: +852-2394 1008 Le Havre Office Fax: +81-59-234 0040
Fax: +852-2787 7652 Tel: +33-235-247 299 Tokyo Office
24 hrs: +852-9097 3165 Fax: +33-235-247 298 Tel: +81-3-5403 1966
Shanghai Office 24 hrs: +33-611-643 942 Fax: +81-3-5403 1953
Tel: +86-21-2606 3000 Marseilles Office 24 hrs: +81-90-7188 0377
Fax: +86-21-6391 2276 Tel: +33-491-095 252
24 hrs: +86-1350-1828 932 Fax: +33-491-609 020 KOREA
24 hrs: +33-679-826 544
CROATIA Busan Office
GERMANY Tel: +82-51-704 0844
Rijeka Office Fax: +82-51-704 0414
Tel: +385-51-289 717 Bremerhaven Office 24 hrs: +82-51-704 0844
Fax: +385-51-287 154 Tel: +49-471-780 41
24 hrs: +385-98-440 260 Fax: +49-471-740 80 MALAYSIA
Zagreb Office 24 hrs: +49-471-780 41
Tel: +385-1-3837 711 Hamburg Office Kemaman Office
Fax: +385-1-3835 563 Tel: +49-40-254 440 Tel: +60-985-92 129
Fax: +49-40-2544 4444 Fax: +60-985-82 272
CYPRUS 24 hrs: +49-40-2544 4120 24 hrs: +60-985-92 129
Kuala Lumpur Office
Limassol Office GREECE Tel: +60-377-828 136
Tel: +357-25-763 670 Fax: +60-377-852 131
Fax: +357-25-763 671 Piraeus Office 24 hrs: +60-122-786 889
24 hrs: +357-99-463 862 Tel: +30-210-428 3838 Miri Office
Fax: +30-210-428 3839 Tel/fax: +60-854-28 136
24 hrs: +30-6974-300 541 24 hrs: +60-122-786 889
MacGregor Cranes Address Telephone Telefax

Cargotec Sweden AB SE-891 85 ÖRNSKÖLDSVIK (+46) 660-29 40 00 (+46) 660-139 77
www.macgregor-group.com/cranes Sweden
1 (2)
SERVICE & PARTS 6.004.1 E rev.: bc 2011-06-21
Worldwide Service Network

Marine Service: Worldwide Service Network
MEXICO SINGAPORE UNITED KINGDOM
Campeche Office Singapore Office Aberdeen Office

Tel/fax: +52-938-286-1528 Tel: + 65-6597 3888 Tel: +44-1224-347 050
24 hrs: +1-985-641-3853 Fax: + 65-6597 3799 Fax: +44-1224-347 051
24 hrs: +65- 6597 3777 24 hrs: +44-7850-313 733
THE NETHERLANDS Liverpool Office
SPAIN Tel/fax: +44-151-708 4177
Rotterdam Office Bilbao Office 24 hrs: +44-7768-334 419
Tel: +31-10-283 2121 Tel: +34-94-480 7339 Newcastle Office
Fax: +31-10-429 3219 Fax: +34-94-431 6945 Tel: +44-191-295 2180
24 hrs: +31-10-283 2121 24 hrs: +34-609-428 066 Fax: +44-191-295 2188
Cadiz Office 24 hrs: +44-7768-334 419
NORWAY Tel/fax: +34-956-877 611 Portsmouth Office
Ferrol Office Tel: +44-2392-210 703
Bergen Office Tel: +34-696-946 086 Fax: +44-2392-210 734
Tel: +47-56-313 300 Fax: +34-981-354 624 24 hrs: +44-7768-334 419
Fax: +47-56-313 070
24 hrs: +47-905-873 71 SWEDEN UNITED STATES
Kristiansand Office Fort Lauderdale Office
Tel: +47-91-68 60 00 Bjuv Office Tel: +1-954-600-4199
Fax: +47-38-01 87 01 Tel: +46-42-85 800 24 hrs: +1-757-558-4580
Oslo Office Fax: +46-42-85 899 Houston Office
Tel: +47-23-10 34 00 Enköping Office Tel: +1-713-681-5452
Fax: +47-23-10 34 01 Tel: +46-171-232 00 Fax: +1-713-681-8204
24 hrs: +47-905-873 71 Fax: +46-171-232 99 Jacksonville Office
Gothenburg Office Tel: +1-904-821 0340
PANAMA Tel: +46-31-721 50 00 Fax: +1-904-821 0850
Fax: +46-31-424 946 24 hrs: +1-757-558-4580
Balboa Office 24 hrs: +46-31-721 50 00 Lafayette Office
Tel: +506-603-45 032 Örnsköldsvik Office Tel: +1-337-231-5961
24 hrs: +1-757-558-4580 Tel: +46-660-29 40 00 Fax: +1-337-231-5966
Fax: +46-660-139 77 New Orleans Office
POLAND 24 hrs: +46-31-721 50 00 Tel: +1-985-892-9833
Fax: +1-995-892-9837
Gdynia Office THAILAND 24 hrs: +1-985-892-9833
Tel: +48-58-785 5110 New York Office
Fax: +48-58-785 5111 Bangkok Office Tel: +1-914-305-9091
24 hrs: +48-602-725 088 Tel: +660-2-726 9516 Fax: +1-914-305-9091
Fax: +660-2-726 9514 24 hrs: +1-914-305-9090
QATAR Norfolk Office
UNITED ARAB EMIRATES Tel: +1-757-558 4580
Doha Office Fax: +1-757-558 4581
Tel: +974-4460 7310 Abu Dhabi Office 24 hrs: +1-757-558-4580
Fax: +974-4460 7314 Tel: +971-2-5541 690 Slidell Office
24 hrs: +974-5507 1093 Fax: +971-2 5541 601 Tel: +1-985-641-3853
24 hrs: +971-50-4510 715 Fax: +1-985-641-3856
RUSSIA Dubai Office 24 hrs: +1-985-641-3853
Tel: +971-4-3213 933
St. Petersburg Office Fax: +971-4-3413 110
Tel: +7-812-493 4284 24 hrs: +971-50-651 0371
Fax: +7-812-493 4285
24 hrs: +7-812-938 0498
Vladivostok Office
Tel: +7-4232-24 34 63
Fax: +7-4232-24 34 62
MacGregor Cranes Address Telephone Telefax

Cargotec Sweden AB SE-891 85 ÖRNSKÖLDSVIK (+46) 660-29 40 00 (+46) 660-139 77
www.macgregor-group.com/cranes Sweden
2 (2)
SERVICE 6.005.7 E rev.: - 2003-02-12
Introduction
Before proceeding to trouble-shooting, the crane ope-

rator and the service staff should familiarize
themselves with the construction and functions of the
crane. It is a bit late in the day to learn how to operate
the crane when it has already broken down.
Begin by learning the hydraulic and electric symbols

used in the circuit diagrams to facilitate tracing the
probable fault in the circuit diagrams, Fig. 1 and 2,
checking the findings afterwards in the crane proper.
Trouble-shooting may thus be divided into a theoreti-

cal and a practical part, each subdivided into hydrau-
lic, electric, and mechanical trouble-shooting. The
hydraulic and electric operations presuppose know-
ledge of the locations of various points of measure-
ment and checking.
Take care always to have correct circuit diagrams Fig. 1.

available on board. If a diagram has gone astray, a
new one can be had from MacGREGOR Cranes. Pro-
per measuring instruments must always be available, Hydraulic circuit diagram
e.g. pressure gauges and voltmeters.
The trouble-shooting method described here is only

intended as a general guide. Methods and practices
may vary, but the purpose is always the same: to
find the fault quickly and methodically in order to put
it right.
Fig. 2.
When a crane function ceases to operate properly, it

generally does so in actual operation. This means
that the crane operator will often be able to give Electric circuit diagram
valuable suggestions, e.g.:
Electric circuit diagram
- Did the crane function fail without warning?

- Was the operating speed first reduced, or did Electric circuit diagram
the movement run irregularly?
- What manoeuvre immediately preceded the
failure?
Fig. 3.
1 (2)
SERVICE 6.005.7 E rev.: - 2003-02-12
As a first check always try to operate the crane and Analysis of information collected
at the same time check the status of the trouble- By methodical trouble-shooting, it is often possible
shooting panel in the CT2 cabinet, according to error to find, at an early stage, the defect producing the
list and signal overview list, (see instruction under faulty operation, thereby avoiding unnecessary waste
section 6.3). of time.
Also measure the feed pressure at gauge outlets 1 and

16. Pressure setting levels can be found in the pressure All important pressure adjusting devices are sealed.
setting list on the hydraulic circuit diagram. Breaking a seal voids the guarantee unless done with
the explicit consent of MacGREGOR Cranes.
When consulting MacGREGOR Cranes for service
or advice, always give the following information at
once:
1. Is the fault electrical, electronic, hydraulic, or

mechanical in nature?
2. In which function does the fault appear:
- Hoisting circuit
- Luffing circuit
- Slewing circuit
3. Is the trouble limited to:
- Raising or lowering of the load
- Raising or lowering of the jib
- Slewing right or left
4. Special observations:
- Is the hoisting, luffing, or slewing capacity restricted?
- Do disturbances occur only at certain speeds?
- In the event of abnormal noise:
- To which of the main functions does the noise
pertain?
- Is the frequency of the noise high or low?
- Try to describe the noise (hissing, blowing,
humming, rasping etc.)
5. What is the status of the trouble-shooting panel in
CT2 cabinet?
6. Have pressures been measured?
- Feed circuit pressure
- Control circuit pressure
- Hoisting circuit high pressure
- Luffing circuit high pressure
- Slewing circuit high pressure.
2 (2)
SERVICE 6.100 E rev.: b 1998-10-22
Measures Before Starting, During and After Completed

Service/Maintenance Work
WARNING !
When it is necessary to search for/or correct faults
in the crane's electrical, hydraulic or mechanical
systems with the crane powered up, only author-
ized personnel may carry out such work.
The following measures must be taken before any

service or maintenance work is started.
1. The jib must be secured preferably in the park-

ing support, (see separate instruction).
2. All lifting equipment must be parked/secured.
3. All power supplies to the crane must be cut.
A. Cut the main power supply to the crane and

all separate supplies such as heating, light-
ing etc., with the power switch(es) in the
ship’s engine room.
B. Warning signs must be hung on the switches

involved.
4. Make sure that the crane is completely without

power. If necessary, lock switches, take out fuses
etc. so nobody by mistake can start the crane.
5. When special work has to be done see separate

instruction or contact our service department.
6. If some special arrangements are done for test-

ing during the service, these arrangements have
to be removed after completed service.
7. Function test safety items i.e. limits, brakes etc.

after completed work.
8. Protections i.e. covers, rails etc. to be reinstalled

after completed work.
1 (2)
SERVICE 6.100 E rev.: b 1998-10-22
2 (2)
SERVICE 6.106.4 E rev.: - 2003-02-03
Trouble-Shooting Chart, Overheating
Fault Probable cause Remedy
A. Overheating in hydraulic sys- Oil cooler fan motor not working. Check connections, contactor,
tem. effect repairs as required.
Oil cooler flanges loaded with dirt. Dismantle and clean cooler.
Pressure control valves incor-

Correct settings.
rectly set.
Trace leaks and replace defective

Internal leakage.
seals, packings, and other parts.
B. Overheating caused by pump,

Internal leakage because of wear. Contact MacGREGOR Cranes.
valving, or hydraulic motor.
Note!
When the hydraulic system is overheated thermostat BT2 (+85oC) opens
and crane stops.
To cool the system press the "Start" button to start main electric motor in
idling while the control system is switched off. The control system will then
start automatically when thermostat BT2 closes.
1 (2)
SERVICE 6.106.4 E rev.: - 2003-02-03
2 (2)
SERVICE 6.117 E rev.: b 1999-12-21
Trouble Shooting, Pumps
Pumps, general
Fault Probable cause Remedy
A. Pump not supplying any fluid. Servo error. Contact MacGREGOR Cranes
Worn or cracked parts in the Measure leakage, contact

pump. MacGREGOR Cranes
B. Excessive wear of the pump. Hydraulic fluid contains abra- Check filters. Change cartridge,
sive particles. if necessary. Analyze sample
of the fluid.
Check pressure switch 1381 and

Low feed pressure.
2481.
C. Fracture of parts in the pump. Pressure shocks. Check valve functions and valve
settings.
Check pressure switch 1381

Low feed pressure. and 2481.
More detailed information regarding the pumps will be found in the

instruction manual.
1 (2)
SERVICE 6.117 E rev.: b 1999-12-21
2 (2)
SERVICE 6.120.18 E rev.: b 2011-12-29
Slewing Gear
General
10 9 8 7 6
Slewing gear
The slewing gearset has these components:
- Motor
- Drive in unit, including disc brake
- Gearbox.
1 2 3 4 5 C-00230
2
1. Disc carrier
2. Inner discs
3. Arrangement of the brake discs
4. Gear side
5. Outer discs
6. Pressure unit
7. Piston
3 8. Motor side
9. Pressure springs
10. Connection, pressure oil
Fig. 2. Disc brake.

C-00229
Gearbox
1. Motor The gearbox is a planetary gearbox. The slewing gear
2. Drive in unit, including disc brake is splash lubricated. The output shaft roller bearing is
3. Gearbox ”for-life” lubricated with ball bearing grease.
Fig. 1. Slewing gearset.
Drive in unit, including disc brake

The drive in unit is mounted on top of the gearbox,
with long assembly screws through the motor adapter
housing and both parts of the brake housing.
The brake discs are pressed together by a set of

pressure springs. The brake is automatically released
by hydraulic pressure when the slewing gear rotates.
1 (4)
SERVICE 6.120.18 E rev.: b 2011-12-29
Maintenance 5. Record the oil level.

6. Put back the dipstick.
For maintenance intervals refer to the "Lubricating
Chart" and "Maintenance Chart" in section 5. Replace oil
For type of oil refer to "Lubricants for Deck Machinery"
Drain oil while still hot. At low ambient temperature,
in section 5.
flush out the gearbox with clean pre-heated oil to
For oil volume refer to the "Technical data" in section 2.
remove particles and sediment. Refer to Fig. 3.
2 1. Open the oil filling plug.

3
2. Remove the oil dipstick/air ventilation valve for bet-
1 ter ventilation.
4 3. Remove the oil drain plug to drain the oil.
4. Clean the oil plug thoroughly. If necessary, replace
the seal ring.
5. Install the oil drain plug.
6. Top up with oil up to the middle of the MIN/MAX
mark.
7. Install the oil dipstick/air ventilation valve.
5
Brake
Inspect brake for leakage. If leakage is detected in
the pressure unit, the complete pressure unit must
be replaced. Hydraulic oil can leak from the brake into
the gearbox and be mixed with the gearbox oil, then
C-00116
the gearbox oil must be replaced. Make sure that the

gearbox oil has not been mixed with hydraulic oil if
1. Oil filling plug leakage from brake is detected.
2. Ventilation filter
3. Brake connection When the brakes are opened the slewing gears must
4. Oil dipstick/ Air ventilation valve not turn. If they turn see instruction "High Pressure
5. Oil outlet (x4) Pumps" in section 6.2.
Fig. 3. Slewing gear. Test brake torque by driving the hydraulic motors
against closed brake.
Close the stop cock 3661 for the pressure to the
Oil level check
brakes.
Oil level can only be inspected when the slewing gear
Drive the motors only for a few seconds, the slewing
not is in operation. As oil expands during operation,
gear must not rotate.
this expansion can falsify the oil level. It is important
to examine the oil level only when the slewing gear
Inspect brake discs and replace if excessively worn.
is cold! The oil must be filled up to the middle of the
If brake discs are colored dark yellow to
MIN/MAX mark. Refer to Fig. 3.
blue, the discs have been overheated. Replace discs
and springs.
1. Remove the oil dipstick.
2. Clean the dipstick.
Check the hydraulic pressure to make sure that it is
sufficient to open the brake completely. Refer to the
4. Remove the dipstick.
hydraulic diagram.
2 (4)
SERVICE 6.120.18 E rev.: b 2011-12-29
Backlash between slewing gear and bear-

ing
A too large of a backlash between the pinion and the

slewing bearing will cause an irregular slewing move-
ment of the crane. Too small of a backlash wears on
the slewing bearing.
Measure backlash
The backlash between slewing gear and slewing bear-
ing varies around the bearing and has one position
where it is tightest. It is where the minimum diameter
of the slewing bearing is. It is therefore recommended
to measure the backlash at (at least) four positions of
the slewing bearing to find the tightest spot. Measure
the backlash with a feeler gauge.
1. Measure the backlash between a slewing gear and

slewing bearing spline with a feeler gauge, see Fig.
4.
2. Proceed to measure the backlash at four 90-degree
positions on the bearing.
3. Compare the backlash values to find the tightest
position with the lowest backlash value.
4. Make a mark at the tightest position.
5. Measure the backlash for each slewing gear at the
tightest position. Backlash must be 0.4-0.6 mm at
that position.
Fig. 4. Measure backlash with feeler gauge.
3 (4)
SERVICE 6.120.18 E rev.: b 2011-12-29
Gearbox oil test

Sampling oil
Take a sample of gearbox oil for inspection at inter-
vals as described in the "Maintenance Chart". The oil
temperature in the gearbox must be at least +40 0C.
Use special oil sampling bottles, you can get them
from oil companies. Take the oil sample from the oil
drain, see Fig 3.
1. Drain 1-2 litres of oil into a bucket. Discard this oil.

2. Fill a oil sample bottle from the gearbox.
3. Send the oil sample to an oil company for analysis.
The oil company will be able to recommend if the oil

can be further used. Feedback on the oil analysis can
also be obtained from Cargotec Services Organisa-
tion.
Oil discoloration
A darkish or black colour of the used oil suggests
that temperatures in excess of 100° C did occur in
operation, causing accelerated aging of the oil and
decreased lubricating properties. In this case the oil
should be changed at shorter intervals.
If the oil sample displays a cloudy aspect, it may be

that water has managed to seep into the oil. The oil
must then be changed at once, and the gearcase
flushed out very thoroughly several times with fresh oil.
Overall assessment
The maximum permissible amount of foreign matter
carried by the oil is some 0.15 per cent of the total
mass of the oil in the gearcase. These impurities
must be, exclusively, very fine abraded matter (max.
25 microns). If the contamination keeps within these
limits, continued operation of the gearset is permitted
after the oil has been changed.
If any material larger than 25 microns or flakes off

material from the gear teeth are found, the gearbox
must be disassambled.
4 (4)
SERVICE 6.120.64 E rev.: q 2012-02-03
Hydraulic Motors
Hoisting, Luffing, and Slewing Circuits
Hydraulic motor 188 1221-801 Oil filling

Drain connection
Before the first operation the hydraulic motor housing

should be pre-filled with hydraulic oil.
Displacement: 106.7 cm3/rev.

Pre-filling volume: 1.0 litre (approx.)
Oil filling
Drain connection

Drain connection
Displacement Vg: 160-79 cm3/rev.

Pre-filling volume: 2.0 litres (approx.)
Oil filling
Drain connection

Drain connection


Oil filling
Drain connection
1 (8)
SERVICE 6.120.64 E rev.: q 2012-02-03

Drain connection


Oil filling
Drain connection

Drain connection


Oil filling
Drain connection

Drain connection


Oil filling
Drain connection
2 (8)
SERVICE 6.120.64 E rev.: q 2012-02-03
Hydraulic motor 188 1774-801 Oil filling / Drain connec-

tion
Displacement: 40 cm3/rev.
T1 alternatively T2 can be used as oil filling and drain

connections.
Oil filling / Drain

connection
Hydraulic motor 189 2418-801

Oil filling
Before the first operation the hydraulic motor housing Drain connection

Oil filling
Drain connection
Oil filling
Hydraulic motor 189 3383-801 Drain connection

Displacement Vg: 160.4 cm3/rev.

Oil filling
Drain connection
3 (8)
SERVICE 6.120.64 E rev.: q 2012-02-03

Oil filling

Oil filling
Drain connection

Drain connection



Oil filling

Oil filling
Drain connection
4 (8)
SERVICE 6.120.64 E rev.: q 2012-02-03

Drain connection


Oil filling
Drain connection

Drain connection
Displacement Vg: 160-72.5 cm3/rev.

Oil filling
Drain connection

Oil filling
Drain connection
Displacement Vg: 160-72.5 cm3/rev.

Oil filling
Drain connection
5 (8)
SERVICE 6.120.64 E rev.: q 2012-02-03

Drain connection

Displacement: 200 cm3/rev.

Oil filling
Drain connection

Drain connection


Oil filling
Drain connection

Drain connection

Oil filling
Drain connection
6 (8)
SERVICE 6.120.64 E rev.: q 2012-02-03

Drain connection


Oil filling
Drain connection

Drain connection

Displacement: 200-100 cm3/rev.

Oil filling
Drain connection

Drain connection


Oil filling
Drain connection
7 (8)
SERVICE 6.120.64 E rev.: q 2012-02-03

Drain connection


Oil filling
Drain connection

Drain connection


Oil filling
Drain connection

Drain connection


Oil filling
Drain connection
8 (8)
SERVICE 6.120.107 E rev.: b 2011-07-05
Winches, Hoisting/Luffing
General 4
1
Winch
The luffing winch is attached to the crane house wall
above the hoisting winch, refer to Fig. 1. One high
speed hydraulic motor with fixed displacement oparates
the luffing winch.
2
The hoisting winch is the lower winch on the crane
house floor, refer to Fig 2. One or two high speed
hydraulic motor with fixed displacement oparates the
3
hoisting winch.
C-00171
Brake
The brake is a hydraulic release multiple disc brake. Fig. 1. Luffing winch
Springs keep the brake engaged, the brake discs
1. Oil filler inlet, gearbox / Oil dipstick
are pressed together. The brake is automatically
2. Oil filler inlet for wet running motor shaft
released by hydraulic pressure when the winch
(for assembly)
rotates. The brake is directly behind the motor(s).
3. Oil drain, gearbox
Refer to Fig. 3.
4. Flange bearing, greasing nipple
Gearbox 4
The gearbox is a planetary gearbox. It is filled with oil 1
and has splash lubrication. The gearbox is behind the
brake inside the winch.
2
C-00172
Fig. 2. Hoisting winch

1. Oil filler inlet, gearbox / Oil dipstick
2. Oil filler inlet for wet running motor shaft
(for assembly)
3. Oil drain, gearbox
4. Flange bearing, greasing nipple
1 (4)
SERVICE 6.120.107 E rev.: b 2011-07-05
5. Note the oil level.

1 11
2 10
Replace oil
3 Drain oil while still hot. At low ambient temperature,
flush out the gearbox with clean pre-heated oil to
remove particles and sediment.
4 9
Grease flange bearing
Grease flange bearing, refer to "Lubricating and
maintenance".
5
8 Brake
6 Inspect brake for leakage. If leakage is detected in
7
C-00173
oil pressure unit, the complete pressure unit must be

replaced.
Fig. 3. Disc brake
1. Disc carrier Test brake torque by driving the hydraulic motors
2. Inner discs against closed brake.
3. Arrangement of the brake discs On hoisting winch, close the stop cock 1663 for the
4. Gear side pressure to the brake.
5. Outer discs On luffing winch, close the stop cock 2661 for the
6. Pressure valve / Air filter / Oil leak pressure to the brake.
7. Pressure unit Drive the motors only for a few seconds, the winch
8. Piston drum must not rotate.
9. Motor side
10.Pressure springs Inspect brake discs and replace if excessively worn.
11.Connection, pressure oil If brake discs are colored dark yellow to
blue, the discs have been overheated. Replace discs
and springs.
Maintenance
Check the hydraulic pressure to make sure that it
For maintenance intervals and number of grease nip- is sufficient to open the brake completely. Refer to
ples refer to the "Lubricating Chart" and "Maintenance hydraulic diagram.
Chart" in section 5.
For type of oil and grease refer to "Lubricants for Deck
Adjustment of pressure roller (if applicable)
Machinery" in section 5.
After replacement of wire the pressure roller must be
For oil volume refer to the "Technical data", section 2.
adjusted. Refer to Fig. 4.
Oil level check 1. Tighten adjusting nut carefully until the pressure
Oil level can only be inspected when the winch not roller touches the hoisting wire on the drum.
is in operation. 2. Tighten adjusting nut 12 turns to get correct
1. Remove the oil dipstick. spring force.
2. Clean the dipstick. 3. Secure with the locking nut.
4. Remove the dipstick.
2 (4)
SERVICE 6.120.107 E rev.: b 2011-07-05
3 2
Fig. 4. Hoisting winch with pressure roller
1. Adjusting nut
2. Locking nut
3. Pressure roller
3 (4)
SERVICE 6.120.107 E rev.: b 2011-07-05
Gearbox oil test contamination keeps within these limits, continued

operation of the gearbox is permitted after the oil has
Sampling oil
been replaced with new oil.
Withdraw a sample of gearbox oil for inspection at
If larger weared off matter (larger than 25 µm) or flake
intervals as described in the "Maintenance Chart".The
off material from the gear teeth is found, the gearbox
oil temperature in the gearbox must be at least +40 0C.
must be disassamble. No matter of the actual amount
Use special oil sampling bottles, you can get them
of foreign matter in the oil, start disassamble at the
from oil companies. Take the oil sample from the oil
input end of the gearbox.
drain on the winch, see Figs. 1 and 2.
1. Drain 1-2 litres of oil into a bucket. Discard this oil.

2. Fill the oil sample bottle.
3. Send the oil sample to an oil company for analysis.
The oil company will be able to recommend if the oil

can be further used. Feedback on the oil analysis can
also be obtained from Cargotec Services Organisation .
Oil discoloration
A darkish or black colour of the used oil suggests that
temperatures in excess of 100°C did occur in opera-
tion, causing accelerated aging of the oil and impaired
lubricating properties. In this case the oil should be
replaced at shorter intervals.
If the oil sample displays a cloudy aspect, it may be
that water has managed to seep into the oil. The oil
must then be replaced at once, and the gear case
flushed out very thoroughly several times with clean oil.
Disassamble the gearbox for inspection, start at the
input side, and examine the components for signs of
corrosion and/or excessive wear.
Foreign solid matter

As a first simple test, drop some of the used oil onto
a special filter fleece. Large foreign matter, if present,
will then show up on inspection, preferably through a
magnifying glass.
A better test is to mix an oil sample with n-heptane,
passing it through a diaphragm filter. Wash and dry it,
and weigh it to determine the mass difference.
Overall assessment
The maximum permitted amount of foreign matter in
the oil is some 0.15 per cent of the total mass of the
oil in the gearbox. These impurities must be, exclusi-
vely, very fine weared of matter (max 25 µm). If the
4 (4)
SERVICE 6.121.3 E rev.: a 1999-03-16
Trouble-Shooting Chart, Hydraulic High Speed Motors
Fault Probable cause Action
The motor does not run. Mechanical stop in the drive. Check system pressure. If the pres-
sure has risen to the relief valve set-
ting, remove the load from the drive.
The motor does not deliver enough Investigate the pressure level in the
torque because the pressure differ- system and correct the setting of the
ence across the motor is not great pressure limiting valve if necessary.
enough for the load.
Insufficient or no oil being supplied Check the hydraulic system. Check

to motor. the external leakage of the motor.
(The T connection)
Motor rotates in wrong direction. Oil supply connections to motor in- Connect the oil supply correctly.
correctly connected.
Motor runs jerkily. Pressure or flow fluctuations in the Find the cause in the system or in
hydraulic system. the driven unit.
Noise in the motor. The motor is being operated with the Adjust the charge pressure to the
charge pressure too low. correct level. See Hydraulic Circuit
- gauge connection 1.
Internal faults in the motor.

Investigate the drain oil.
External oil leakage on the motor. The radial lip seal is worn. Replace the radial lip seal.
1 (2)
SERVICE 6.121.3 E rev.: a 1999-03-16
Insufficient braking torque. The brake discs are worn out. Dismantle the brake and replace
the worn discs.
The brake does not open. Insufficient brake opening pres- See Hydraulic Circuit - gauge con-
sure. nection 2.
Seals or piston damage. Replace seals. Replace the piston.

IMPORTANT!
The springs in the brake cylinder
are tensioned.
Variable hydraulic motors
Motor only works at one speed. Pilot pressure low. Suitable pilot pressure. See Hy-
draulic Circuit - gauge connection
2.
The valve 1221 has stuck due to Inspect valve piston and remove
impurities in the oil. impurities.
No electric supply to the valve Check the electric system.

1221.
2 (2)
SERVICE 6.127.51 E rev.: b 2010-03-30
High Pressure Pumps
General
All pumps are the straight axial piston type with A complete hydraulic circuit diagram for your crane will
variable displacement controlled by a servo valve be found in the instruction and spare parts manual,
mounted on the pump housing. section 9.4.
The pumps are equipped with two adjustments, one for

“plussing“ and the other for pressure adjustment (maxi-
mum working pressure). “Plussing“ of the pumps is
done to compensate for internal leakage in pumps and
motors to prevent load drops, see Fig. 1.
Servo valve Zero setting screw
Electrical connector
Electrical onnector
Pressure cut-off valve
Fig. 1. High pressure pump.
1 (4)
SERVICE 6.127.51 E rev.: b 2010-03-30
Function checking/Adjusting of
“plussing“
Hoisting winch
- No load in hook. - Actuate directional valve 1221 manually with a small
- Stop the crane. screwdriver or similar during checking and
- Install a pressure gauge 0-400 bar at connection 3.1 adjustment, see Fig. 2.
on pump 1111, see the hydraulic circuit diagram.
- Lock the brake in closed position by closing ball - Adjust the plussing pressure on the hoisting pump by
valve 1663, see Fig. 2. turning the set screw. Turn the set screw clockwise
- Start the crane. The oil temperature should be 40°C. or counter-clockwise to increase or decrease the
- Actuate directional valve 1221 manually with a small plussing pressure. Pressure should be set according
screwdriver or similar during checking and to the hydraulic circuit diagram.
adjustment, see Fig. 2. - Control the pressure at connection 3.1.
- Check the plussing pressure on the pressure gauge - After adjustment tighten the locking nut. After tight-
at connection 3.1 according to hydraulic circuit ening of the locking nut, make sure the hydraulic
diagram. pressure has not been changed.
- If the plussing pressure is incorrect according to the - If there is more than one hoisting pump, the upper
hydraulic circuit diagram an adjustment must be pump should be adjusted.
made. - Stop the crane.
- Open valve 1663, see Fig. 2
- Stop the crane.
- Loosen the locking nut with a hook wrench.
- Start the crane.
Directional valve 1221
Directional
valve 1226
Actuate
C-00013
Ball valve 1663
Fig. 2. Valves on hoisting winch.
2 (4)
SERVICE 6.127.51 E rev.: b 2010-03-30
Luffing winch
- No load in hook. - Stop the crane.

- Park the crane or move the hook block close to the - Loosen the locking nut with a hook wrench.
jib top. - Start the crane.
- Stop the crane. - Actuate directional valve 2221 manually with a small
- Install a pressure gauge 0-400 bar at connection 5.1 screwdriver or similar during checking and adjustment.
on pump 2111. See the hydraulic circuit diagram. See Fig. 3.
- Lock the brake in closed position by closing valve
2661, see Fig. 3. - Adjust the plussing pressure on the luffing pump by
- Start the crane. The oil temperature should be 40°C. turning the set screw. Turn the set screw clockwise
- Actuate directional valve 2221 manually with a small or counter-clockwise to increase or decrease the
screwdriver or similar during checking and plussing pressure. Pressure should be set according
adjustment, see Fig. 3. to the hydraulic circuit diagram.
- Check the plussing pressure at connection 5.1 - Control the hydraulic pressure at connection 5.1.
according to the hydraulic circuit diagram. - After adjustment, tighten the locking nut. After tight-
- If the plussing pressure is incorrect according to the ening of the locking nut, make sure the hydraulic
hydraulic circuit diagram an adjustment must be pressure has not been changed.
made. - If there is more than one luffing pump, the upper
pump should be adjusted.
- Stop the crane.
- Open valve 2661, see Fig. 3.

Actuate

C-00012
Ball valve 2661
Fig. 3. Valves on luffing winch.
3 (4)
SERVICE 6.127.51 E rev.: b 2010-03-30
Slewing gears Installation of a new servo or a complete

new pump
Zero setting of slewing pump When a new servo unit or a complete pump is
installed, a function check of the "plussing" and zero
- No load in hook.
setting has to be carried out. Proceed according to
- Start the crane. The oil temperature should be 40°C.
“Function checking/Adjusting of “plussing”.
- Actuate directional valve 3221 manually with a
small screwdriver or similar during checking and
adjustment. See Fig. 4.
- Make sure that there is no slewing movement,
otherwise the zero setting must be adjusted.
Zero setting
- If the crane does move, right or left, an adjustment
must be made using the set screw for zero setting,
see Fig. 1 .
- Loosen the locking nut with a hook wrench.
- Actuate directional valve 3221 manually with a small
screwdriver or similar during checking and
adjustment. See Fig. 4.
- Adjust the zero setting on the slewing pump by
turning the set screw. Turn the set screw clockwise
or counter-clockwise. Hydraulic oil tank
- After adjustment tighten the locking nut. After
tightening of the locking nut make sure the zero
setting has not been changed.
- Stop the crane.
Ball valve 3661
Actuate
C-00015
Fig. 4. Valves for slewing.
4 (4)
SERVICE 6.132.18 E rev.: a 2010-10-07
Replacement of Vane Pump

Crane Type GLB
Introduction
The vane pump is attached to the pump unit. To Note! Ball valve 4335 must be open before the crane
replace the vane pump follow the sequence below. is started otherwise the vane pump will be damaged.
- Close ball valve 4335. To limit the oil leakage.

- Remove the suction hose.
- Replace the vane pump.
- Open ball valve 4335.
Pump unit
Suction hose
Ball valve 4335
Oil tank
Vane pump 4113
Vane pump 4113
Ball valve 4335
Fig. 1. Pump unit.
1 (2)
SERVICE 6.132.18 E rev.: a 2010-10-07
2 (2)
SERVICE 6.142.5 E rev.: a 2002-01-09
Recommendation for Inspection and

Replacement of Hydraulic Hoses
Hydraulic hoses and couplings assembled

inside crane house
Hydraulic hoses assembled inside crane house If the rubber in the hose is damaged so that the steel
should be inspected for damage every five (5) years, core can be exposed to corrosion the hose should be
see Maintenance Chart in section 5. replaced.
If the rubber in the hose is damaged so that the steel The hose couplings should also be inspected for
core can be exposed to corrosion the hose should leakage and damage of the corrosion protective Den-
be replaced. syl tape. If the corrosion protection is damaged so
The hose couplings should also be inspected for that the coupling can be exposed to corrosion the
damage and leakage. If the coupling is damaged or corrosion protection should be removed and the
severely corroded the hose should be changed. coupling inspected for damage and severe corrosion.
If the coupling is leaking the coupling should be tighte- If the coupling is damaged or severely corroded the
ned at first. If tightening does not help, the hose and hose should be changed.
the mating couplings should be changed, see Fig. 1. If the coupling is leaking the coupling should be tighte-
If the coupling is of flange type the O-ring and screws ned at first. If tightening does not help, the hose and
should be changed, see Fig. 2. the mating couplings should be changed, see Fig. 1.
If the coupling is of flange type the O-ring and screws
Hydraulic hoses and couplings should be changed, see Fig. 2.
assembled on outside of crane house
Replacement of hydraulic hoses
Hydraulic hoses assembled on outside of crane house
should be inspected for damage every two (2) years, All hydraulic hoses assembled inside crane house
see Maintenance Chart in section 5. should be replaced after ten (10) years due to safety
reasons.
All hydraulic hoses assembled on outside of crane
house should be replaced after five (5) years due to
safety reasons.
Hose coupling
Mating coupling O-ring
Screw
Fig. 1. Hose coupling with O-ring. Fig. 2. Flange coupling with O-ring.
1 (2)
SERVICE 6.142.5 E rev.: a 2002-01-09
2 (2)
SERVICE 6.189 E rev.: f 2007-04-11
Hydraulic Piston Accumulators
Function Charging hydraulic accumulators with nitrogen (N2)

A hydraulic accumulator functions as a source of pres- All crane motors must be immobilized.
surized fluid. Conversely, when the pressure falls off,
the accumulator supplies oil to the hydraulic system. 1. Dismount valve guard and unscrew the
protective cap from gas valve.
Note! - Do not bleed hydraulic accumulators! 2. New design, see Fig. 1. Connect the three-way
valve to the gas valve of the accumulator. The
bleed valve should be tightly closed.
Charging equipment
2a. Old design, see Fig. 2. Connect the three-way
To charge hydraulic accumulators, art. nos. see
valve to the gas valve of the accumulator. The
below, MacGREGOR (SWE) AB supply a charging
filling screw of the three-way valve shall be
valve and associated equipment, Fig. 2, comprising:
backed out completely, and the bleed valve
- a three-way valve
tightly closed.
- a 0-25 bar pressure gauge
3. Connect the charging valve, see Fig. 3 to the
- a 0-60 bar pressure gauge
reducing valve at the nitrogen cylinder.
- a 1-metre hose with a W24 connector for nitro-
4. Back out the adjusting screw of the reducing
gen cylinder
valve on the nitrogen cylinder until the valve
- two reduction connectors, W24/32M and W24/14D.
spring is unloaded.
5. Open the nitrogen cylinder valve.
Charging pressure for 388 0362-801: 15 ±1 bar at 20°C.
6. Adjust the reducing valve to the correct charg-
ing pressure.
New design
Valve guard
Protective
Gas valve cap
Protective cap Gas valve Open/close
Valve guard hexagonal nut
Open/close
hexagonal nut
Fig. 1. New design. Piston accumulators.
1 (4)
SERVICE 6.189 E rev.: f 2007-04-11
7. New design, see Fig. 1. Open the hexagonal nut 10. Close the nitrogen cylinder valve.
on the gas valve counter-clockwise to stop, by 11. Open the bleed screw of the three-way valve to
using a 19 mm fork wrench. discharge the pressure in the filling hose.
7a. Old design, see Fig. 2. Screw in the filling screw 12. Adjust the reducing valve to zero.
of the three-way valve but not so tightly that the 13. Unscrew the charging equipment from the nitro-
gas valve of the accumulator is damaged. gen cylinder and from the accumulator.
8. Fill nitrogen. 14. Check tigthness of accumulator gas valve, us-
9. New design, see Fig. 1. Check the nitrogen ing soap water.
pressure when the temperature and the pressure Note! - The protective cap shall be fitted with an
of the gas become stable. When the correct O-ring which must fit correctly into its groove.
charging pressure has been obtained, close the 15. Screw on protective cap of the gas valve.
gas valve by turning the hexagonal nut clockwise 16. After charging the accumulator, fit a lable carry-
by use of the 19 mm fork wrench. ing the charging date and signed by the operator.
9a. Old design, see Fig. 2. Check the nitrogen
pressure when the temperature and the pressure Note! For charging, it is not necessary to install a
of the gas have become stable. When the correct reducing valve on the nitrogen cylinder.
charging pressure has been obtained, again
back out the filling screw of the three-way valve.
Old design
Valve guard Valve guard
Protective cap Gas valve Gas valve Protective

cap
Fig. 2. Old design. Piston accumulators.
2 (4)
SERVICE 6.189 E rev.: f 2007-04-11
Filling screw, to be
used for old design
Pressure gauge
Bleed valve connection
Connector for hose

Connector for accumulator coupling
gas valve
Hose
W24 connector for

nitrogen cylinder
Fig. 3. Charging equipment.
3 (4)
SERVICE 6.189 E rev.: f 2007-04-11
4 (4)
SERVICE 6.209.15 E rev.: a 2012-09-05
Inspection of Climb Protection and Shafts,

Jib and Crane House Top
Climb protection
Check climb protection for wear and damage, see Fig.

1 and Fig. 2.
Check distance between outer edge of wire sheave

and climb protection. The distance between the outer
edge of wire sheave and the climb protection must not
be more than 1/3 of wire rope diameter, max. 10 mm
and 8 mm respectively, see Fig. 1 and Fig. 2.
Max. 8 mm
Max. 10 mm
1. Climb protection 1. Climb protection
Fig. 1. Jib top, example. Fig. 2. Crane house top, example.
1 (2)
SERVICE 6.209.15 E rev.: a 2012-09-05
Shafts for wire sheaves
Shafts for the wire sheaves are installed on the crane

top, jib stay (if installed) and jib top, see Fig. 3.
Make sure that the lockwashers for the sheave shafts
are correctly secured, see Fig. 4.
2
C-00280
1. Crane top
2. Jib stay (if installed)
3. Jib top
Fig. 3. Sheave shafts on crane (example)
Fig. 4. How to secure the lock washers.
2 (2)
SERVICE 6.214 E rev.: i 2007-03-02
Tightening Torques
Studs/Screws and Bolts
Introduction
This instruction applies to studs, screws and bolts Note!

generally, if separate recommendations are not gi- Threads that have been rolled after hardening have a
ven. Apply Molykote R 1000 lubrication on the threads lower surface notch indicating that the permitted ten-
and under the bolt head. For stainless elements and sion amplitude at fatigue can be about doubled
hydraulic pipe couplings apply Gleitmo paste. compared to threads that have been rolled before
hardening. If the screw has been loaded beyond the
yield limit, this feature will disappear.
Slewing bearing, studs/screws
See drawings "Slewing bearing mounting" and
"Slewing bearing yard mounting" in Section 9.3.
Phosphatized bolts greased with Molykote R 1000 Untreated bolts greased with Molykote R 1000
(Also valid for bolts greased with Loctite 243 or oil.) (Also valid for bolts greased with Loctite 243 or oil.)
Thread Tightening torque in Nm Thread Tightening torque in Nm

10 Nm ≈ 1 kpm 10 Nm ≈ 1 kpm
M UNC 8.8 10.9 12.9 M UNC 8.8 10.9 12.9
4 2.5 3.4 4.2 4 2.9 4.0 4.9

5 4.9 7.0 8.3 5 5.7 8.1 9.7
6 8.4 12.0 14.6 6 9.8 14.0 17.0
7 13.8 19.8 23.2 7 16.1 23.0 27.0
8 20.6 28.4 34.4 8 24.0 33.0 40.0
10 40.4 55.9 67.9 10 47.0 65.0 79.0
12 69.7 98 117 12 81.0 114 136
1/2" 80.8 114 136 1/2" 94.0 132 158
14 110 156 187 14 128 181 217
5/8" 159 224 269 5/8" 185 260 312
16 169 238 286 16 197 277 333
3/4" 280 393 471 3/4" 325 457 548
18 237 332 398 18 275 386 463
20 331 465 558 20 385 541 649
22 445 626 752 22 518 728 874
24 572 804 963 24 665 935 1120
1" 670 942 1131 1" 779 1095 1315
27 826 1161 1393 27 961 1350 1620
30 1127 1582 1901 30 1310 1840 2210
1 1/4" 1308 1840 2208 1 1/4" 1521 2140 2567
33 1522 2133 2563 33 1770 2480 2980
36 1961 2761 3311 36 2280 3210 3850
39 2520 3543 4248 39 2930 4120 4940
42 3130 4395 5280 42 3640 5110 6140
1 (4)
SERVICE 6.214 E rev.: i 2007-03-02
As a rule, always change screws with specified tight- Stainless bolts and hydraulic pipe couplings
ening torque on cranes in operation if the joint has to greased with Gleitmo paste
be opened for some reasons.
Thread Tightening torque in Nm
If any joint has been opened apply Intertuf after tight- d 10 Nm ≈ 1 kpm
ening the joint to avoid rust damage. Austenite (A)
50 70 80
6 3.3 7 9.3
8 7.8 17 22
SAE flange for high pressure hose couplings
10 15 33 44
Tightening torque in Nm 12 27 57 76
Flange Screw 10 Nm ≈ 1 kpm 14 43 91 121
6000 psi Class H 10.9 and 12.9 16 65 140 187
18 91 195 260
3/4" M10 54
20 127 273 364
1" M12 94
22 171 367 490
1 1/4" M14 150
24 220 472 629
1 1/2" M16 230
27 318 682 909
2" UNC 3/4 377
30 434 930 1240
33 585 1250 1670
36 755 1620 2160
39 969 2080 2770
2 (4)
SERVICE 6.214 E rev.: i 2007-03-02
Strength of screws and bolts
Strength class Min. ultimate strength Min. tensile strength Corresponding strength
N/mm2 (kp/mm2) N/mm2 (kp/mm2) class of nuts
4.6 400 (40) 240 (24) 4

5.8 500 (50) 400 (40) 5
6.6 600 (60) 360 (36) 6
8.8 800 (80) 640 (64) 8
10.9 1000 (100) 900 (90) 10
12.9 1200 (120) 1080 (108) 12
Examples of markings:
Hexagonal screw Allen screw
Strength class 4.6: Strength class 12.9:
BH 12 9 M
Strength class 8.8:
Hexagonal nut
Strength class 8:
Strength class 10.9:
M-thread UNC- and UNC- and

UNF-thread UNF-thread
Cold forged Forged
Strength class 10:
M-thread UNC- and UNF-thread

Forged
3 (4)
SERVICE 6.214 E rev.: i 2007-03-02
Tightening Torques
Hydraulic Couplings
The values below presume greasing of threads when

assembling.
Type of Thread Tightening Type of Thread Tiightening

coupling M and R torque in Nm coupling M and R torque in Nm
GE 10-LM M 14x1,5 ca 39 GE 10-SM M 16x1,5 ca 59

GE 10-LR R 1/4 ca 39 GE 10-SR R 3/8 ca 69
GE 12-LR R 3/8 ca 59 GE 12-SR R 3/8 ca 69
GE 15-LR R 1/2 ca 108 GE 14-SR R 1/2 ca 128
GE 18-LR R 1/2 ca 108 GE 16-SR R 1/2 ca 128
GE 22-LM M 26x1,5 ca 128 GE 20-SM M 27x2 ca 196
GE 22-LR R 3/4 ca 157 GE 20-SR R 3/4 ca 206
GE 28-LM M 33x2 ca 216 GE 25-SM M 33x2 ca 294
GE 28-LR R1 ca 265 GE 25-SR R1 ca 314
GE 35-LM R 42x2 ca 353 GE 30-SM M 42x2 ca 491
GE 35-LR R 1 1/4 ca 392 GE 30-SR R 1 1/4 ca 491
GE 42-LM M 48x2 ca 491
GE 42-LR R 1 1/2 ca 491 Table 2.
Example: GE 10 - LM
Table 1. Sealing
d = 10
Fitting
Sealing cone
Insert the sealing cone into the 24-degree coupling
fitting, firmly tighten the coupling by hand. Using a
wrench, tighten the coupling nut another 1/4 to 1/2
turn. The O-ring should preferably be oiled.
Hose Coupling Tables 1 and 2

Grease
O-ring sealed Sealing
4 (4)
SERVICE 6.215.21 E rev.: b 2007-06-08
Service Door (Opening and Closing)

Service and Lubrication of Door Hinges
Warning!
There is a risk of falling down when opening or
closing the service door. Always use a safety belt!
Note! Before opening the service door you should A. Procedure for opening
always check the condition of the door hinges. Also
make sure that the doors are secured before opening, 1. Put on safety belt.
see Fig. 1. 2. Loosen the two nuts (1) and the washer (2), see
Fig. 2.
3. Unhook the eye bolt (3).
4. Swing service door outward.
Note! Do not forget to secure yourself using safety
belt.
5. Release the locking rod (5) from its parking posi-
tion by loosening the chapel strop (6), see Fig. 3.
6. Remove the screw (7) from its bracket.
7. Swing the locking rod (5) and secure it by use of
the screw (7).
1
2
3
4
Fig. 1. Securing service door to top of crane. Fig. 2. Opening service door.
1 (2)
SERVICE 6.215.21 E rev.: b 2007-06-08
B. Procedure for closing
1. Put on safety belt.

2. Remove the screw (7), see Fig. 3.
3. Swing the locking rod (5) back to its parking position.
4. Secure the locking rod (5) by use of the chapel strop
(6).
5. Reinstall the screw (7).
6. Swing the door inward, see Fig. 3.
7. Hook on the eye bolt (3) on the bracket (4), see Fig.
2.
8. Retighten the two nuts (1) and the washer (2).
C. Procedure for lubrication of service

door hinges
5 7
The service door hinges should be lubricated every 5
6
six months. See also "Lubricating Chart" in section 5
of your Instruction Manual.
Note! To be able to properly lubricate the hinges the

service door must be open.
D. Inspection of door hinges Fig. 3. Locking rod.
At the same time as the service door is opened for

lubrication of the hinges, inspection of the hinges and
the surrounding areas should be done. If the findings
show that any areas are rusty or are otherwise in bad
condition a proper repair must be done.
Please contact MacGREGOR if you have any

questions.
2 (2)
SERVICE 6.216.83 E rev.: a 2003-03-11
Rope Reeving Diagram for Cranes Type GLB-2
Important! Important!
It is of utmost importance to grease the wire thim- The wire rope thimble must be safely secured by
ble according to instructions "Lubricating Chart" and bending the lock washers, see Fig. 2 on page 2.
"Lubricants for Deck Machinery".
Number of reeving parts: Note! Before rigging slacken the pressure roller on
Luffing: 6 parts the hoisting winch. See Fig. 4.
Hoisting: 6 parts
Fig. 1. Rope reeving and securing wire rope thimbles.
1 (4)
SERVICE 6.216.83 E rev.: a 2003-03-11
Luffing wire rope
Hoisting wire rope
Fig. 2. How to secure the lock washer for the wire Fig. 3. Rope reeving for Slack wire safety switch,
rope thimble. hoisting and luffing. Slack wire condition.
2 (4)
SERVICE 6.216.83 E rev.: a 2003-03-11
Adjustment of pressure roller on the

hoisting winch
After replacement of wire the pressure roller on the - Tighten adjusting nut 12 turns to get correct spring
hoisting winch must be re-adjusted. force. Adjustment shall be done at full drum condi-
tion.
- Tighten adjusting nut carefully until the pressure - Secure with the locking nut.
roller touches the hoisting wire on the drum.
- Check that the play (approx. 2 mm) between wire
and pressure roller corresponds to Fig. 4. Adjust if
necessary by changing location (rotation) of frame
bearings, see Fig. 4.
Empty drum Full drum

Approx. 2 mm
Approx. 2 mm
Full drum
Empty drum
Pressure roller
Frame bearing Adjusting nut
Frame
Adjust play by rotating Frame bearing

the washer/bearing.
Locking nut
Fig. 4. Hoisting winch with pressure roller.
3 (4)
SERVICE 6.216.83 E rev.: a 2003-03-11
This page is intentionally left blank
4 (4)
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.
Instead, it should be lifted by means of a wide tex-

Storing steel wire ropes
tile 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
corrosion problems. Although plastic foil protects An unreeling stand (turnable) should be used to
the ropes from rain, condensation from beneath unwind a wire rope from its reel.
might not be able to escape and could damage the
ropes permanently. To avoid condensation prob- Another accepted unreeling method is to mount the
lems, it is advisable to use breathable water-proof reel on a shaft supported by two jacks or a stand.
fabric covers readily available from tarpaulin manu-
factures.
When storing a number of spare ropes, the follow-

ing 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, specification, 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 Rolling the wire rope along the floor, as is some-
or reel without torsions and without any outer dam- times recommended in the relevant literature, does
age. The same applies to reeving the ropes into not work very well in practice because the reel al-
the system. ways unwinds less wire than the distance the reel
travels, so that with this method the rope has to be
dragged along the worker.
Unwinding steel wire ropes from the coil
If a rope is delivered on a coil, it is either unwound

on a turntable or the coil is rolled along the ground
like a hoop. In the latter case ensure that the sur-
face 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 If one end of the ropes has a fitting attached, as it
off a coil while it is lying on the ground or looped is mostly the case with deck cranes, there is no
over the head of the reel, because this will inevita- other possibility than pulling the loose rope end
bly induce one torsion per wrap into the rope. through the 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 fi-
nally the distribution 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 enforced torsions The cast steel ferrule with mechanical splice.
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 Below is shown an example of a typical deck crane,
wire rope varies from crane to crane. In any case a where the rope must be spooled from the reel via
procedure should be chosen that (under justifiable sheaves S1 through S9 onto the drum.
expenditure) 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 after-
wards. With other cranes, particularly with bigger
ones, it might be better to pull in the new rope at-
tached 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-

cessary 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 tional wire ropes one must at least make sure that
block. It must be secured in an upright position so they have the same direction of lay as rope to be
that the rope can be spooled without any fleet an- installed.
gles occuring between the rope and the block´s
sheaves. If the new rope is pulled in with help of the used
one, the two rope ends are often buttwelded to-
gether. A connection of that kind can transfer the
Winding the steel wire rope from the reel twist of the old rope, built up in the reeving system,
onto the drum into the new rope. By that method of installation the
new rope may be extremely damaged.
During the manufacturing process every steel wire
rope receives its preferred bending direction when There are even more reasons why that procedure
being drawn from the wire rope closer by means of is highly problematic: It is true, that when using spe-
a capstan. When delivered to the customer the rope cial electrodes the welded connection presents
is bent in that direction. Make certain that it bends acceptable results in a pull test with a straight rope;
in the same direction when it is wound from the reel but because of the great length of rigid connection
onto the drum. zone the very same connection could break due to
the enormous bending stresses when running over
sheaves.
If that connection is applied, its safety should be

increased by using a Chinese finger. Fewer prob-
If the rope is wound at the bottom of the drum, it lems are caused by con-
should leave the reel at the buttom and vice versa: necting wire ropes with
i.e., always reel from top to top or from bottom to welded-on pad eyes or
bottom. chain links, which are
joined by either strands or
If this procedure is not strictly followed, the rope thin wire ropes.
will either try to twist between reel and drum or it
will later try to regain its preferred position when in
practical service. In both cases structural changes
of the rope may occur. This connection provides satisfactory
load capacity, it is flexible and pre-
vents the transfer of twist from the old
rope into the new one. When using
two strands to pull the rope into place,
these will indicate the intensity of twist
in the old rope on the basis of the
number of turns they have made dur-
Installing the rope with the help of the old ing the installation procedure.
one or by a thinner rope
Another possibility is connecting the
If the new rope is pulled in by the old one or by a rope ends with Chinese fingers. These
thinner rope one must make sure that the connec- are tubes made out of braided
tion between these ropes is absolutely safe. In ad- strands, which are pulled over the
dition it must be ensured that the thinner rope can- rope ends and then secured at their
not rotate. Rotation-resistant steel wire ropes or ends with tape or seizing wire. Under
three-strand ibre ropes for instance, can be re- load the Chinese fingers will contract
commended for this purpose. When using conven- and hold the rope ends by friction.
5 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
When installing a lang lay rope one must take care Under no circumstances should one attempt to gen-
that the Chinese finger cannot unwind from the rope erate the tensioning load by jamming the rope, for
like the nut from a screw. It is recommended to wrap instance between two boards. Structural changes
a tape around the whole rope length to be held by would deform the rope beyond repair.
the Chinese finger to increase the friction.
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
common 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 lay-
ers under load. This could seriously damage the
rope. The unwinding rope might even be clamped, Attaching the rope termination to the fix
so that the direction of spooling could suddenly be point
reversed during the course of unwinding. The re-
sult could be the abrupt lifting of the load that was After the rope has been pulled through the reeving
actually travelling downwards. system, the rope termination (e.g. the mechanical
splice with the aluminum ferrule) must be brought
The tensioning load should range from 1% to 2% of up to the fix point. A pulling jack can be used to pull
the minimum breaking load of the wire ropes. In the rope termination to the fix point, where it must
many cases it might suffice to wind the rope quite secured with a bolt.
normally in order to unwind it and then rewind it
with the help of an outer load. Prior to fixing, if necessary, the rope termination
may be aligned with the fix point by using a steel
In other cases, however, the procedure mentioned bar. The bar should be attached to the rope by
above is not possible. In these cases the tensioning means of a short length of chain. Under no circum-
load must already be applied when installing the stances should the rope be gripped with a wrench,
rope. as this will damage the outer wires.
Ample rope tension can be provided by a simple

plank bearing against the reel flanges or by a brak-
ing disk attached to the reel.
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 mov-
ing away from the location of the intended cut.
After the rope has been installed and before it is
going 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 themselves to the actual The rope is tightly wrapped for a distance of approx.
operating conditions. It is most un- three rope diameters.
fortunate that in practice only too
often the exact opposite of this
recommendation is performed:
quite frequently after installing the
rope overload tests are carried out
with loads beyond the safe work-
ing load of the system. Both ends of the seizing wire are then pulled tight
and twisted together for a length of one rope diam-
eter.
Cutting steel wire ropes
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 re-
quired for larger sizes. The twisted connection is then hammered into a
gusset between the strands. After preparing the
The best method is to use a high speed disk cutter. other side of the intended cut accordingly the rope
Unless the rope is being scrapped the use of flame can now be cut.
cutting equipment is not recommended.
Careless cutting can result in the balance of ten-

sion in the rope being destroyed. This is particu-
larly important when cutting rotation resistant ropes
where the strands may have been deliberately non-
preformed as part of the manufacturing specifica- Instead of using one long seizing it is also possible
tion. to apply at least three seizing the size of one rope
diameter each on both sides of the intended cut.
In every case, each side of the cut must be prop-
erly seized to prevent strand disturbance. Insulat-
ing tape cannot prevent strand movement, so an- The maintenance of steel wire ropes
nealed (iron) wire should always be used.
Steel wire ropes must be serviced regularly, the kind
After marking the position of the cut the end of the of maintenance depending on the lifting device, its
seizing wire is laid along the rope axis leaving suf- use and the selected rope. Regular maintenance
ficient length to secure both ends by twisting when may considerably increase the service life of a steel
the seizing complete. 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

relubrication of steel wire ropes that they are car-
During production the rope receives intensive lu- ried out regularly right from the beginning of the
brication. This in-process treatment will provide the service life of the rope and not only after the first
rope with ample protection against corrosion and is damage has been ascertained.
meant to reduce the friction between the elements
which make up the rope as well as the friction be-
tween rope and sheaves or drums. This lubrication, Cleaning steel wire ropes
however, 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
subjected to bending. If for operational reasons up chemicals.
relubrication cannot be carried out, shorter service
life of the rope is to be expected and the inspection Effective cleaning without proper tools is quite a
intervals have to be arranged accordingly." laborious job. For cleaning steel wire ropes the Ca-
nadian Rigging Manual recommends an appliance
When choosing the relubricant, it must be ensured with three rotating wire brushes and an air blast
that it is in accordance with the recommendations drying system to follow. An American manufacturer
of the rope manufacturer. offers a "rope porcupine", a sleeve equipped with
brushes, which is drawn along the steel wire rope.
There are several techniques of lubricant applica-
tion: The most common ones at present are paint-
ing or swabbing. Removing broken wires
Quite often the lubricant is applied at a sheave, If during an inspection ends of broken wires are
sometimes a continuous drip method is used. If only detected which might cross adjacent wires and
a little lubricant is required, pressure spray nozzles destroy them when running over sheaves, these
can be applied. broken wire ends must be removed.
Maximum penetration of the lubricant into the gaps Under no circumstances should the broken wire
of the rope, can only be quaranteed if high pres- ends be pinched off with a pair of nippers. The best
sure lubrication is applied with the help of a pres- method is to move the wire ends backwards and
sure lubricator. forwards until they break deep in the valley between
two outer strands. With thicker wires a tool should
With this method the two halfs of a sleeve, which is be moved backwards and forwards on the surface
equipped with rubber sealings, are clamped round of the rope, thus bending the wires until they break.
the rope and screwed together. While the rope runs
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 dam-
aged, 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, shift-
ing 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
adjacent 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 different 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 exam-

ples 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 tor-
sional 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, Wear and identations of surface wires also promote
(e.g., if a slack line suddenly snaps taut under full fatigue and lead to premature wire rupture.
load).
Crown wires of outer strands may wear so thin that Corrosion may cause wire ropes to break. As a
the residual cross sectional area of steel in the rope safety measure, inspect ropes regularly and care-
will not support the normal design load and con- fully to prevent catastrophes; observe manufactur-
traction rupture may ensue. er's instructions
Rupture from fatigue will often occur when under-

size 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
12 (12)
SERVICE 6.223.20 E rev.: c 2011-02-07
Replacement of Wires, One or Two Fall Rigging

General
The procedure is general and should be seen as a - Stop the crane. Use pushbutton S13 Start/Stop on
guidance only. the control panel in cabin.
- Mark the position of the wire drum in relation to the
See instruction "Handling, Installation and Mainte- bracket, this to avoid setting of all hoisting limits
nance of Steel Wire Ropes" in section 6.2. again after installing the new hoisting wire.
- Remove the cover from the limit switch box.
- Mark the position of the shaft in relation to the box.
Hoisting winch / wire
See Fig. 5.
For cranes with one or two fall rigging proceed as
- Remove the limit switch box.
follows:
- Measure the AL measure, see Fig. 3.
- Place the jib in the jib rest.
- Secure the wire, so the wire clamps that hold the
If applicable, park the crane, slewing position locked
end of the wire can be removed safely.
with parking cylinders, and the jib at maximum
- Attach a long rope (longer than the wire rope) to
outreach.
the wire end and place it 4 to 5 turns around the
If applicable see also special instruction "Parking
wire drum.
of Crane in Wires" in section 4.
- Park the lifting block on deck and support it so that
WARNING!
the wire can easily be spooled through the lifting
When the crane is operated in Rig mode the crane
block, see Fig. 1.
has no software limits.
- Disengage the slack wire switch by blocking the
It is not permitted to have any load in the hook.
spring tensioned roller, which can be done with a
Inappropriate use may cause severe damage to the
piece of wood, see Fig. 2.
crane and bodily injury.
- Loosen the wire rope socket/thimble attached to
the crane house top, see Fig. 9 or 11.
See instruction "Preparation for Rig Mode", section
- Run the winch by paying out the hoisting wire, and
6.3.
at the same time pull on the loose wire end.
- Stop the winch just before it enters into the empty
- Activate Rig mode.
drum limit.
- Run the winch to pay out the old wire until it is on
the deck.
- Attach the new hoisting wire to the same rope by
using tool 662 0754-000, see Fig. 8.
- Attach the wire rope end to the wire drum with the
wire rope clamps and tighten the bolts. For tighten-
ing torques, see instruction "Tightening Torques..."
in section 6.2.
- Run the winch by pulling in the new hoisting wire,
so that the AL measure is the same as noted ear-
lier and that the winch corresponds to the position
marked earlier.
- Stop the crane. Use pushbutton S13 Start/Stop on
the control panel in cabin.
- Exit Rig mode. Set key switch in position Normal.
- Assemble the limit switch box in its proper place,
Fig. 1. Lifting block parked in support. the marking on the shaft/box must correspond.
1 (6)
SERVICE 6.223.20 E rev.: c 2011-02-07
- Start the crane again. Piece of wood

- Run in the rest of the wire. Leave enough slack to 100 x 200
secure the wire rope socket.
- Secure the hoisting wire rope socket/thimble on
jib top and the luffing wire thimble on crane house
top. See Fig. 9 or 11.
Piece of wood
- Remove the wooden piece holding the slack wire 100 x 200
roller.
- Test the winch and check all limits, which should
now function correctly, if the new wire is the same
length as the old one. If necessary, adjust the limits
according to instruction "Limit Switches in..." in sec-
tion 6.3, instruction "Technical Data" in section 2,
and calibrate the encoder according to instruction
"Absolute Encoder Calibration" in section 6.3.
Luffing winch / wire

- Place the jib in the jib rest or move the lifting block
up against the jib top.
- Disengage the slack wire switch by blocking the Fig. 2. Disengage of slack wire safety switch.
spring tensioned roller, which can be done with a
piece of wood, see Fig. 2. AL
- Run winch and stop just before it enters into empty
drum limit.
- Stop the crane. Use pushbutton S13 Start/Stop on
- Note how many revolutions of the wire there are
left on the drum at this position. Make a mark on
the drum. Measure the AT measure, see Fig. 4.
- Mark the position of the wire drum in relation to the
AL = Empty drum flange
bracket. side/ At least three locking
- Remove cover from the limit switch box. turns/Tank top
Mark the position of the shaft in relation to the box.
Fig. 3. Hoisting winch.
See Fig. 5.
- Remove the limit switch box.
AT
- Loosen the wire rope socket/thimble attached to
the crane house top / jib, and lower it to deck by Wire lock
means of a rope, see Fig. 9 , 10 or 11. side
- Secure the wire, so the wire clamps that hold the
end of the wire can be removed safely.
- Attach a long rope to the wire end (longer than the
wire rope) and place it 4 to 5 turns around the wire
drum.
- Start the crane again. AT = Empty drum flange
side/ Stop lowest position/
At least three locking turns
Fig. 4. Luffing winch.
2 (6)
SERVICE 6.223.20 E rev.: c 2011-02-07

- Run the winch to pay out the old luffing wire, and
at the same time pull on the loose wire end until it
is on the deck.
- Attach the new luffing wire to the rope, by using
tool 662 0754-000, see Fig. 8.
- Run the winch by pulling in the wire so that the wire
rope end just enters into the crane house.
- Attach the wire rope socket/thimble to the crane
house top or jib, see Fig. 9, 10 or 11.
- Secure the hoisting wire rope socket on jib top and
the luffing wire thimble on crane house top. See Fig.
Fig. 5. Marking inside limit switch box.
9 or 11.
- Run the winch by pulling in the wire, so that the AT
measure is the same as noted earlier and that the
winch corresponds to the position marked when
the limit switch box was disconnected.
Limit box
Check that the AT measure is the same as before
removing the wire.
- Attach the wire rope end to the wire drum by the
wire rope clamps and tighten the bolts. For tighten-
ing torques see instruction "Tightening Torques..."
in section 6.2.
- Stop the crane. Use pushbutton S13 Start/Stop on Winch drum
- Exit Rig mode. Set key switch in position Normal.
Fig. 6. Limit switch box, hoisting winch.
- Assemble the limit switch box in its proper place.
- Start the crane again.
- Run in the rest of the wire.
- Remove the wooden piece holding the slack wire Winch drum
roller.
Limit box
- Test the winch and check all limits, which should
now function correctly, if the new wire is the same
length as the old one. If necessary, adjust the limits
according to instruction in section 6.3 and calibrate
the encoder according to instruction "Absolute En-
coder Calibration" in section 6.3.
Tightening torque: In the first place look for tightening

torque on the winch spare part picture, in the second Fig. 7. Limit switch box, luffing winch.
place see instruction 6.214 E.
Note!
To adjust the pressure roller on winch see instruc-
tion "Rope Reeving Diagram ..." in section 6.2 in the
instruction and spare parts manual.
Fig. 8. Tool, wire rigging sock, 662 0754-000.
3 (6)
SERVICE 6.223.20 E rev.: c 2011-02-07
Securing of wire rope socket applicable

to crane type GL
See the "Rope Reeving Diagram" (6.216.xx E) that

applies to your crane.
Example
Install a new split pin
when replacing wire
Securing the luffing wire socket to crane house top
Securing the hoisting wire socket to crane house top

Applicable to cranes with loadcell
New pin attached to wire socket.
New pin
Fig. 9. Securing wire sockets to crane house top.
New pin
Fig. 10. Securing the wire socket to the crane jib.
4 (6)
SERVICE 6.223.20 E rev.: c 2011-02-07
Securing of wire rope thimble applica-

ble to crane type GLB
See instruction "Rope Reeving Diagram..." in sec-

tion 6.2.
Important!
Important! It is of utmost importance to grease the wire thimble
The wire rope thimble must be safely secured by refer to instructions "Lubricating Chart" and "Lubri-
bending the lock washers, see Fig. 12. cants for Deck Machinery" in section 5.
Fig. 11. Securing of the wire thimbles to the crane house top.
Fig. 12. How to secure the lock washer for the wire rope thimble.
5 (6)
SERVICE 6.223.20 E rev.: c 2011-02-07
Securing of wire, applicable to cranes

with attached load cell
Load cell
Wire rope socket
Install a new split pin

when replacing wire
Fig.13.Securing of the wire socket to the loadcell on jib top.
6 (6)
S E RV I C E I N F O R M AT I O N
625/1669 E rev.: - 2013-01-29
Indentation and Wear on Wire Sheaves
General Maximum wear of the sheave side plate

To ensure safe working conditions and long lifetime When the wear on the wire sheave side plate exceeds
of the wire rope it is important to inspect the condition maximum allowed wear, it will decrease the lifetime of
of the wire sheaves. the wire rope and reduce load capacity.
Maximum allowed wear (a) on the wire sheave is set

Wear criteria
to 25% or 3 mm of the sheave thickness (t), see Fig.
There are two criteria that has to be considered to
1 and Table 1.
determine if a wire sheave is fit for use.
The wear can occur anywhere where the wire rope is

• Maximum wear of the sheave side plate
in contact with the sheave.
• Maximum wear in the sheave radius
t (mm) a max (mm)

16 3
12 3
10 2.5
8 2
6 1.5
Table 1. Maximum wear on wire sheave.
Fig. 1. Wear on wire sheave.
1 (4)
625/1669 E rev.: - 2013-01-29
Maximum wear in the sheave radius

Wear in the sheave radius will decrease the lifetime
of the wire rope.
For maximum allowed wear in the sheave radius, see

Table 2.
150⍭
Original wire Maximum allowed sheave radius

diameter
Ø18 - Ø34 Wire sheave original radius + 2 mm
Ø36 - Ø56 Wire sheave original radius + 4 mm
Ø38 - Ø76 Wire sheave original radius + 6 mm Fig. 4. Correct way of measuring.
Table 2. Maximum wear in sheave radius.
For original wire specifications, see instruction Techni-

cal Data in the instruction manual.
Wire sheave original radius is calculated: wire diam-

eter x 0.56.
Example for 30 mm wire:

Wire sheave original radius = 30 mm x 0.56 = 16.8.
Maximum alllowed sheave radius = 16.8 mm + 2 mm
= 18.8 mm.
Measuring wear in the sheave radius

Use a radius gauge to measure wear in the sheave
radius, see Fig. 3 and 4.
Fig. 3. Radius gauge.
2 (4)
625/1669 E rev.: - 2013-01-29
Indentation An old wire rope and a worn wire sheave might have
A new wire rope and wire sheave are in contact on cer- good contact condition, see Fig. 6, but when a new
tain spots, see Fig. 5. After some time the indentation wire rope is installed the contact condition might be
will have the shape shown in Fig. 6. This is considered very bad, see Fig. 7. This will decrease the lifetime of
as normal wear. the wire rope and wire sheave.
It is therefore important to inspect the wire ropes ac-

cording to paragraph "Wear criteria".
Fig. 5. Contact spots.
Fig. 7. Bad contact between a new wire rope and the

wire sheave.
Fig. 6. Good contact between an old wire rope and

the wire sheave.
3 (4)
625/1669 E rev.: - 2013-01-29
4 (4)
625/1560 E rev.: g 2013-03-14
Lifting Block/Beam
WARNING!
Where equipment has swivelling and moving parts
there are potential safety hazards. Care should be
taken when working with or repairing equipment.
If used incorrectly, breakage could occur injury or
death.
General safety
Eyes for stabilizing
wires (extra equipment)
When equipment is in use, do not put hands:
• Between sheaves, side plates, and guards
• In area of hook, hook nut, and swivel.
Fig. 1. Lifting block for crane with two sheaves.
Take great care to avoid clothing becoming trapped.
Repair and reeving should be carried out by trained

personnel only. Power should be switched off before
operations are carried out. Work should only take
place when equipment is supported on a firm surface.
Maintenance and service
Inspection should be carried out on every possible

occasion before taking into operation.
Fig. 2. Lifting block for crane with one sheave.
Pay particular attention to the items below:

• Wear in hook, centre pin, steel structure, and
threads
• Play in sheave bushes or bearings
• Spacer bolts and nuts
• Examine for cracks in welds in steel structure
• Condition of safety latch and grease nipples
• Wear in holes in side plates and links.
If cracks or heavy gouges appear, the equipment

should not be used until a qualified person examines
the equipment. Contact MacGregor Cranes, Service
Division.
NO welding should be carried out unless prior author-

ity is obtained.
Fig. 3. Lifting beam for 4-rope crane.
1 (2)
625/1560 E rev.: g 2013-03-14
Limits of wear down and corrosion

Important!
When replacing genuine parts an overload test
If any part of the Lifting Block/Beam exceeds the below
of the complete unit must be performed and new
limits the part must be replaced or maybe repaired,
certificate must be issued. See Table 1.
see Fig. 4. Contact MacGregor for instructions.
Limits: Lubrication
• 5% on any diameter
• 2% on any diameter of a pin in a hole.
As a general rule sheaves, shafts, and swivels should
be greased through nipples every 100 working hours,
see also separate lubrication chart.
Pins without nipples should be removed and lubricated
with a brush.
Limitation of use
• Safe working load should never be exceeded,

see Table 1.
• Crane blocks must only be used in vertical lift.
• Shock or side loading should not be applied, un-
less equipment is designed for that purpose.
• Load should always be in seat of hook or eye.
Fig. 4. Lifting eye.
All repairs must be carried out by responsible person-

nel, and great care should be taken in the reassembly
of the equipment and retaining parts, i. e., grub screws,
pins, etc. Make sure they have the correct sizes and
threads and refit them.
Proof load for lifting blocks with 2-part rigging

Class Working load limit Proof load
ABS PL = 2 x WLL
BV WLL < 25 T PL = 2 x WLL
25 T < WLL < 160 T PL = (0.933 x WLL) + 27
WLL > 160 T PL = 1.1 x WLL
DNV PL = 2 x WLL
GL WLL < 25 T PL = 2 x WLL
WLL > 25 T PL = (1.22 x WLL) + 20
LRS WLL < 25 T PL = 2 x WLL
WLL > 25 T PL = (1.22 x WLL) + 20
WLL = Working Load Limit (SWL)
T = 1 metric ton = 1000 kg
PL = Proof Load
Table 1.
2 (2)
625/1579 E rev.: k 2011-10-28
Measuring Procedure for Wear in Slewing Bearings
General at the reference point in the front of the crane and

"B, C" at the reference point at the back of the crane.
Below measuring procedure is valid for the crane Remove excessive wear (burr) from slewing gear teeth
types G, TG, GL, TGL, GLB, H, TH, L, and TL. before measuring.
Note! Measurements shall be taken at four positions of the

The procedure is not valid for measuring the slewing slewing bearing, if possible. With the jib pointing:
bearing under the twin platform. - Forward to the ship
- Starboard
The slewing bearing is an essential part of the crane - Aft
and must be well maintained. Over the years the slew- - Port side
ing bearing will have some wear, and to be able to It is important to use the same position for all further
know if there is a need for changing the slewing bear- measurements to be able to compare the measure-
ing records of the wear are needed. 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 wear measurement shows wear, grease samples to be taken, see Fig. 2.
can be taken 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. Measurements can be sent to Cargotec
- for roller bearings 1.5 mm
Service Organisation for evaluation.
- for ball bearings 3.0 mm.
Note!
Contact Cargotec Service Organisation for exact maxi-
When measurements are to be taken the ship shall
mum slewing bearing play for your crane.
have as little list/trim as possible.
See Slewing Specification spare part picture or Slew-

Neither a load nor cargo handling equipment should
ing Bearing drawing for type of bearing in your crane,
be attached to the hook.
section 9.3 in spare parts manual.
Procedure
Deviation
First time a measurement is to be taken two reference
The deviation is related to differences in production
points on the crane's bottom plate must be grinded
tolerances and material. For Cargotec a part for a more
and marked. These reference points shall then always
accurat evaluation of the bearing play.
be used at any future measuring, see Fig. 4. Write "A"
1 (4)
625/1579 E rev.: k 2011-10-28
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.: k 2011-10-28
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
Fig. 4. Reference points, how to measure
3 (4)
625/1579 E rev.: k 2011-10-28
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.: a 2012-01-04
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 and collect the first used grease
single laboratory test of a grease sample gives very which will come out at the seal.
little information. Laboratory tests must be done on
regular basis to see trends. Attention: Do not take fresh grease for analysing!
The required quantity of grease for analysing is ap-
The play measuring normally tells more about the proximately 3 cm3.
bearing condition than a grease sample. Both methods
provide together the best basis for evaluation of the The normal interval for grease sampling is 6 months.
bearing condition.
If steel particles are seen when the simplified grease
analysis is done or if the laboratory grease analysis
Procedure of grease sampling shows a too high value the grease sampling period
should be increased to each 50 crane operating hours
Following information is necessary in order to give a or every two months.
correct statement and allow further advice:
1. Type of grease used at lubrication (manufacturer

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

important, below procedure should be done.
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.: a 2012-01-04
Grease sampling area Grease sampling area

(see below figures) (see below figures)
Grease sampling
area (inner seal) Grease sampling
area (inner seal)
Outer seal
Slewing bearing with rollers.
Outer seal
Slewing bearing with balls.
Fig. 1. Grease sampling areas.
2 (6)
625/1651 E rev.: a 2012-01-04
Grease sampling area Grease sampling area

(see below figure) (see below figure)
Inner seal
Grease sampling
Slewing bearing with balls. area (outer seal)
Fig. 2. Grease sampling area.
3 (6)
625/1651 E rev.: a 2012-01-04
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.: a 2012-01-04
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
* Depend on the fresh grease / max. allowable water content of the manufacturer
** Thus a high PQ - index always indicates wear.
5 (6)
625/1651 E rev.: a 2012-01-04
6 (6)
SERVICE 6.303.49 E rev.: e 2010-05-31
Troubleshooting
GLB-Crane
CT2
Contents
1. Description of input and output signals ............................................................................................. 2
2. Control system input and output signal levels................................................................................... 6
3. Troubleshooting for the control system............................................................................................ 9
4. Spare parts ....................................................................................................................................... 11
1 (12)
SERVICE 6.303.49 E rev.: e 2010-05-31
Error MP SP
Display
Select/Info button
Up
Down/Exit
1 Description of input and output signals
1.1 General
The following description refers to the
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",
section 3. For detailed information about the control
system a complete electric circuit diagram, relating
specifically to your crane, will be found in the
instruction manual, section "Spare Parts", Group
9.5. Also for detailed information about the
hydraulic system a complete hydraulic circuit
diagram will be found in section "Spare Parts",
Group 9.4.
2 (12)
SERVICE 6.303.49 E rev.: e 2010-05-31
1.3 Power supply, Control system anti-

1.2 Power supply, Control system condensation heating
operation The anti-condensation heating in CT2 cabinet is
powered with 24V DC when the control system is
The power supply transforms the input
switched off and the crane is not in operation. A
380/400/440V AC to 24V DC. See Fig. 1.
separate power supply is used for all anti-
condensation heating in the crane. A separate
It consists of a three-phase power supply. The
power line feeds the power supply.
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 1.4 Control levers - potentiometers,
switches (terminal 42). There are fuses on each outputs to and inputs from
supply in the CT1 cabinet.
The control levers linear potentiometers are fed
with 0V, +6V and +12V from their appropriate MC
The 0V level for 24V DC is grounded in power
and CC card. The potentiometer output is approx.
supply unit.
+6V with the lever in neutral. The output signal is
controlled by the lever and is depending on the
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. 1. CC3000 Power supply principle.
3 (12)
SERVICE 6.303.49 E rev.: e 2010-05-31
1.6 Pressure/force sensor input

1.5 Control levers - direction signal If fitted a pressure sensor giving 4-20 mA is used to
inputs measure the hydraulic oil pressure for hoisting
winch in use, to be used for calculation of the hook
The control lever for hoisting selects two out of four
load. The signal is connected to the control system
24V direction signals, for selection of low speed/
via the backplane card.
high speed and hoisting/lowering. See Fig. 2. The
control lever for luffing/slewing gives two out of four
24V direction signals for selecting luffing in/luffing
out and slewing left/slewing right.
Fig. 2. Control lever signals, hoisting movement.
4 (12)
SERVICE 6.303.49 E rev.: e 2010-05-31
1.7 Overload pressure switch input 1.10 Displacement/unloading outputs

Each MC card has two separate outputs. They are
The overload pressure switch makes the MC card
used for selecting low speed or high speed for the
control program to switch over from high speed to
hoisting movement and for the unloading function
low speed operation or, if already in low speed,
for the luffing movement. Each output giving a fixed
stopping the hoisting and luffing crane movement.
24V output with a maximum current of 2A. The
The input signal from the overload pressure switch
system is capable of detecting short-circuited
is often only seen as a short pulse.
output and then giving an error-message, see sign
ERROR MESSAGES.
1.8 Pump solenoid outputs
Each hydraulic pump has two solenoid valves, one 1.11 Low feed pressure input
for each direction of the oil-flow. The solenoids are
The low feed pressure switch indicates that the
controlled with a 24V PWM (Pulse Width
pump feed pressure is too low for safe operation.
Modulated) signal with current feedback control. If
Output signals to pumps, displacement/unloading
wanted output current is not reached (due to short-
valves and brake relief valves are immediately
circuit, open-circuit or MC card failure) the system
switched off. If the low-pressure signal comes back
then gives an error message, see sign ERROR
within approx 0.3 s the crane operation continues
MESSAGES. Each MC card is capable of
with the same output signal levels as before the
controlling a maximum of four pumps with a total of
pressure drop. However, if short pressure drops are
eight output drivers, one for each solenoid valve.
repeated 4-5 times within a short period of time the
Each driver is capable of outputting a maximum
crane operation is stopped and starts 4-5 seconds
current of 1A. To obtain the value of the current it is
after the feed pressure has a stable high level
possible to get it on the display on the cards in CT2
again.
cabinet.
1.9 Brake release/direction valve 1.12 Lamp output "Control System Error
outputs in CT2"
The LED no 28 on the CC Card are wired to a lamp
Each MC card has an output driver for the brake
in crane operator's cabin. The first time an error
release signal (or direction valve for cranes
occurs, the lamp flashes. When the error is
equipped with cylinder luffing). The system is
acknowledged by pushing the Select/Info push-
capable of detecting short-circuited output and then
button on the appropriate MC or CC card the lamp
giving an error-message, see sign ERROR
is on if the error remains or out if the error is not
MESSAGES.
present for the moment. See chapter 3.5 for
detailed information about error messages.
5 (12)
SERVICE 6.303.49 E rev.: e 2010-05-31
2 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". 6V from MC
Outputs to control lever potentiometer hoisting CT2-X10:202 Ho
"Ho". 0V from MC "Ho".
CT2-X10:203
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
Hoisting CT2-X10:207 Ho 24V when control lever actuated
Lowering CT2-X10:208 Ho hoisting lowering low speed high
Low Speed CT2-X10:209 Ho speed
High speed CT2-X10:210 Ho
Outputs to control lever potentiometer CT2-X10:301 12V from MC "Lu". 6V from MC

Lu
Luffing CT2-X10:302 "Lu". 0V from MC "Lu".
CT2-X10:303
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
Luffing Out CT2-X10:308 Lu
CT2-X10:401
12V from MC "SL". 6V from MC
Outputs to control lever potentiometer slewing CT2-X10:402 SL
"SL". 0V from MC "SL".
CT2-X10:403
Control lever potentiometer input signal slewing CT2-X10:404 SL
10.5V with 6V in neutral position.
Control lever direction inputs slewing
CT2-X10:407 24V when control lever actuated
Slewing Left SL
CT2-X10:408 slewing left slewing right
Slewing Right SL
Brake relief valve - outputs
Ho
Hoisting CT2-X10:230 24V, max. 2A, open circuit gives
Lu
Luffing - (direction valve if cylinder luffing) CT2-X10:330 error message.
SL
Slewing CT2-X10:430
24V, max. 2A, open and short
Hoisting displacement low speed output CT2-X10:231 Ho
circuit gives error message.
Hoisting displacement output high speed CT2-X10:232 24V, max. 2A, open and short
Ho
Current return CT2-X10:248 circuit gives error message.
Luffing unloading output CT2-X10:331 Lu 24V, max. 2A, open and short
circuit gives error message.
Pump PWM signals for Hoisting Pump1 CT2-X10:233 Ho 24V, 0 to approx. 600 mA, error
6 (12)
SERVICE 6.303.49 E rev.: e 2010-05-31
Hoisting output CT2-X10:234 message if wanted current not

Lowering output CT2-X10:235 achieved. 1mA gives approx.
Current return and current measure input 1mV.
Pump PWM signals for hoisting pump2 (if fitted) 24V, 0 to approx. 600 mA, error
CT2-X10:236 Ho
Hoisting output message if wanted current not
CT2-X10:237 Ho
Lowering output achieved. 1mA gives approx.
CT2-X10:238 Ho
Current return and current measure input 1mV.
Pump PWM signals for luffing pump1 24V, 0 to approx. 600 mA, error
Luffing In output CT2-X10:333 Lu message if wanted current not
Luffing Out output CT2-X10:334 Lu achieved. 1mA gives approx.
Current return and current measure input CT2-X10:335 Lu 1mV.
Pump PWM signals for luffing pump2 (if fitted) 24V, 0 to approx. 600 mA, error
Luffing In output CT2-X10:336 Lu message if wanted current not
Luffing Out output CT2-X10:337 Lu achieved. 1mA gives approx.
Current return and current measure input CT2-X10:338 Lu 1mV.
Pump PWM signals for slewing pump1 24V, 0 to approx. 600 mA, error
Slewing Left output CT2-X10:433 SL message if wanted current not
Slewing Right output CT2-X10:434 SL achieved. 1mA gives approx.
Current return and current measure input CT2-X10:435 SL 1mV.
24V, 0 to approx. 600 mA, error
Pump PWM signals for slewing pump2 (if fitted)
CT2-X10:436 SL message if wanted current not
Slewing Left output Slewing Right output
CT2-X10:437 SL achieved. 1mA gives approx.
Current return and current measure input
CT2-X10:438 SL 1mV.
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.
Speed-reduce limit inputs hoisting
CT2-X10:211 Ho 24V at normal operation, 0V at
Hoisting
CT2-X10:212 limit.
Lowering
Limit switch inputs luffing 24V at normal operation, 0V at
CT2-X10:314 Lu
Luffing In limit. At limit movement is
CT2-X10:315
Luffing Out, slack wire stopped and brake closed.
Speed-reduce limit inputs luffing
CT2-X10:311 Lu 24V at normal operation, 0V at
Luffing In
CT2-X10:312 limit.
Luffing Out
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.
Speed-reduce limit inputs slewing
CT2-X10:411 24V at normal operation, 0V at
Slewing left SL
CT2-X10:412 limit.
Slewing right
CT2-X10:256
Slack wire
CT2-X10:356
CT2-X10:219 Ho
24V at normal operation, 0V at
Pressure switch input for low feed pressure CT2-X10:319 Lu
low feed pressure.
CT2-X10:419 SL
Pressure switches for overload CT2-X10:220 Ho 24V at normal operation, 0V at
CT2-X10:320 Lu overload.
Output "Error in control system CT2" CT2-X10:128 Sc 24V outputs wired together to
error lamp in drivers cabin.
7 (12)
SERVICE 6.303.49 E rev.: e 2010-05-31
Output for "Speed dependent" overload function 24V when the hoisting speed is
CT2-X10:229 Ho
(if fitted). less than approx. 3 rpm.
Ho 24V when the hoisting pressure
Output for "Hoisting Overload" indication lamp CT2-X10:255
Lu exceeds adjusted value.
24V input from cabin switch,
CT2-X10:217 Ho
Speed reduction, input signal ext. 1 (bit 0) to such as Grab operation, Parking
CT2-X10:317 Lu
reduce normal operation speed (utilization). Lock Slewing, Power Limiter,
CT2-X10:417 SL
Twin operation, etc.
Speed reduction, input signal ext. 2 (bit 1) to
CT2-X10:218 Ho
reduce normal operation speed (utilization). 24V input from cabin switch,
CT2-X10:318 Lu
Same as above, but could be used with different same as above.
CT2-X10:418 SL
utilization.
Prevent high speed function. CT2-X10:210 Ho 24V (Optional)
input from switch in cabinet CT2.
Two-position switch
“Normal/Low speed”
Jack-knife CT2-X10:358 Lu 24V (Optional)
High hook CT2-X10:359 Lu 24V (Optional)
8 (12)
SERVICE 6.303.49 E rev.: e 2010-05-31
3 Troubleshooting the Crane Control system
3.1 General
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 and hydraulic diagrams provided in Group 9.5 and
corrective actions. If a malfunction is not listed, or is 9.4.
not corrected by the listed corrective actions, notify
your supervisor.
3.2 Troubleshooting Chart

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 chapter joysticks and electro-
4.3. hydraulic interfaces,
see chapter 4.4.
9 (12)
SERVICE 6.303.49 E rev.: e 2010-05-31
• Check for missing Green input signal LEDs

3.3 Checking Power supply 24V DC in - from joystick.
CT2 cabinet
• Check electric cable connections to control
See chapter 1.2. for explanation of the power lever.
supply function. • Check analogue input signal from joystick
• Check over-current relay F3 in cabinet potentiometer.
CT1. • Check for missing Green output signal
• Check fuse F16 in CT1 for 24V in terminal LEDs: Exchange the MC card with other
48 in CT2 cabinet. movement MC card. Replace broken MC
• Check fuse F17 in CT1 for 24V in terminal card with a new one.
42 in CT2 cabinet.
• Check relay K34 in cabinet CT1, see Check direction and brake valves
electric circuit diagram.
• No LED and display readout on MC card See hydraulic circuit diagram in Spare Parts
indicates missing 24V in terminal 48. Manual, group 9.4.
• Check electric cable connections.
• Replace electric coil.
3.4 Checking Limit switches, Joysticks
• Replace valve.
and Electro-Hydraulic Interfaces
Check Limit Switches, see Control system CT2 Check pump servo valves on each high
cabinet pressure pump
See chapter 3 for explanation of signal indication See instruction “High Pressure Pump” in section 6.1
and hydraulic circuit diagram in Spare Parts
LEDs.
Manual, group 9.4.
• No LEDs on and no display readout -
indicates missing 24V in terminal 48. • Check electric cable connections.
• Check for Red LEDs - indicating stop limits. • How to obtain error codes from the CC3000
• Check for Yellow LEDs - indicating speed system.
reduces.
• Check electric cable connections for limit 3.5 Error message codes from CC3000
switches.
• For checking and adjustment of limit If the error from the CC3000 has no influence on
switches see instruction for “Limit Switches the performance of the crane the “control system
in Hoisting …” in "Service", section 6.3. error” lamp in the driver’s cabin will not flash.
Check control lever (joystick) With the crane still running, the following steps are
necessary to obtain the error code(s).
See chapter 1.4 for explanation of the control lever
functions.
10 (12)
SERVICE 6.303.49 E rev.: e 2010-05-31
4 Spare parts
4.1 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 instruction manual.
Customers that purchase a replacement card will

receive a credit note of 15% of the sales price when
the damaged card has been returned to Cargotec
Sweden AB, MacGREGOR Cranes in Örnsköldsvik.
4.2 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.
4.3 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, and send it back with the
exchanged card.
4.4 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.
11 (12)
SERVICE 6.303.49 E rev.: e 2010-05-31
12 (12)

SERVICE 6.303.61 E rev.:d 2012-02-22

Card front menus CT2, CC3000

General Depending of crane type there can be

This instruction describes how to use the additional cards. On the front of each card
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.
ϭ
Ϯ
ϯ
ϰ
ϱ
ϲ
1. Error MP (Main Processor) and SP

4. Select/Info
(Safety Processor)
Push the button = Select.
• Flashing diode = there are active
Push and hold the button = Information
errors that have not been
will scroll by on the display.
acknowledged.
• The diode is on (fixed) = there are 5. Up button
active errors but they have been Browse upwards
acknowledged.
• The diode 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.:d 2012-02-22

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 (LOGIN
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
All errors must be acknowledged before you Only to be used during commissioning of
can move on to other modes. (Diode 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 (Login
2 CAL 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 ,Ϭϰ͘ϬϬͿ 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.:d 2012-02-22

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 ● ● ● ● ● ● ● ● ● ● ●
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 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 Down/Exit until the display shows
MFG.

3 (4)

SERVICE 6.303.61 E rev.:d 2012-02-22

d,/^W'/^/EdEd/KE>>z>&d>E<

4 (4)
SERVICE 6.303.68 E rev.: - 2011-01-18
Absolute Encoder Calibration, CC3000
General Preparation of minimum outreach luffing
Absolute encoders are used for position control WARNING! Always use safety belt when measuring
purposes. Each encoder gives an accurate position the MV distance.
feedback to the control system.
To operate the crane in Rig mode see instruction
The encoder calibration has to be done when the wire "Preparation for Rig Mode" in section 6.3.
or the absolute encoder has been replaced.
WARNING!
Absolute encoders for hoisting and luffing winches When the crane is operated in Rig mode the crane has
are installed in the limit switch box or on jib bearing. no software limits.
It is not permitted to have any load in the hook.
For slewing motion the absolute encoder is mounted Inappropriate use may cause severe damage to the
under the crane towards the slewing bearing. 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 6.303.68 E rev.: - 2011-01-18

- 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

- Start to operate the crane to definition "AL"
(hoisting winch), see Fig. 2, refer to table "Limit
switches - hoisting winch" in Technical Data,
section 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.
Table 1, page 4.
- Exit Rig mode by stopping the crane and set the
key switch to Normal.
2 (4)
SERVICE 6.303.68 E rev.: - 2011-01-18
Preparation of slewing
- To calibrate the absolute encoder for slewing aim

the crane jib straight ahead, i.e. 0°, see Fig. 3.
Table 1, page 4.
0°
Fig. 3. Reference points.
3 (4)
SERVICE 6.303.68 E rev.: - 2011-01-18
Calibration of encoders in cabinet CT2
Hoisting Luffing/slewing
Operation of rig mode see instruction "Preparation for To calibrate the encoder on the other cards proceed in
Rig Mode" in section 6.3. 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
"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
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)
Page Date
SIGNAL OVERVIEW 1 (2) 2011-11-30
No Revision
Crane Control System CC3000 E
424 0738
LEDs - 24V Input/Output signals are indicated with coloured LEDs
.Colour Indicating LEDs on External communication
when LEDs within the COM box are external communication and
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. The MP LED must always be lit.
Yellow 17,18 Speed reduction switches +24V
Software
Red Limit switches, low pressure, 0V Sw before “LED No” means the software (orange means
slack wire and overload that the motion is blocked).
SC – Supervisory Ho – Hoisting
CC Card MC Card
LED Plinth LED Plinth
Signal Description Signal Description
No No No No
07 Overload test 107 07 Hoisting, input 207
08 Rigging mode 108 08 Lowering, input 208
09 Parking of jib 109 09 Low speed, input 209
Hardware
324 1670-901 10 110 Hardware
324 1665-901
10 High speed, input 210
11 Mode A (Container) 111 11 Speed reduce hoisting 211
12 Mode B (Grab) 112 12 Speed reduce lowering 212
13 Mode C (Hatch C.) 113 14 Limit switch hoisting 214
16 116 Sw14/15 Speed reduce, stop, block
17 Pump Unit 1/ RBTS 117 15 Limit switch lowering 215
18 Pump Unit 2 118 17 Speed reduction, ext1 217
19 119 18 Speed reduction, ext2 218
20 120 19 Low pressure switch 219
26 Run enable in 126 20 Overload switch input 220
27 Run enable out 127 Sw20 Overload load cell/pressure
28 Alarm (error in CT2) 128 26 Run enable in 226
29 Ready to run 129 27 Run enable out 227
Indication Speed
30 Twin not synch. 130 29 229
reduce/stop
31 131 30 Hoisting brake, output 230
32 132 31 Low speed, output 231
33 ARC Cabin A Lamp 133 32 High speed, output 232
34 ARC Cabin B Lamp 134 33 Pump1 hoisting, output 233
35 ARC 180 deg. rotation 135 34 Pump1 lowering, output 234
36 ARC Run enable out 136 36 Pump2 hoisting, output 236
37 137 37 Pump2 lowering, output 237
38 Brake Failure lamp 138 39 Pump3 hoisting, output 239
39 139
49 149 43 Pump4 hoisting, output 243
53 153 49 Angle Check Cam 249
56 Twin on 156 51 251
57 Calibration 157 52 252
58 Twin reset 158 53 VFD Run enable out 253
59 159 54 254
60 Em. op. request 160 55 Indication Overload 255
61 Em. op. activated 161 56 Slack wire 256
24 V Power supply +24V Sw56 Slack wire from LU
C1 CAN1 (ALM) Sc_C1
Software
57 Brake Open Indication 257
Software C2 CAN2 (Cabin display) Sc_C2 CC3K H01_00 58 Ext stop 1 258
CC3K H01_00 Rev B
Rev B Ext stop 2
C3 CAN3 Sc_C3 59 259
El.motor high temp
C4 CAN4 Sc_C4 C1 CAN1 (VFD) Ho_C1
R1 RS485_1 (Remote) Sc_R1 C2 CAN2 Ho_C2
R2 RS485_2 (Twin) Sc_R2 R1 RS485_1 Ho_R1
R3 RS485_3 Sc_r3 MP Internal communication
MP Internal communication
Page Date
SIGNAL OVERVIEW 2 (2) 2011-11-30
No Revision
Crane Control System CC3000 E
424 0738
LEDs - 24V Input/Output signals are indicated with coloured LEDs
.Colour Indicating LEDs on External communication
when LEDs within the COM box are external communication and
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. The MP LED must always be lit.
Yellow 17,18 Speed reduction switches +24V
Software
Red limit switches, low pressure, 0V Sw before LED No means the software (orange means
slack wire and overload that the motion is blocked).
Lu - Luffing Sl - Slewing
MC Card MC Card
LED Plinth LED Plinth
Signal Description Signal Description
No No No No
Hardware 07 Luffing in, input 307 07 Left, input 407
324 1665-901 Hardware
08 Luffing out, input 308 324 1665-901 08 Right, input 408
11 Speed reduce luffing in 311 11 Speed reduce left 411
12 Speed reduce luffing out 312 12 Speed reduce right 412
14 Limit switch luffing in 314 14 Limit switch left 414
Sw14/15 Speed reduce, stop, block Sw14/15 Speed reduce, stop, block
15 Limit switch luffing out 315 15 Limit switch right 415
17 Speed reduction, ext1 317 17 Speed reduction, ext1 417
18 Speed reduction, ext2 318 18 Speed reduction, ext2 418
19 Low pressure switch 319 19 Low pressure switch 419
20 Overload switch input 320 20 320
26 Run enable in 326 26 Run enable in 326
27 Run enable out 327 27 Run enable out 327
29 Indication Speed 29
329 329
reduce/stop
30 Luffing brake, output 330 30 Slewing brake, output 430
31 Unloading, output 331 31 431
32 32 432
33 Pump1 luff in, output 333 33 Pump1 left, output 433
34 Pump1 luff out, output 334 34 Pump1 right, output 434
36 Pump2 luff in, output 336 36 Pump2 left, output 436
37 Pump2 luff out, output 337 37 Pump2 right, output 437
39 Pump3 luff in, output 339 39 Pump3 luff in, output 439
40 Pump3 luff out, output 340 40 Pump3 luff out, output 440
43 Pump4 luff in, output 343 43 Pump4 luff in, output 443
45 Pump4 luff out, output 345 45 Pump4 luff out, output 445
49 Angle Check Cam 349 49 Angle Check Cam 449
51 Jack-knife 351 51 Remote on 451
52 352 52 Brake low oil level warning 452
53 VFD Run enable out 353 53 VFD Run enable out 453
54 Cooling fan #1 354 54 Cooling fan #2 454
55 Indication Overload 355 55 455
56 Slack wire 356 56 Brake low oil level stop 456
57 Brake Open Indication 357 57 Brake Open Indication 457
58 Ext stop 1 (Jack knife) 58 Ext stop 1
358 458
Software
(Luffing Slewing limit off)
Software
CC3K H01_00 Ext stop 2 (High hook) CC3K H01_00
Rev B
59 Ext stop 1
Rev B 59 (El.motor high temp Klixon) 359 (Luffing Slewing limit off) 459
(El.motor high temp Klixon)
C1 CAN1 (VFD) Lu_C1
C2 CAN2 (ARC angle swivel) Lu_C2 C1 CAN1 (VFD) Sl_C1
R1 RS485_1 (ARC gyro) Lu_R1 C2 CAN2 (ARC Angle Cabin) Sl_C2
MP Internal communication R1 RS485_1(Outdoor display) Sl_R1
MP Internal communication
Page Date
ERROR MESSAGES
1(2) 2012-08-24
No Revision
424 0739 G
Error message codes from CC3000 Note!

If the error from the CC3000 has no influence on the performance of the Before reporting to Cargotec (MacGregor) in Örnsköldsvik, please look
crane the ”control system error” lamp in the driver’s cabin will not flash. for the error code in the display of the MC or CC card and use the
With the crane still running, the following steps are necessary to obtain “select/info” button to view all error codes. It is essential that all faults to
the error code(s). be corrected to allow the crane to function correctly.
 Open the control system cabinet and look for the Sc-card (the
lestmost card in the rack). LED 28 is now flashing. Then look for the Abbreviations: VFD = Variable Frequency Drive
card with the flashing LED “error MP” or “error SP” on top of the ALM = Active Line Module
cards. Error code Description
Green LED 28 on the Sc-card Indicate error status in the
01 S ys t e m E r r o r s
whole system (All cards)
01_01 to 01_15  Contact Cargotec in Örnsköldsvik
Red LED “Error MP” Indicate error status from MP in
the local card 01_12 System Software version mismatch
Red LED “Error SP” Indicate error status from SP in  Check the software version in the cards
the local card 02 MC or CC Card
 Push the “Select/Info” button once on the card with error LED 02_01 to 02_61  Restart system or replace the card
flashing. An error code (e.g. E51_11) is shown on the display on the  Contact Cargotec in Örnsköldsvik
card. 03 Safety processor
 Hold on pressing “Select/Info” button, the description of this error will 03_01 to 03_91  Contact Cargotec in Örnsköldsvik
be rolling on the display. Release the button, the description
disappears and the error code is shown. 10 MEM card
 Continue to press “Select/Info” or “Down/Exit” button once to see the 10_10  Replace the MEM card
next error and so on.  Contact Cargotec in Örnsköldsvik
 Pressing “Up” button once to show the previous error and so on. 11 Parameters
 When there are no more error messages, the display shows three 11_01 to 11_30  Contact Cargotec in Örnsköldsvik
hyphens “---”. When all errors have been shown on the display, the 24 24V Supply Voltage
error LED is either on or off. 24_01 to 24_04  Check 24V supply
 All errors can be shown round and round if you continue pressing
30 J o ys t i c k
“Select/Info” or “Down/Exit” button or “Up” button.
30_01 Joystick level, normally 1.25 V to 11.75 V.
LED flashing New error, not acknowledged
 Check connection to joystick
LED on Error remains, now acknowledged
 Check switches/cam in joystick
LED off No error present at the moment
 Measure potentiometers in joystick
 The display returns to normal mode (Sc, Ho, Lu, Sl, Cl, Au, Ec, Tl,
Tr, Li, Io) fifteen seconds after one of the three buttons was last 30_02 Joystick logic error for “Lowering”, “Luffing Out” or
pressed, or holding on pressing “Down/Exit” button longer than one “Slewing Right” movement.
second. 30_03 Joystick logic error for “Hoisting”, “Luffing In” or
 If the system is restarted (i. e. 24V power supply is switched off for a “Slewing Left” movement.
short time) all alarms disappear and only reappear when the error 30_04 Joystick is not in zero position when system starts.
recurs. 31 An g l e E n c o d e r
How to see the remaining errors after acknowledging (i.e. error LED is 31_01 Angle encoder communication error
on)?  Check angle encoder connection
 Errors can be shown again from normal mode when pressing  Replace the angle encoder
“Select/Info” twice.
31_02 Angle shaft coupling
 Pressing “Up” or “Down/Exit” button to see the previous respective
 Check angle encoder connection
next error, following the same instruction above.
 Replace the angle encoder

31_03 Angle encoder or speed encoder error
Hardware
324 1670-901
Hardware
324 1665-901
Hardware
324 1665-901
Hardware
324 1665-901  Replace the angle encoder or speed encoder
 Contact Cargotec in Örnsköldsvik
Encoder
Calibration Error MP SP 31_04 Angles at CAM control place mismatch.
 Check angle encoder cable and connection
 Replace the angle encoder
 Calibrate encoder again.
 Contact MacGREGOR Cranes in Örnsköldsvik
31_05 Shaft not connected
31_11 Different angle values when more than one encoder
31_12 for luffing.
31_13 (Only on Sc-card).
Display 31_51 to 31_53 Power Swivel angle encoder
31_54 to 31_57 ARC angle encoder in cabin
32 Speed Encoder
Select/Info button 32_01 No data from speed encoder
Up  Check speed encoder cable and connection
Down/Exit  Replace a new speed encoder
Software
CC3K H01_00
Rev B
Software
CC3K H01_00
Rev B
Software
CC3K H01_00
Rev B
Software
CC3K H01_00
Rev B
 Exchange cards
32_02 VFD or CC3000 encoder
Page Date
ERROR MESSAGES
2(2) 2012-08-24
No Revision
424 0739 G
32_03 Wrong speed direction 49 External analogue in

 Change speed encoder direction or shift cable 49_01 to 49_07 A1, A2, A3, A4, A5, A6, A7
connection (switch A and B)  Check cable, connection
 Replace the speed encoder  Check sensor
 Exchange cards  Replace the MC or CC card
 Contact Cargotec (MacGregor) in Örnsköldsvik 50 Displacement
32_04 VFD encoder 50_11, 50_21 Open circuit (Low speed, high speed, unloading,
32_05, 32_06 Encoder error 50_31, 50_41 plussing valve [LC])
32_10 No data from speed encoder  Check cable and connection
33 Weight 50_12 Short circuit (Low speed, high speed, unloading,
33_01 Loadcell 50_22, 50_32 plussing valve [LC]))
 Check loadcell cable and connection 50_42  Check output cable is not connected to 0V(ground)
 Replace the loadcell  Replace the MC or CC card
 Contact Cargotec in Örnsköldsvik 50_13, 50_23 Transistor (Low speed, high speed, unloading,
33_02 Pressure 50_33, 50_43 plussing valve [LC]))
33_03 Loadcell Check  Check cable and connection
33_04 Torque  Replace the MC or CC card
33_07 Load system, in EO 50_24 High speed valve
33_11 Difference Loadcell 50_34 No plussing pressure
33_12 Difference Pressure 51 Brake
33_13 Difference Loadcell check 51_11, 51_21 Open circuit
33_14 Diffeerence Torque  Check cable and connection
33_31 Outreach, angle Lu 51_12, 51_22 Short circuit
33_32 Outreach, angle Sc  Check output cable is not connected to 0V(ground)
33_33 Outreach, angle Sc speed  Replace the MC card
33_37 Outreach, in EO 51_13, 51_23 Transistor
33_41 Change to Main not possible  Check cable and connection
33_42 Change to Whip not possible  Replace the MC card
35 Temperature 51_14, 51_24 Control Circuit
35_01, 35_02 MC card temperature is too high 51_15, 51_ 25 VFD Brake output
 Power off system 51_31 Read back (pressure or switch)
 Contact Cargotec in Örnsköldsvik 51_32 Closed (pressure or switch)
35_11 ALM high temp 51_33 Closing failure
35_12 VFD high temp 51_34 Slip
35_13, 35_41 Electric motor high temp 51_50 to 51_52 Low oil level or temp error
35_14, 35_42 Hydraulic oil high temp 52 Pump
35_15, 35_43 High temp 51_01 to 51_05 Pump PWM current
35_16 Air intake high temp 51_11 to 51_14  Check that PWM output is not connected to
35_44 Winch oil high temp 0V(ground)
35_45 Braking resistors overheated  Check that cable is not broken
36 Power  Replace the MC card
36_01, 36_02 High current 53 VFD
36_03 No data from power sensor 53_01 to 53_50 VFD
37 Limit 54 ALM
37_01 to 37_06 Limit error at stop cam 54_01 to 54_06 ALM
 Check stop cam connection or switch 55 Stab Winch
37_10 Limit: Software limits 55_01 to 55_04 Stab winch
37_21 Limit: Luffing Slewing 56 Power Swivel
37_22 Limit: Anticollision 56_01 to 56_23 Power Swivel
38 Run Enable 62 Twin
38_01 Run enable: No input on terminal X26 62_01 No data from Slave
38_02 Run enable: Terminal X26 is always set 62_02 Error in Slave
38_03 Run enable: No run enable in 62_10 to 62_14 Angle error Master Ho, Lu, Ll, Tr
38_04 Run enable: Team 62_20 to 62_24 Angle error Slave Ho, Lu, Ll, Tr
39 Low feed pressure 63 Team
39_01, 39_02 Low feed pressure 63_01 to 63_05 Team
40 Lubrication 70 Speed
40_01, 40_02 Lubrication 70_10 Speed control deviation
41 Power limitation 70_20 Variable Frequency Drive zero speed timeout
41_01 to 41_03 Power limitation
45 External IO
45_01 to 45_36 External IO
48 Motion Sensor
48_01, 48_02 Power swivel
48_11, 48_12 Swing
48_21, 48_22 Ship
SERVICE 6.305.16 E rev.: - 2008-10-30
Electrical Equipment, General Maintenance
Introduction
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 block diagrams and detailed circuit
diagrams can be found 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.
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.
DANGER! Fig. 1. Electrical equipment cabinet.

Electrical equipment can be alive unless the main
switch and the separate supply is disconnected.
- Clean contacts, insulating parts, cams, contact

Earth connection, hull rolls, and rotary potentiometers.
Verify that the protective earth connection of the crane - Make sure that all cable connnections are clean
is made to the ship’s hull. and securely tightened.
Clean contact surfaces, when required. - Clean the control levers, and grease their sliding
surfaces.
- Check on the return springs and grease lightly so
Earth connection, crane
that no grease transfers to the contacts.
Check crane system earth connections, and clean
contact surfaces as required.
Jib light
Make sure that connections in the junction box are
Portable control boxes (Optional)
clean and well tightened.
Control panels and remote control boxes may be
subjected to abuse an abnormal wear, and should be
- Remove moisture and dirt.
inspected after every use. The control boxes must be
- When necessary, clean contact surfaces of terminal
stored in a compartment that is well protected against
strips and of lamp holder.
moisture. Remove moisture that may have collected
- Make sure that lamp holder gasket seals correctly.
in the boxes, and find out how it entered.
- Make sure that the work light can be rotated.
1 (2)
SERVICE 6.305.16 E rev.: - 2008-10-30
Slip-ring unit
DANGER!
Before opening the slip-ring unit, make sure that po-
wer 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.
- Verify that slip ring contact surfaces are smooth and

even, clean as required.
- Check contact pressure of brushes.
- Replace carbon brushes or entire slip ring assem-
blies as required.
- Make sure that cable connections are securely
tightened.
- Make sure that rocker arm mounting screws are
securely tightened.
The removal and installation of the slip-ring unit is the

subject of a separate description.
Oil thermostats
BT 2
The task of the oil thermostat is to protect the crane
against overheating.
Verify that the thermostat is set to +85oC, and that it

functions correctly. The thermostat is placed on the
oil filter outlet line.
BT 3 (Optional)
The task of the thermostat is to start the oil cooler
when the oil reaches +45oC when crane is set to
winter position.
Verify that the thermostat is set to +45oC, and that it

functions correctly. The thermostat is placed on the
oil filter outlet line.
2 (2)
SERVICE 6.306.6 E rev: - 2010-11-03
Installation of Power Supply Cable

and
Cable for "Grab Control Equipment", Interlock
General Installation of power supply cable for

"grab control equipment"
Preparations for installation of the "grab control
equipment", are made in all cranes to get an interlock The power supply cable to the "grab control equipment"
connection between the external mounted "grab needs to be connected as shown in Fig. 1. To protect
control equipment" and MacGregor Cranes' safety the "grab control equipment" we recommend that the
functions. Some preparations are done in the cabinet power supply cable is connected after the circuit breaker
CT1 and on control panel (CT3) in cabin. The two- Q1 in the cabinet CT1, see Fig. 1.
position key switch "Cargo/Grab Handling" (S26) has
another function, which is adaptable to the "grab
control equipment", see instruction "Controls and
Indicators", section 4.
Connection of power supply cable Q1
Fig. 1. Cabinet CT1.
1 (2)
SERVICE 6.306.6 E rev: - 2010-11-03
Contactor relay K59
To energize the contactor relay K59 in cabinet CT1

the two-position key switch "Cargo/Grab Handling"
must be in position 2, "Grab", to get reduced SWL for
operation with grab. See instruction "Controls and
Indicators", section 4.
Fig. 2. Contactor relay K59 in cabinet CT1.
Grab control equipment
When the cranes are equipped with "grab control

equipment" make sure that
- the electrical installation is done according to the
circuit diagram valid for the crane
- the two-position key switch "Cargo/Grab Handling"
(S26) is in position 2 (Grab), to reduce SWL for
operation with grab.
See instruction "Controls and Indicators", section 4.
"Grab control equipment"
Fig. 3. Interlock of "grab control equipment", example.
2 (2)
SERVICE 6.307.14 E rev.: - 2003-02-19
Slip-Ring Unit
The function of the slip-ring assembly may not be

Danger! changed in any way. Especially safety devices must
Before opening the slip-ring unit, make sure that not be made ineffective. Other than during mainte-
power supplied by separate transformers is nance and inspection work the housing must always
switched off in the ship's engine room. Also check remain closed.
by means of a voltmeter that the slip-ring unit is not
alive. Make sure that the current can not be Use only insulated tools and original spare parts.
switched on again during the maintenance
operation. No responsibility will be assumed for damage to
property or injury to persons caused by improper
General use of the slip-ring assembly.
The slip-ring unit is mounted inside the crane house

under the platform.
Work on a slip-ring assembly may only be carried

out by a qualified electrician or by persons under
the supervision of a qualified electrician and only
according to accepted electrical safety procedures.
Connection crane
Slip-ring unit
Mounting screws
Connection box
Connection ship
power Guide pins
Driver
Rubber protection
Note! Must be
tightened.
Fig. 1. Slip-ring unit.
1 (2)
SERVICE 6.307.14 E rev.: - 2003-02-19
Removal Maintenance
1. Park the jib in a suitable manner. Always cut current before accessing the collector
2. Disconnect the ship's power supply at all points for inspection or maintenance. Make sure that the
of feed. current can not be switched on again during the
3. Disconnect all the cables connection from crane- maintenance operation.
and ship supply.
4. Remove the driver. Note the cables' mounting At regular intervals
sequence.
- Check collector for damaged parts
5. Remove mounting screws holding the slip-ring unit
- Check contact pressure of brushes
to the platform. See Fig. 1.
- Check brush holders
6. Remove the slip-ring unit.
Any extra equipment such as extra limit switches Carbon brushes

fitted on top of the slip-ring unit are removed prior to - The carbon brushes must never wear down so
removal of the entire slip-ring unit. far that metal parts of the brush holder come into
contact with the slip-ring.
The carbon dust is to be removed with dry, oil
Installation free, compressed air or with a vacuum cleaner.
No substance containing oil or grease may come
Clean all contact surfaces between slip-ring unit and into contact with the brushes or the slip-rings.
platform. Tighten all screws properly. See instruc-
tion "Tightening torque". Wire brushes
- Check wire brushes.
- Assemble the slip-ring unit under the platform.
Debris caused by wear is to be removed with dry,
- Assemble the driver to the bottom of the
oil free, compressed air or with a vacuum cleaner.
foundation.
Afterwards the slip-ring ways and wire brushes
- Remove the cover around the slip-ring unit.
should be lightly sprayed with "Cramolin B" or
- Fit the slip-ring unit guide pins to the driver's slot- equivalent contact spray.
ted holes by pulling apart the driver and lock it
with help of the through bolt.
- Install the cables against the driving bar. Others
- Connect the crane cables from the crane in cor- - Check tightness of electric and mechanical
rect mounting sequence. fasteners.
- Remove the connection box plates. - Check gaskets and cable glands for tightness.
- Connect the cables to the plinths.
Keep grease and oil products away from the plastic
After installation insulating parts in the collector.
- Check tightness of all electric and mechanical

fasteners regularly for the first working period.
- Check alignment. The slip-ring unit must not be
allowed to slope in relation to the driver.
- Rotate the crane to ensure that no mechanical
side forces are transferred to the unit.
- Tighten the rubber protection , see Fig. 1.
2 (2)
SERVICE 6.311.12 E rev.: - 2008-09-03
Oil Level Float Switch and Overheating Protector
Introduction
To prevent operation of the crane with too little oil in
the hydraulic oil tank, an oil level guard is installed in
the oil tank, see Fig. 1. The level float switch controls
an alarm lamp on the control panel and a siren. A
FLOAT SWITCH key switch is placed on the control
panel to select different modes depending on oil level
in hydraulic oil tank. See Fig. 2.
LOW OIL LEVEL lamp
FLOAT SWITCH key switch
0
1 2
Fig. 1. Oil level float switch. Fig. 2. Control panel in cab.
1 (4)
SERVICE 6.311.12 E rev.: - 2008-09-03
Normal oil level

Normal oil level is between marks MIN and MAX MAX
and LOW OIL LEVEL warning lamp is off. Key switch
FLOAT SWITCH must be in position "0". See Fig. 3. 0
1 2
MIN
Low oil level

A low oil level should be attended to as soon as pos-
sible. Certain emergency measures may be underta-
ken as described below. Fig. 3. Normal oil level.
MAX
Oil level MIN
If the oil level drops to MIN, the float activates the up-
0
per switch and lamp LOW OIL LEVEL goes on. At the MIN
1 2
same time, the siren sounds. See Fig. 4.
Oil level MIN, continued operation

In an emergency, the operation of the crane may be
Fig. 4. Oil level MIN.
continued for a short time if there is no important
leakage of oil. In this case, turn key switch FLOAT
SWITCH to position "1"; the siren will then be silent MAX
and lamp LOW OIL LEVEL goes out. See Fig. 5.
0
1 2
MIN
CAUTION!
Operating crane when oil level is below MIN can cause
damage to crane equipment.
Fig. 5. Oil level MIN, continued operation.
Oil level below MIN

When the oil level has dropped a certain distance MAX
below MIN level, the float activates the lower switch
0
and stops the crane. LOW OIL LEVEL lamp goes on. 1 2
MIN
See Fig. 6.
Oil level below MIN, emergency operation

In an extreme emergency (e.g. if the crane has stop-
ped with a load suspended on the hook) the crane can Fig. 6. Oil level below MIN.
be started again and operated if key switch FLOAT
SWITCH is turned to position "2". The lamp LOW OIL MAX
LEVEL goes on and the alarm siren sounds. This is
permitted if no important leakage is present, but is 0
1 2
MIN
entirely at the risk and responsibility of the crane
operator or the officer who gives the order. See
Fig. 7.
Fig. 7. Oil level below MIN, emergency operation.
2 (4)
SERVICE 6.311.12 E rev.: - 2008-09-03
Testing oil level float switch

The float of the level float switch is fitted with a built-in
magnet which makes a control circuit when the oil level
drops below certain levels. The function of the float is
preferably tested when performing oil changes or tank
cleaning. For the purpose of this test, the main switch
HIGH OIL TEMP lamp
will have to be temporarily switched on.
Overheating protector
The crane stops automatically when the oil tempe-
rature exceeds 85°C. The overheating protector is
fitted on the inlet line of the oil cooler. An alarm lamp
HIGH OIL TEMP on the control panel lights when oil
temperature is more than 85°C, see Fig. 8.
Fig. 8. Right-hand control panel.
3 (4)
SERVICE 6.311.12 E rev.: - 2008-09-03
4 (4)
SERVICE 6.320.373 E rev.: b 2012-02-03
Limit Switches in Hoisting and Luffing Winch Systems

CC3000
General High hook (optional)
The movements and outreaches of the crane jib and This function prevents the jib from mechanical touching
hoisting block are controlled by limit switches in the of the hook block when luffing out. If the crane is equip-
limit switch boxes. At large outreaches there is a risk ped with high hook, values for outreaches for both
that hook block and jib top will meet and that is taken luffing and hoisting winches can be found in tables in
care of by crane's safety system. Some cranes are instruction "Tecnical Data", section 2.
equipped with extra limit switches to prevent this, see
paragraph "High Hook (optional)".
Limit switches
The limit switches of the hoisting and luffing winches

are contained in limit switch boxes in the cranehouse,
one box for each winch system. Every switch function
is set separately by means of a rotating cam which
controls a microswitch. The cams are driven by the
winches through gearboxes.
The limit switch system performs the following fun-

ctions:
1. Stop function - hook and jib movements are halted

at chosen safety limits.
2. Speed reduction - the speed of a hook or jib mo-
vement is reduced to 25-30% at a predetermined
point before the stop position is reached.
3. Position control function - the jib working radius and
the level of the crane hook are controlled in relation
to each other.
The limit switch boxes of the hoisting and luffing win-

Limit switch box,
ches are similar except for the demultiplication ratios luffing winch
of their driving gearboxes.
Limit switch box,
hoisting winch
The cams in the luffing winch limit box are marked
BL1, BL2, BL3 etc.; those of the hoisting winch box,
BH1, BH2, BH3 etc.
Fig. 1. Limit switch boxes in crane house.
1 (10)
SERVICE 6.320.373 E rev.: b 2012-02-03
Setting limit switches
Back off the lockscrews of the switch cams in the limit

switch boxes, using a 10 mm articulated wrench; the
cams are then easily rotated to their proper settings.
H
- Use the cam end as measure line when setting the
cam(s), see Fig. 2 and 3. The measure between H
K
each hole is 5°.
- Set the cam(s) according to the table in instruction Jib radius
"Tehnical Data", section 2.
K
Jib radius
Measure line
5°
Adjustment screw Fig. 4. Jib radius lifting height.
Measure references
30° 55°
The following measures are stated in the document
"Technial Data" in section 2, Technical Description.
Lock screw Jib radius, Max. (m)

Jib radius, Min. (m)
Jib radius, High hook (m)
Force limitation for parking position (m)
Fig. 2. Cam.
Lifting height, H (m)
Lifting height, K (m)
Lifting height, High hook (m)
Center line
Note that the jib radius measures refer to the crane
5° house slewing centre (Not to the jib bearing centre!).
The measures H and K refer to the jib bearing centre.
Measure line Measure line
Adjustment Adjustment
screws screws
Setting outreaches and hook position by
100° 245° measuring on winches
- AT and BT - luffing winch

- AL and BL - hoisting winch
AT, BT, AL, and BL measurements should be taken

Lock screw on the front side of the winch.
Fig. 3. Cam.
2 (10)
SERVICE 6.320.373 E rev.: b 2012-02-03
AT and AL measures (wire lock side), - from the Limit switches - Luffing winch
side of the empty drum flange side to the side of the
wire, see Fig. 5 and 6. The included limit switches are shown in the below
figs. Note that switches BL2 and BL4 actuate speed
BT and BL measures - second layer, from the side of reduction of the crane jib.
the full drum flange side to the wire, see Fig. 5 and 6.
Note! When adjusting the luffing limits it is important to
Values of AT, BT (luffing) and AL, BL (hoisting) can be start with BL1 and to continue according to Fig. 8. For
found in instruction "Technical Data", section 2, see measurement values see table "Basic limit switches"
tables for hosting and luffing winches. in Technical Data.
When changing wires it is important that the procedure

in instruction "Replacement of Wires" in section 6.2 is
followed, thus to avoid readjustments of limits.
AT - Empty drum flange side/

Stop lowest position/
At least three locking turns
BL1
Wire lock side BT - Full drum flange
side/second layer BL2
BT BL3
AT
BL4
BL5
BL6
BL7
~
~ ~
~
BL13
Fig. 5. Luffing winch outreaches.
BL14
BL15
AL - Empty drum flange side/
At least three locking turns/Tank top BL16
BL - Full drum flange

side/second layer Wire lock side
Fig. 7. Limit switch box on the luffing winch.
BL
AL
Fig. 6. Hoisting winch, hook position.
3 (10)
SERVICE 6.320.373 E rev.: b 2012-02-03
Basic limit switches - luffing winch

For setting values see "Technical Data", section 2.
After the cam settings are done, retighten the lock

screws and operate the luffing movements to check all
cam settings on the luffing winch. Begin at minimum
jib outreach and luff out to maximum jib outreach.
Measure of the "Distance MV", see Fig. 9.
Min. jib outreach BL5 Measure of the "Distance MV".
BL4 Speed reduce, luffing in
BL2 Speed reduce, luffing out
BL3 Max. jib outreach
BL6 Force limitation for

parking position
BL1
C (m) A- Jib parking position

(Stop lowest position -
C spr (m) B spr (m) at least three locking
turns.)
= B (m)
D (m)
Fig. 8. Luffing winch limit switches.
= Max. jib outreach. To by-pass this position, cor-

rect operation mode has to be selected by help
= Force limitation for parking position. of the key switch "Parking of jib" in cabin.
= Speed reduce. = Stop position.
4 (10)
SERVICE 6.320.373 E rev.: b 2012-02-03
Measurement of the minimum jib outreach, CC3000
See instruction "Absolute Encoder calibration" in

section 6.3.
Center line of crane house
MV
(m First jib stay
m)
Measure of
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. 9. Crane house top.
5 (10)
SERVICE 6.320.373 E rev.: b 2012-02-03
Additional minimum jib outreach -

"Jack knife" (optional)
For tilt switch setting and setting the safety cam values
read "Technical Data", section 2.
Read instruction about "Jack knife" in section 3 in the

Instruction Manual.
BL (X) Safety cam
"Jack knife" (m)
Tilt switch setting
Fig. 10. Additional minimum jib outreach - "jack knife".
6 (10)
SERVICE 6.320.373 E rev.: b 2012-02-03
Limit switches - hoisting winch

BH1
For setting values see "Technical Data", section 2. BH2
Raise the jib into the MIN Jib radius position, which BH3
is the correct jib position for setting the limit switches BH4
according to the below figures. Note that the switches
BH5
BH2 and BH3 actuate speed reduction of the crane
hook. BH6
After cam settings are done, retighten the lock screws

and operate the hoisting movements. Lower the lifting
block until empty drum limit is reached and then hoist
the lifting block until full drum limit is reached and Fig. 11. Limit switch box on the hoisting winch.
check the cam settings.
BH 4 Full drum limit, stop position.
BH 3
Speed reduce,
full drum H spr (m)
H (m)
Speed reduce,
empty drum K spr (m)
K (m)
BH 2
Empty drum limit, stop position.

BH1
At least three locking turns or tank top.
Speed reduce
= Stop position.
Fig. 12. Hoisting winch limit switches.
7 (10)
SERVICE 6.320.373 E rev.: b 2012-02-03
Limit switches, high hook (optional) *)

Speed reduce, luffing out BL(X)
Max. jib,
For setting values see "Technical Data", section 2. stop limit
BL(X) *)
Note! Not all cranes are equipped with the function
high hook. If the crane is equipped with high hook,
values for outreaches for both luffing and hoisting
winches can be found in tables in instruction "Tecnical
Data", section 2.
This function prevents the jib from mechanical touching E spr (m)
E (m)
of the hook block when luffing out.
*) If high hook is applicable then BL7 and BL8 are used.

Limit switch BH5 (speed reduce switch, hoisting) takes NA = High hook is not applicable.
care of the area . See Technical Data, section 2.
Speed reduce.
Limit switch BH6 (detector switch) takes care of the
area and gives signal to BL8 (stop cam, luf- Stop. To by-pass those positions correct operation
mode has to be selected by help of the key switch
fing) if the hook block is in the wrong area. in cabin.
There is no stop function on the hoisting winch. De- Fig. 13. Extra luffing limit switches, high hook.
tector switch BH6 prevents the jib from mechanical
touching of the lifting block.
Full drum 500 mm
BH4
F ds - Detector switch
ib E (m) BH(X)
*)
c/c j Note! To be set
Stop limit at maximum
F spr (m)
outreach (BL3),
BH(X) *) luffing winch.
Speed reduce switch
towards jib top
*) If high hook is applicable

Max. R then BH5 and BH6 are used.
NA = High hook is not applicable.
See Technical Data, section 2.
Fig. 14. Extra hoisting winch limit switches, high hook.
8 (10)
SERVICE 6.320.373 E rev.: b 2012-02-03
Jib top and hook block functions at large

outreaches
Note! If the crane is equipped with a high hook fun- The cranes are designed, calculated and manufactu-
ction, this is not applicable. red in accordance with and approved by classification
societies.
In a certain area there is a possibility that hook block
and jib top will meet. See Figs. 15 and 16. This will A slacking luffing or hoisting wire rope should stop
not cause any problem as the cranes safety system the luffing out and hoisting movements by use of the
takes care of it. slack wire switch BWL1.
It is only possible for the hook block to reach jib top Hook block hoisting the jib:
at large outreaches. - This actuates the slack wire switch BWL1 and the
hoisting movement stops.
The hook block and the crane jib is designed and
calculated to take care of the forces which occur when Jib landed on the hook block:
the hook block is hoisting the jib top or the jib top lands - Luffing wire slackens and the slack wire switch
on the hook block. BWL1 actuates. The luffing out movement stops.
At small outreaches the full drum limit, BH4, on the

drum will be in operation.
Area for large outreaches where hook block

and jib top will possibly meet.
Fig. 15. Large outreaches.
9 (10)
SERVICE 6.320.373 E rev.: b 2012-02-03
Hook way (full drum) limit BH4
Lifting height
H (m)
Block touches
jib top
jib
c/c
Jib bearing
centre Outreach (m)
Min. jib Max. jib

outreach outreach
Fig. 16. Hook way.
Hook stop
Hook stop
Fig. 17. Jib top.
10 (10)
SERVICE 6.321.13 E rev.: a 1999-11-23
Slack Wire Safety Switch Hoisting and Luffing Winches
Function Functional test, luffing

A slacking luffing or hoisting wire rope shall stop the Run the hoisting wire block/swivel slowly against the
respective winch movement before the spooling of jib top and lift the jib, to cause the luffing wire to
the rope on the drum has been damaged. The slacken. The hoisting winch shall then stop. Some
adjoining figs. show the arrangement of the wire sen- cranes are equipped with safety switches to prevent
sing device with built-in switch. When the wire slack- the block from touching the jib. This safety switch must
ens, the spring-loaded pressure roll forces the wire be made inoperative. Lower the hoisting wire block/
towards the wire drum, at the same time swinging swivel so that the luffing wire rope is taut. Check that
the arm to actuate the built-in switch. The pump the switch returns properly.
returns to zero and the winch stops.
The slack wire function is approved as long as the Note! The slackwire device is not designed to detect
wire is spooling properly on the drum. slack in the rope at the position of the lifting block. It
will only detect slack at winch.
Functional test, hoisting The lifting block may lay flat on the ground/deck and
the slack wire device may still not be activated.
Lower the hook block on to the deck to slacken the
hoisting wire rope. Hoist the hook in order to check
This is most evident at minimum outreach. In these
that the switch returns properly.
cases there will probably never be a slack at the winch
and therefore never an automatic stop of the lowering
motion.
Wire rope slack

Wire rope
Switch
Arm
Slack wire safety switch. Normal condition. Slack wire safety switch. Slack wire condition.
1 (2)
SERVICE 6.321.13 E rev.: a 1999-11-23
2 (2)
SERVICE 6.324.1 E rev.: b 2010-11-02
Preparation for Overload (OL) Test Mode
WARNING!
Overload test is only permitted when requested by
the classification society. A classification surveyor
must be present during the overload test. Key switch
Note! The surveyor has to fill in and undersign the
form on page 2.
WARNING! Error
Input
07 18
08 19
09 20
10 26
11 49
12 51
13 56
14 57
15 58
16 59
MP SP
Output
27
28
29
30
31
32
33
34
35
36
Error
07
08
09
10
19
20
11
Input
31
32
Sw19
MP
33
39
34
40
30
Sw20 55
14 Sw14
56 Sw56
SP
Output
36
43
37
45
Error MP
07
08
09
10
19
20
11
Input
31
32
Sw19
33
39
34
40
30
Sw20 55
14 Sw14
56 Sw56
SP
Output
36
43
37
45
Error
07
08
09
10
19
20
11
Input
31
32
Sw19
MP
33
39
34
40
30
Sw20 55
14 Sw14
56 Sw56
SP
Output
36
43
37
45
Error
07
08
09
10
19
20
11
Input
31
32
Sw19
MP
33
39
34
40
30
Sw20 55
14 Sw14
56 Sw56
SP
Output
36
43
37
45
17 60 37 12 15 Sw15 12 15 Sw15 12 15 Sw15 12 15 Sw15

24V 38 26 27 26 27 26 27 26 27
Com 39 58 59 58 59 58 59 58 59
During the overload test the load limits increase and

40 49 17 29 49 17 29 49 17 29 49 17 29
53 51 18 53 51 18 53 51 18 53 51 18 53
61 52 54 52 54 52 54 52 54
57 57 57 57
Com Com Com Com
the crane can lift a specified per cent more than the SC
C3
IO
C3
SC Supervisory
A1 C1
HOHoisting
A1 C1
LU Luffing
A1 C1
SL Slewing
A1 C1
AU Auxiliary
A1 C1
IO
A1
Input/Output
C1
HO_C1
SC_C3
SC_C1
AU_C1
LU_C1
SL_C1
IO_C3
IO_C1
HO_A1
SC_A1
AU_A1
LU_A1
SL_A1
IO_A1
safe working load. Inappropriate use may cause severe C4 C4 A2 C2 A2 C2 A2 C2 A2 C2 A2 C2 A2 C2
HO_C2
SC_C2
AU_C2
LU_C2
SL_C2
IO_C2
HO_A2
SC_C4
SC_A2
AU_A2
LU_A2
SL_A2
IO_C4
IO_A2
485.2 485.2 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1
HO_485.1
SC_485.1
AU_485.1
LU_485.1
SL_485.1
IO_485.1
SC_485.2
IO_485.2
HO_A3
SC_A3
AU_A3
LU_A3
SL_A3
IO_A3
485.3 485.3 Sp SSI Sp SSI Sp SSI Sp SSI Sp SSI Sp SSI
SC_485.3
IO_485.3
HO_SSI
SC_SSI
AU_SSI
LU_SSI
SL_SSI
IO_SSI
HO_Sp
SC_Sp
AU_Sp
LU_Sp
SL_Sp
IO_Sp
damage to the crane and bodily injury.
- Start the crane with pushbutton S13, START/STOP.

Fig. 1. Key switch in cabinet CT2.
- Wait until pilot light H1, "DO NOT OPERATE", goes
off.
- Wait until the display comes on.
- Set the key switch in position OL test. See Fig. 1.
NOTE! The key switch has to be set within 4 minutes
after the pilot light H1 goes off.
- A login window shows on the display. See Fig. 2.
- Write the password to accept overload test mode.
Use the software keyboard on the display.
NOTE! The password is the last four digits of the
manufacturing No., which can be found in the
instruction manual or at the sign in the cabin. The
password must be written within 5 minutes after
the key switch has been turned.
- The display should now show "OVERLOAD TEST" Fig. 2. Login window overload test.
and the diagram for load/outreach should have an
additional red area on top of the normal green area.
See Fig. 3.
- Overload test can now be done refer to MacGregor
Cranes' procedure. Contact MacGregor Cranes for
further information.
NOTE! Motions are speed reduced in overload test

mode. When the test is finished, the crane has to
be stopped to exit the overload test mode.
Fig. 3. Example of display in overload test mode.
1 (2)
SERVICE 6.324.1 E rev.: b 2010-11-02
Overload test report
Cause Date Classification Signatur Clarification of signature
2 (2)
SERVICE 6.324.2 E rev.: - 2010-11-10
Preparation for Rig Mode
WARNING! NOTE! The password is the last four digits of the

When the crane is operated in Rig mode the crane crane's manufacturing No., which can be found in
has no software limits. the instruction manual or on the sign in the cabin.
It is not permitted to have any load in the hook. The password must be written within 5 minutes after
Inappropriate use may cause severe damage to the the key switch has been turned.
crane and bodily injury.
- The display should now show "RIGGING" and the
WARNING! diagram shows only a red line. See Fig. 3.
Operation in Rig mode is only permitted together with NOTE! Motions are speed reduced in Rig mode. To
below intructions: exit Rig mode the crane has to be stopped and the
- Absolute Encoder Calibration, CC3000 key switch must be set to position "Normal".
- Rope Reeving Diagram
- Limit Switches and Software Limits
- Replacement of Wires
Procedure
- Set key switch in position Rig. See Fig. 1.

- A login window shows on the display. See Fig. 2.
- Write the password to accept Rig mode. Use the
software keyboard on the display.
Fig. 2. Login window.

Key switch
Fig. 1. Key switch in cabinet CT2. Fig. 3. Example of display in Rig mode.
1 (2)
SERVICE 6.324.2 E rev.: - 2010-11-10
2 (2)
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
to a limited extent by releasing their respective brakes operation is two "brake releasers" and one crane
with utmost care. operator.
The release of the brakes of the hoisting, luffing, and Contact between the two "brake releasers" and the
slewing functions is facilitated by employing a hand crane operator is absolutely essential, e.g. by use of
pump designed for this purpose. Quick couplings and head-sets.
shut-off valves are also installed in the hydraulic
system of the crane for this purpose. All necessary material comprising this emergency
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
coupling (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
connection 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 By-pass line,
included in
connection 3.2) on hoisting pump to avoid emergency
uncontrolled lowering. equipment
3B
Flush-unloading unit 1128
3A
Ball valve 1663
Connection P
Pilot hoses
(disconnected)
Wedge
valve 4332
Oil tank
Quick
coupling
4333
Quick
coupling1664 Pilot hose,
disconnect and plug **)
Hand pump 1A
**)Plug to pilot hose and included in pump set,
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 in,
that the motor hydraulically controls the load. If the 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 pressure - Remove check-restriction valve 1241-1 from flush-
side of the motor and on the brake. The pressure can unloading unit 1128, see Fig. 3.
be read on pressure gauge 1D. The brake opens at - Attach the bushing and screw into coupling in
approx. 1.2 MPa. Oil from the high pressure side (pump connection “P”, flush-unloading unit 1128-1. Screw
MB-port) goes through the needle valve 3B and flow in the threaded bushing up to the neck, screw to
control valve 3A to the low pressure side (pump MA- actuate the piston to blocked position. See Fig. 3.
port). Flow control valve 3A is fixed and load - Close ball valve 1663 and open wedge valve 4332.
independent. With a load in the cargo hook, needle See Fig. 2 and 4.
valve 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 controlled.
- Install the hand pump to the base plate using the Speed can be reduced by closing needle valve 3B,
provided screws. partially or completely.
- Disconnect pilot hoses at MA- and MB-port on the
pump. The load must be lowered slowly by pumping in a
- Connect the by-pass line. See Fig. 2 and 4. slow 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 during
MB are not switched, because the load could be
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 -

connection 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 uncontrolled
lowering.
Gauge
connections
removed
3B 3A
By-pass line
Unloading unit 2127 Included in

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

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

Ball valve 2661
Hand pump 1A
**)Plug to pilot hose and included in pump set,
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
that the motor hydraulically controls the load. If the unloading unit 2127, see Fig. 7.
motor tends to overspeed, by the force from the load, - Attach the bushing and screw into coupling in con-
the brake will close. nection 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
port). Valve 3A is fixed and load independent. Valve
pump.The jib must be lowered slowly and carefully
3B can be completely or partially closed in order to
controlled. Speed can be reduced by closing needle
reduce the speed.
valve 3B, 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 MA-
If only the luffing circuit is out of operation, try to lower
and MB-port are not switched, because the load
the load onto deck or quay with the hoisting winch.
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, re-
- Disconnect the pilot hose from connection P, set the crane to “NOT EMERGENCY COUPLED“,
unloading unit 2127. Plug the disconnected hose. wedge valve 4332 must be closed and ball valve 2661
See Fig. 6, 7, and 8. must 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
the crane to NOT EMERGENCY COUPLED. Wedge
with 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)
EXTRA EQUIPMENT 7.075.12 E rev.: - 2012-08-31
MacHeavyvisor Release 3.6
General
The MacHeavyvisor software is a part of the log-

ging and information system delivered by MacGregor
Cranes. The application is installed on a dedicated
display inside the crane cabin.
MacHeavyvisor communicates with the crane control
system (CC3000) via a data communication cable.
The display is automatically started and stopped when
the electric power of the crane system is switched
on/off.
Purpose Fig. 1. Example of Crane computer view (Main)

MacHeavyvisor has two main purposes:
- Displays real-time information about current

properties of the crane such as jib outreach,load in
the hook and hoisting speed.
- Log information about crane operations, allowing
future analysis.
Load diagram
The centre part of the screen shows a diagram, which

visualize the current load in the hook and jib outreach
in addition to the text values displayed in the blue
boxes, see Fig.1 and Fig. 2.
Fig. 2. Example of Crane computer view (Whip)
The current values are indicated by a white “ball” with
a black circumference. The areas displayed in the
diagram are defined by CC3000.
A horizontal black line indicates the area with low
speed only.
Note!
This view changes depending on the crane's different
load areas and on the extra equipment delivered with
the crane.
Fig. 3. Example of Crane computer view (Auto Team)
1 (8)
Icons in crane computer view

Disconnected
If there is no communication with the CC3000 sys-
Different icons is viewed depending on the cranes
tem, the message “Disconnected!” on the screen.
equipment.
Joystick, hoisting with

high and low speed
See below
Joystick, hoisting
See below
Fig. 4. Example of Crane computer view (ELCCL) Joystick, luffing/slewing

Above circles represent the joysticks used when op-
erating the crane. When an operation is not permitted
Standard crane by CC3000 a white cross will over cross the corre-
No text appears sponding arrow.
If an arrow goes yellow the motion is speed reduced

GLH crane operating by CC3000.
Main Hoist The small white “ball” on the hoisting joystick indicates
the speed of the hoisting winch. During operation, the
“ball” will move along the hoisting circle, to indicate
GLH crane operating the direction and movement when hoisting or lower-
Whip Hoist ing. Hoisting is indicated by a clockwise rotation and
lowering by a counterclockwise rotation.
Crane with ELCCL

Different modes depend on type of crane and
equipment. If there is a mode it shows centered
on top level of the screen.
Ton in hook
The current load in the hook. If the value exceeds the
Date and Time overload limit the box background will flash in red and
The current date and time is displayed in UTC an audio warning is also given. The overload informa-
time. tion is indicated by CC3000.
Optional
Logo, info version Visual warning with or without alarm sound can be
information configured by CC3000 parameter. This warning can
The MacGREGOR logo is displayed. When be set to be triggered between 1-99% of maximum
touching the logo, version information will be load (at current outreach). The box will flash in yellow
displayed. colour when this warning is on.
2 (8)
Anti-collision (optional)
If the crane has anti-collision system an indication
shows the status of the system.
The current jib outreach The green arrows shows that Anti-collision system is
When reached the limit the box will flash in yellow. active against AFT and FORE crane. Operates from
the middle crane.
The current hoisting/

lowering speed
Indicator for lowering speed.
The current lifting height Anti-collision is active in master crane. Filled white
dot is only showed in the master crane.
The current hoisting/

lowering speed together
with current lifting height
Anti-collision is inactive in the master crane.
List (optional)
The list of the ship in degrees. When this value ex-
ceeds an adjustable warning level, the background The green arrow shows that Anti-collision system is
in the box starts to flash yellow. Exceeding the alarm active against AFT crane. Operates from FORE crane.
level the background starts to flash red and an audio
warning sounds.
The green arrow shows that Anti-collision system is

Trim (optional) active against FORE crane. Operates from AFTcrane.
The trim of the ship in degrees. When this value ex-
ceeds an adjustable warning level, the background
in the box starts to flash yellow. Exceeding the alarm
level the background starts to flash red, and an audio
warning sounds.
The yellow arrows shows that the communication
between the cranes works but not activated.
Jack-knife (optional)
When jack-knife limit is reached this icon shows on The blue arrows shows that there is no communica-
the screen. tion between the cranes. The others crane are OFF.
3 (8)
Ton in hook
Anti-collision (optional) The current weight between the hooks in team lift.
The red arrows shows that the communication Shows the total rounded weight from crane 1 and
between the cranes is out of function. crane 2.
Hook to hook distance

Shows the lenght between the hooks of two cranes
Twin platform (optional)
working as a Team. It turns green when the actual
If the crane is a twin crane with anti-collision an indi-
distance is close or equal to the calibration value and
cator helps the crew to position the twin platform into
blue when it is not.
“single position” and operate the anti-collision system
in single mode.
Mass center
ELCCL mode Shows if the mass center is above the connection
Electronic Load Cell system for Comined Lift points. Shows in the view for Auto team
Standard mode
Buttons to switch different modes. To navigate back
Mass center is below the connection points.
to the Main view.
Power
Limitation Power limitation
Power limitation system is functioning correctly
Load diagram
The load diagram that is used during normal operation.
Power It is visualized as a column bar and shows max load
Limitation and current outreach.
If an arrow goes yellow the speed is reduced by the White ball indicates load in hook.
Power Limitation system.
Power
Limitation
The Power Limitation system is turned off from the key

switch
4 (8)
Error and warning Log from Control

System
System error
When tapping the “System Error” box an error log
shows, see below.
Examples of Events
Events
Below are examples from the comprehensive informa-
Current Events, information, warnings and errors from
tion provided by Macheavyvisor.
the Control System is displayed. If the event is of a
serious nature, a pop-up is forced to the middle of
the screen.
Otherwise the user can watch the events through a
push on the information field on the bottom of the
menu.
Event, type pop-up
Event, Information field
5 (8)
Dialog alternatives 1. Admin (top left corner)

The program is controlled through a dialog box system This manual does not cover this menu alternative,
and you get access to it by touching the background which is protected by an administrator password. The
of the display. If the user stays idle (does not push functions are intended for MacGregor Cranes’ person-
the screen) for a while (1-2 minutes) any entry will be nel.
ignored and the dialog box closes. There are three
areas to get access to the functions and settings: To get access to the Admin dialog box tap the top left
corner of the screen. A password dialog box shows.
Software keyboard
Enter admin password and push OK.
When a dialog box needs input, a keyboard shows
If correct password is entered then the Admin dialog
on the screen.
box shows.
Fig. 5. Software keyboard
a. First button:
Fig. 6. Rig Mode
Date, time and the copy logs. This is the same diaolog
box that shows for users.
Fig. 7. Overload test
6 (8)
b. Second button
g. Seventh button
c. Third button
d. Fourth button: h. Eighth button
2. User (bottom left corner)

e. Fifth button: Tap the bottom left corner and a password dialog box
shows. Enter the user password (set to 1111) and
push OK. Input of an incorrect password is notified by
a warning message, push OK to close.
f. Sixth button:
7 (8)
3. Offset (weight box)

To change the weight offset tap the box which displays
the weight in the top centre of the screen. The weight
offset dialog box shows on the screen.
The “Use Current” button will set the offset to the cur-
rent weight. To enter an own value just type it in the
box in the “Manual Offset” and push “Use Manual”
button. To discard any changes or just quit the dialog
box push “Cancel (No Change)”.
8 (8)
7.076.2 E rev.: c 2009-06-29
USER MANUAL
DISPLAY
CC Pilot XS
1 COMPATIBILITY .............................................................................................................................................. 2
2 THE INSTALLATION AND SERVICE .............................................................................................................. 2
3 THE CONNECTION OF PERIPHERAL DEVICES........................................................................................... 2
4 CODE DATA ..................................................................................................................................................... 2
5 THE SERVICE AND PROTECTION INSTRUCTIONS..................................................................................... 2
6 DISPLAY UNIT ................................................................................................................................................. 3

6.1 BUTTONS:.................................................................................................................................................... 3
6.2 LEDS: .......................................................................................................................................................... 3
6.3 CONNECTORS: ............................................................................................................................................. 3
7 STARTUP ......................................................................................................................................................... 3
8 PROBLEM SOLVING ....................................................................................................................................... 4

8.1 THE DISPLAY IS DARK OR DIM ........................................................................................................................ 4
8.2 SERIAL PORT FAULTS ................................................................................................................................... 4
8.3 LED IS BLINKING RED BUT PROGRAM DOESN’T START .................................................................................... 4
9 TECHNICAL DATA .......................................................................................................................................... 4
1 (4)
7.076.2 E rev.: c 2009-06-29
1 Compatibility
The display is compatible with Windows CE and Linux.
2 The installation and service

Only authorized service personnel from MacGREGOR service department is allowed to install, repair or open the
device. Faulty installation, repair or device opening can be dangerous and cancel the product warranty.
3 The connection of peripheral devices

The compatibility of peripheral devices of the display shall be ensured from MacGREGOR Service department to
exclude connection of incompatible products with each other.
4 Code data
Device's code data is placed at the back of the unit.
Code data are important from the service point of view, and so beware from disposing those.
5 The service and protection instructions

Your display is of a high quality product, and it should be used carefully. Following instructions help you to keep
product in good condition for a long time.
• The display shall be cleaned regularly. Wipe out the screen of the device by the soft moist fabric. Do not
use alkaline or alcohol including cleaning agents.
• Do not scratch, damage or press the surface of the display.
If the display would not work correct, please contact MacGREGOR, Service Department, Örnsköldsvik,
Sweden.
2 (4)
7.076.2 E rev.: c 2009-06-29
6 Display unit
X1
1 X2
2 X8
3
4 X5
5
X9
X6
The display screen has 10.4” LCD TFT display with a touch screen.
6.1 Buttons:
1. Power button can be used to turn on/off the unit. If pressed for a long time, there will be a
forced power off.
2. Increase brightness.
3. Decrease brightness.
6.2 LEDs:
4. Red LED that blinks at start up.
5. Light detector of automatic brightness adjustment.
6.3 Connectors:
X1 Power
X2 Ethernet1
X5 Misc (Used as Serial communication port)
X6 CAN1
X8 USB1
X9 USB2
7 Start up
The display starts up at the same time as the crane. First it loads the operating system and after that
the display starts the program. When starting, screen is black and the red LED is blinking.
3 (4)
7.076.2 E rev.: c 2009-06-29
8 Problem solving
If there are some problem with the display check the following first, then call MacGREGOR Service Department.
8.1 The display is dark or dim when crane is working
• Check the brightness adjustment of the screen.
• Check cables and connectors to the display unit.
• Push the power on button on the display unit.
8.2 Communication faults
• Check that the cables are properly connected.
8.3 LED is blinking red but program does not start
• Try to switch off the unit and start again with the power button.
9 Technical Data
This display is especially developed for use of heavy machinery, which guarantees system durability and flexible
expandability to the different applications.
Kernel Power
Processor Intel XScale, 533 MHz Voltage 10 - 36 VDC
Compact Flash 32 MB -> commercially available Current < 500 mA at 24 VDC (6.5’’)
Kernel Flash 32/ 64 MB Environment
RAM -> 256 MB SDRAM IP-class IP65
Graphic controller Silicon motion, 8 MB RAM Temperature range -40 °C - +65 °C (operating)
Interfaces -40 °C - +70 °C (storage)
2 x CAN 2.0B, ISO 11898 – 24V,1 Mbit EMC conformity In accordance with 89/336/EEC:
2 x Ethernet 10/100 Base-T EN 50081-2: 1993
2 x USB 2.0 Software
RS232 OPTION. 115000 baud, replaces Operating system: Windows CE 5.0
Keyboard & Mouse Via USB Internal control
Display Status LED In front panel
10.4’’ SVGA 800x600 TFT Photo diode Automatic backlight control
Backlight CCFL ~400 nit Internal temperature protection against overheating
Touch screen Resistive in abnormal ambient conditions.
Mechanical
Enclosure Aluminum Dimensions
Mounting Stand Screen size: 10.4’’
Connectors DIN M12 Depth: 40 mm
Height: 217 mm
Width: 285 mm
4 (4)
9.0 How to order
spare parts
Cargotec Sweden AB
MacGregor Cranes
Sjögatan 4G
Telephone: 46 - 660 - 29 40 00 9.1 Machinery
Telefax: 46 - 660 - 139 77
www.cargotec.com
Spare Parts Manual 9.2 Pump unit

Oil cooler
9.3 Mechanical
equipment
9.4 Hydraulic
components
9.5 Electric
components
9.6
9.7 Extra equipment

SERVICE 6.000 E rev.: e 2010-09-08
How to Order Spare Parts
Important details when enquiring or ordering spare parts
Please send your inquiry or order to closest MacGregor global service station, see instruction "MacGregor Global
Services", 6.004.1 E.
To speed up the process we request you to provide us with below information:
State name of company as well as your name
Vessel's name and IMO number (and/or Lloyd's number)
Crane type (see manual or name plate in operator's cabin)
Crane place on the vessel. No. 1 counted from the fore
Crane serial number (see manual or name plate in operator's cabin)
Spare part figure or drawing number. To be found in section 9 in the manual
Part description
Item number from spare part figure or drawing respectively
Part number, if available, from spare part figure or drawing respectively
Quantity required
When you order a wire rope or lifting block, please specify which certificate is needed.
Deadline - when or where in the world do you need the parts?
Delivery details such as: consignee as well as phone and fax numbers
Terms of delivery: by DHL, air freight direct or consignment, by truck or shipping freight
The more you can provide us with above details the faster and more reliable replies and deliveries will be made.
Address:
Cargotec Sweden AB
MacGregor Cranes
Phone: 46 - 660 - 29 40 00
Telefax: 46 - 660 - 139 77
1 (2)
6.000 E rev.: e 2010-09-08 page 2 (2)
Tel: 46 - 660 - 29 40 00
Direct: Fax: 46 - 660 - 139 77
Date: ................................................
Spare parts/Service specification

Please use this form whenever assistance is needed. Service request
Confirmation of
phone call/conv.
From: .. ............................................................. E-mail address: ................................................
.............................................................. Phone no.: ......................................................
.............................................................. Telefax no.: ......................................................
Re: M/V ........................................................ IMO /Lloyd's no.: ..............................................
Crane type: ............................................. Serial no: .........................................................
Crane place: ........................................... Our ref.: ..........................................................
For following spares we would like to: have your quotation
place order, deadline for arrival :................................
Part no. Qty Description Fig./Drwg. Item
1. .......................................... ..... ............................................ .............................. ..............
2. ........................................... ..... ............................................ .............................. ..............
3. ........................................... ..... ............................................ .............................. ..............
4. ........................................... ..... ............................................ .............................. ..............
5. ........................................... ..... ............................................ .............................. ..............
6. See enclosure
Delivery/Agent's address: ............................................................................................................
............................................................................................................
............................................................................................................
...................................................................................................................
Name/ Title/
PARTS MANUAL Date Group Fig. Page
2003-01-22 9.1 625-1440.047 1 (2)
HOISTING WINCH
2003-01-22 9.1 625-1440.047 2 (2)
HOISTING WINCH
Item Qty Article no Description Supplementary data
000 1 189 2796-801 HOISTING WINCH
001 1 189 2255-801 WINCH SEE FIG. 625-1450.055
002 x .. O-RING SEE FIG. 625-1450.055
003 1 289 2557-801 . VALVE UNIT
004 1 388 3580-801 . FLUSH AND UNLOADING UNIT
005 1 189 2418-801 . HYDRAULIC MOTOR
016 4 2121 2032-631 . SCREW M6S 16 x 55 -8.8 FZB; 163 Nm
020 4 2121 2022-185 . WASHER BRB 17 x 30 FZB

2003-11-07 9.1 625-1450.055A 1 (4)
HOISTING WINCH
2003-11-07 9.1 625-1450.055A 2 (4)
HOISTING WINCH
000 1 189 2255-801 HOISTING WINCH
001 1 875 13030-006 . PRESSURE ROLLER, COMPLETE SEE FIG. 625-1451.010
002 22 2121 2032-720 . SCREW M6S 24 x 60 -8.8 FZB; DIN 933
003 22 875 13014-002 . WASHER M 24
004 2 875 13016-001 . SPACER
005 4 2121 2532-380 . SCREW MC6S 6 x 50 -8.8 FZB; DIN 912
006 1 875 13009-002 . OIL PIPE, COMPLETE
007 8 2121 2030-676 . SCREW M20 x 60; -10.9
008 8 875 13014-023 . WASHER M20
011 18 2121 2032-719 . SCREW M6S 24 x 55 -8.8 FZB; DIN 933
012 18 2121 2032-719 . SCREW M6S 24 x 55 -8.8 FZB; DIN 933
013 1 875 13017-014 . CABLE FIXING
014 4 875 13018-011 . SCREW M 20 x 45
021 1 875 13019-071 . GEAR, COMPLETE Includes item 22-28.
022 1 875 13020-001 .. SEALING BAND Length depending on gear.
023 1 875 13020-002 .. LOCKING BAND L = 2000 mm
024 1 875 13020-003 .. SOCKET
025 1 875 13014-003 .. WASHER
026 1 875 13007-009 .. SHAFT SEALING
027 2 875 13038-001 .. PLUG WITH OIL VALVE
028 2 875 13007-008 .. SEALING
031 1 875 13026-002 . FLANGE PLATE
032 1 875 13014-011 . WASHER
033 1 875 13020-004 . SEALING BAND L = 500 mm
034 1 875 13011-009 . BEARING
035 1 875 13023-003 . COVER
037 1 875 13010-002 . COUPLING
038 1 875 13009-006 . PIPE

2003-11-07 9.1 625-1450.055A 3 (4)
HOISTING WINCH
2003-11-07 9.1 625-1450.055A 4 (4)
HOISTING WINCH
039 1 875 13010-003 . COUPLING
040 1 875 13032-002 . GREASE NIPPLE M10 x 1; DIN 71412
041 1 875 13016-002 . CLAMP
061 1 875 13004-078 . DRIVE IN, COMPLETE Includes item 62-86.
062 8 875 13001-003 .. MULTIPLE DISC, OUTER Change all 15 discs at the same time.
063 7 875 13001-004 .. MULTIPLE DISC, INNER Change all 15 discs at the same time.
064 14 875 13002-003 .. SPRING Change all 28 springs at the same time.
066 1 875 13003-008 .. PRESSURE UNIT
067 1 875 13027-002 .. MOTOR FLANGE
068 1 875 13028-001 .. DISC CARRIER
069 1 .. BRAKE FLANGE Not sold separately. See item 61.
070 1 875 13013-020 .. DRIVING SLEEVE Includes item 71-72.
071 1 875 13012-007 ... CIRCLIP
072 10 875 13014-001 ... SHIM
073 1 875 13007-006 .. SHAFT SEALING
074 1 875 13007-005 .. SHAFT SEALING
075 1 875 13011-004 .. BEARING
076 1 875 13012-008 .. CIRCLIP
077 1 875 13012-009 .. CIRCLIP
078 1 875 13015-003 .. O-RING
079 1 875 13015-002 .. O-RING
080 12 2121 2532-561 .. SCREW MC6S 12 x 160 -8.8 FZB;DIN 912
081 8 2121 2532-540 .. SCREW MC6S 12 x 40 -8.8 FZB; DIN 912
082 1 875 13008-011 .. VENTILATION FILTER M10
083 1 875 13006-004 .. PLUG M18
084 1 875 13007-008 .. SEALING
085 3 875 13006-003 .. PLUG M10
086 3 875 13007-007 .. SEALING

2012-09-10 9.1 625-1451.010A 1 (2)
PRESSURE ROLLER, COMPLETE

2012-09-10 9.1 625-1451.010A 2 (2)
PRESSURE ROLLER, COMPLETE

000 1 875 13030-006 PRESSURE ROLLER, COMPLETE
005 4 875 13039-001 . SPRING
011 1 875 13033-007 . ROLLER
012 2 875 13033-008 . ROLLER
016 2 875 13033-009 . COVER
022 4 2121 2032-453 . SCREW M6S 8 x 25 -8.8 FZB
023 8 2121 2032-453 . SCREW M6S 8 x 25 -8.8 FZB
026 2 2126 2032-124 . NUT M6M 16 -8 FZB
031 2 875 13012-034 . CIRCLIP
032 6 875 13012-020 . CIRCLIP
036 1 875 13025-004 . PIN 8 x 50
043 2 875 13014-043 . WASHER M 24
047 1 875 13040-001 . KEY
050 6 875 13011-029 . BEARING
052 1 875 13037-002 . BUSHING
053 1 875 13037-003 . BUSHING

2010-08-18 9.1 625-1451.224 1 (2)
OIL PIPE, COMPLETE
17
16
23
192001353
23
41 42
875 13009-002
625-1451.224 /0
Weight 3 kg
2010-08-18 9.1 625-1451.224 2 (2)
OIL PIPE, COMPLETE

000 1 875 13009-002 OIL PIPE, COMPLETE
016 1 875 13007-018 . SEALING
017 1 875 13008-006 . OIL DIPSTICK G3/4"; 0.2 bar
023 2 875 13007-001 . SEALING
041 1 2528 2762-220 . PLUG
042 1 2528 2772-220 . NUT

2010-03-12 9.1 625-1440.046A 1 (2)
LUFFING WINCH, C
19
15
1
20 19
17 16
163 Nm
189 1625-801
625-1440.046
2010-03-12 9.1 625-1440.046A 2 (2)
LUFFING WINCH, C
000 1 189 1625-801 LUFFING WINCH, C
001 1 188 1221-801 . HYDRAULIC MOTOR SEE FIG. 625-2205.009
002 1 189 1622-801 . LUFFING WINCH SEE FIG. 625-1450.056
003 1 289 1639-801 . VALVE UNIT SEE FIG. 625-7207.006
004 1 388 3576-803 . UNLOADING UNIT SEE FIG. 625-7802.004
015 2 2121 2032-469 . SCREW M6S 8 x 90 -8.8 FZB
016 4 2121 2032-471 . SCREW M6S 8 x 100 -8.8 FZB
017 4 2121 2032-630 . SCREW M6S 16 x 50 -8.8 FZB
019 6 2151 2022-164 . WASHER BRB 8.4 x 16 FZB; DIN 125A
020 4 2151 2022-185 . WASHER BRB 17 x 30 FZB

2003-10-22 9.1 625-1450.056A 1 (4)
LUFFING WINCH
2003-10-22 9.1 625-1450.056A 2 (4)
LUFFING WINCH
000 1 189 1622-801 LUFFING WINCH LUFFING
001 22 2121 2030-674 . SCREW M6S 20 x 50 -10.9; DIN 933
002 22 875 13014-023 . WASHER
003 6 2121 2032-628 . SCREW M6S 16 x 40 -8.8 FZB; DIN 933
004 1 875 13009-050 . OIL PIPE, COMPLETE
005 2 875 13016-001 . SPACER
011 18 2121 2032-673 . SCREW M6S 20 x 45 -8.8 FZB; DIN 933
012 18 2121 2032-673 . SCREW M6S 20 x 45 -8.8 FZB; DIN 933
013 1 875 13017-011 . CABLE FIXING
014 5 875 13018-003 . SCREW M 16 x 45; DIN 912
021 1 875 13019-067 . GEAR, COMPLETE Includes item 22-25.
022 1 875 13007-020 .. SHAFT SEALING
023 1 875 13014-017 .. WASHER
024 2 875 13038-001 .. PLUG WITH OIL VALVE
025 2 875 13007-008 .. SEALING
031 1 875 13021-028 . FLANGE, COMPLETE Includes item 32-42.
032 1 875 13026-003 .. FLANGE
033 1 .. FLANGE PLATE Not sold separately. See item 31.
034 1 875 13014-016 .. WASHER
035 1 875 13012-016 .. CIRCLIP
036 1 875 13022-001 .. FELT STRIP L = 400 mm
037 1 875 13011-012 .. BEARING
038 1 875 13023-004 .. COVER
039 1 875 13024-001 .. DRIVER
040 1 2121 2532-468 .. SCREW MC6S 8 x 85 -8.8 FZB; DIN 912
041 2 875 13025-001 .. PIN

2003-10-22 9.1 625-1450.056A 3 (4)
LUFFING WINCH
2003-10-22 9.1 625-1450.056A 4 (4)
LUFFING WINCH
042 1 875 13032-002 .. GREASE NIPPLE M10 x 1; DIN 71412
051 1 875 13004-074 . DRIVE IN, COMPLETE Includes item 52-76.
052 8 875 13001-003 .. MULTIPLE DISC, OUTER Change all 15 discs at the same time.
053 7 875 13001-004 .. MULTIPLE DISC, INNER Change all 15 discs at the same time.
056 1 875 13003-008 .. PRESSURE UNIT
057 1 875 13027-001 .. MOTOR FLANGE
058 1 875 13028-001 .. DISC CARRIER
059 1 .. BRAKE FLANGE Not sold separately. See item 51.
060 1 875 13013-019 .. DRIVING SLEEVE Includes item 61-62.
061 1 875 13012-030 ... CIRCLIP
062 24 875 13014-018 ... SHIM
063 1 875 13007-006 .. SHAFT SEALING
064 1 875 13007-005 .. SHAFT SEALING
065 1 875 13011-004 .. BEARING
066 1 875 13012-008 .. CIRCLIP
067 1 875 13012-009 .. CIRCLIP
068 1 875 13015-001 .. O-RING
069 1 875 13015-013 .. O-RING
070 6 2121 2532-559 .. SCREW MC6S 12 x 140-8.8 FZB; DIN 912
071 6 2121 2532-562 .. SCREW MC6S 12x170 -8.8 FZB; DIN 912
072 1 875 13008-011 .. VENTILATION FILTER M 10
073 2 875 13006-012 .. PLUG M 10
074 2 875 13007-007 .. SEALING
075 1 875 13006-006 .. PLUG M 18
076 1 875 13007-008 .. SEALING

2001-01-12 9.1 625-2205.009A 1 (2)
HYDRAULIC MOTOR
2001-01-12 9.1 625-2205.009A 2 (2)
HYDRAULIC MOTOR
001 1 188 1221-801 HYDRAULIC MOTOR LUFFING
002 1 489 6119-801 . GASKET SET

1998-10-09 9.1 625-2205.010 1 (2)
HYDRAULIC MOTOR
1998-10-09 9.1 625-2205.010 2 (2)
HYDRAULIC MOTOR
001 1 188 1223-801 HYDRAULIC MOTOR SLEWING
002 1 489 6118-801 . GASKET SET

2003-01-16 9.1 625-2205.021 1 (2)
HYDRAULIC MOTOR
2003-01-16 9.1 625-2205.021 2 (2)
HYDRAULIC MOTOR
001 1 189 2418-801 HYDRAULIC MOTOR
002 1 489 6115-801 . GASKET SET

2003-02-10 9.1 625-2250.008 1 (2)
WINCH MOUNTING SET

2003-02-10 9.1 625-2250.008 2 (2)
WINCH MOUNTING SET

000 1 289 1944-801 WINCH MOUNTING SET
003 10 489 5009-010 . WASHER
004 10 489 7386-002 . WASHER
005 14 488 7386-001 . WASHER
006 14 488 7386-005 . WASHER
007 2 489 6415-801 . LIMIT SWITCHES BOX, MOUNT.
009 24 2121 2037-737 . SCREW M6S 24 x 160 -10.9 SPEC
010 10 2126 2039-126 . NUT M6M 24 -10 SPEC.

2007-11-23 9.1 625-3254.024A 1 (2)
SLEWING GEAR ASSEMBLY SET
5 6
2 540 Nm
1
3
391 0247-801
625-3254.024
2007-11-23 9.1 625-3254.024A 2 (2)
SLEWING GEAR ASSEMBLY SET

000 1 391 0247-801 SLEWING GEAR ASSEMBLY SET
001 X . SLEWING GEAR See mechanical specification
002 24 2121 2030-678 . SCREW M6S 20 x 70 -10.9; DIN 933
003 24 487 2826-009 . WASHER
005 1 487 7218-002 . NIPPLE
006 1 2152 2151-178 . SEALING

2007-11-22 9.1 625-3254.022A 1 (2)
SLEWING GEAR ASSEMBLY
3 dl
135 Nm 6
1 dl
391 0279-801
625-3254.022
2007-11-22 9.1 625-3254.022A 2 (2)
SLEWING GEAR ASSEMBLY

000 1 391 0279-801 SLEWING GEAR ASSEMBLY
001 X . SLEWING GEAR See mechanical specification
002 1 188 1223-801 . HYDRAULIC MOTOR SEE FIG. 625-2205.010
004 4 487 2826-004 . WASHER
006 4 2121 2541-540 . SCREW MC6S 12 x 40 -12.9

2008-06-27 9.1 625-3255.034 1 (2)
SLEWING GEAR
40
360 361 362 363
289 1855-801
625-3255.034 /0
Weight 360 kg
2008-06-27 9.1 625-3255.034 2 (2)
SLEWING GEAR
000 1 289 1855-801 SLEWING GEAR MODULE 16
040 1 875 13004-127 . DRIVE IN, COMPLETE SEE FIG. 625-3256.007
360 1 875 13006-001 . PLUG, MAGNETIC M22
361 1 875 13007-001 . SEALING
362 3 875 13006-002 . PLUG M22
363 3 875 13007-001 . SEALING

2008-09-22 9.1 625-3256.007B 1 (2)
DRIVE IN, COMPLETE
59 7
46 Nm 22
64 65
69
60 61
75 76
95
96
97 98
606 607
80 Nm 20
621 622
1000000081890
50 40 30 41 43 70
Disc arrangement,
item 97 + 98
Motor side
Outer discs
Center line
Inner discs
Gear side
875 13004-127
625-3256.007 /B
Weight 34 kg
2008-09-22 9.1 625-3256.007B 2 (2)
DRIVE IN, COMPLETE

000 1 875 13004-127 DRIVE IN, COMPLETE
007 1 875 13027-006 . MOTOR FLANGE
020 17 2121 2532-554 . SCREW MC6S 12x110 -8.8 FZB; DIN 912
022 12 2121 2532-515 . SCREW MC6S 10x120 -8.8 FZB; DIN 912
030 1 875 13011-001 . BEARING
040 1 875 13012-002 . CIRCLIP
041 1 875 13012-001 . CIRCLIP
043 2 875 13012-015 . CIRCLIP
050 1 875 13007-002 . SHAFT SEALING
059 1 875 13015-009 . O-RING 126 x 3.0
060 1 875 13006-003 . PLUG M10
061 1 875 13007-007 . SEALING
064 1 875 13006-004 . PLUG M18
065 1 875 13007-008 . SEALING
069 1 875 13008-001 . VENTILATION FILTER M10; 0.04 bar
070 3 875 13014-012 . SHIM
075 16 875 13002-001 . SPRING Change all springs at the same time
076 16 875 13002-002 . SPRING Change all springs at the same time
095 1 875 13003-011 . PRESSURE UNIT
096 1 875 13028-002 . DISC CARRIER
097 9 875 13001-001 . MULTIPLE DISC, OUTER Change all discs at the same time
098 7 875 13001-002 . MULTIPLE DISC, INNER Change all discs at the same time
606 1 875 13008-018 . OIL DIPSTICK M18; 0.2 bar
607 1 875 13007-008 . SEALING
621 1 875 13006-010 . PLUG M22
622 1 875 13007-001 . SEALING

2012-12-20 9.2 625-4935.217A 1 (2)
PUMP UNIT
NOTE 12
When replacing electric
motor, also order:
- Centre gearwheel.
- Distance spacer(s).
- Washer.
- Screw.
For ordering article no,
see separate spare part 72 11
illustration for Gear box.
330 Nm
47
48
330 Nm
13
6
17 17
Slewing
61
5 16 15
Hoisting 47
330 Nm
5
61 14
Luffing
16
330 Nm 47
5
61 Hoisting 59
61
330 Nm 49
45
49
1196619 67 Nm
625-4935.217 330 Nm
2012-12-20 9.2 625-4935.217A 2 (2)
PUMP UNIT
000 1 1196619 PUMP UNIT
005 3 289 6004-801 . HYDRAULIC PUMP SEE FIG. 625-4945.062
006 1 289 6005-801 . HYDRAULIC PUMP SEE FIG. 625-4945.063
011 1 388 3580-801 . FLUSH AND UNLOADING UNIT SEE FIG. 625-7449
012 1 390 5126-801 . ELECTRIC MOTOR
013 1 390 6453-801 . GEAR BOX SEE FIG. 625-4940.027
014 1 390 2422-801 . VANE PUMP SEE FIG. 625-4945.037
015 1 390 7952-801 . DISTANCE PIECE SEE FIG. 625-4963.012
016 2 390 7953-801 . DISTANCE PIECE SEE FIG. 625-4963.013
017 2 1202481 . PRESSURE SENSOR
045 2 2121 2032-538 . SCREW M6S 12 x 35 -8.8 FZB; DIN 933
047 12 2121 2032-674 . SCREW M6S 20 x 50 -8.8 FZB; DIN 933
048 2 2121 2032-678 . SCREW M6S 20 x 70 -8.8 FZB
049 4 2121 2032-682 . SCREW M6S 20 x 90 -8.8 FZB
059 2 2151 2052-178 . WASHER TBRB 13 x 24 FZB
061 8 2151 2052-192 . WASHER TBRB 21 x 36 FZB
072 4 2197 2525-055 . RUBBER BUSHING

2005-01-27 9.2 625-4940.027B 1 (2)
GEAR BOX
2005-01-27 9.2 625-4940.027B 2 (2)
GEAR BOX
000 1 390 6453-801 GEAR BOX Ratio 0.6531
020 1 875 21401-003 . GEAR WHEEL Z = 49
030 2 875 21401-004 . GEAR WHEEL Z = 32
040 2 875 21402-002 . HUB
050 1 875 21407-001 . SPACER
060 1 875 21406-001 . WASHER
070 2 875 21406-003 . WASHER
100 4 875 21404-002 . BEARING
110 2 2152 2115-837 . O-RING 150.0 x 3.0 - NBR - 70 IRHD
120 2 875 21403-004 . CIRCLIP DIN 471
130 2 875 21403-002 . CIRCLIP DIN 471
140 2 875 21403-005 . CIRCLIP DIN 472
160 2 875 21408-001 . KEY
170 1 2121 2032-674 . SCREW M6S 20 x 50 -8.8 FZB; DIN 933
180 1 875 21405-001 . PIN 6 x 30
190 1 875 21411-001 . PLUG M42
200 1 875 21409-001 . OIL SIGHT GLASS R 3/4
210 1 875 21410-001 . SEALING
220 1 875 21410-002 . SEALING

2010-04-01 9.2 625-4945.062A 1 (2)
HYDRAULIC PUMP
289 6004-801
625-4945.062
2010-04-01 9.2 625-4945.062A 2 (2)
HYDRAULIC PUMP
000 1 289 6004-801 HYDRAULIC PUMP
001 1 391 1550-801 . SERVO VALVE SEE FIG. 625-4948.011

2010-04-01 9.2 625-4945.063A 1 (2)
HYDRAULIC PUMP
289 6005-801
625-4945.063
2010-04-01 9.2 625-4945.063A 2 (2)
HYDRAULIC PUMP
000 1 289 6005-801 HYDRAULIC PUMP
001 1 391 1550-801 . SERVO VALVE SEE FIG. 625-4948.011

2009-04-24 9.2 625-4948.011 1 (2)
SERVO VALVE
391 1550-801
625-4948.011
2009-04-24 9.2 625-4948.011 2 (2)
SERVO VALVE
000 1 391 1550-801 SERVO VALVE

2003-02-04 9.2 625-4945.037 1 (2)
VANE PUMP
2003-02-04 9.2 625-4945.037 2 (2)
VANE PUMP
001 1 390 2422-801 VANE PUMP
002 1 490 4186-801 . GASKET SET

2006-09-08 9.2 625-4963.012 1 (2)
DISTANCE PIECE
2006-09-08 9.2 625-4963.012 2 (2)
DISTANCE PIECE
000 1 390 7952-801 DISTANCE PIECE
001 1 390 7952-001 . PUMP FLANGE
003 1 390 7952-003 . SPLINES CAGE
004 1 390 7952-004 . O-RING
006 2 390 7952-006 . O-RING
007 4 390 7952-007 . SCREW MC6S 12 x 40 -8.8

2006-09-08 9.2 625-4963.013 1 (2)
DISTANCE PIECE
2006-09-08 9.2 625-4963.013 2 (2)
DISTANCE PIECE
000 1 390 7953-801 DISTANCE PIECE
001 1 390 7953-001 . PUMP FLANGE
002 1 390 7953-002 . PUMP RING
003 1 390 7953-003 . SPLINES CAGE
004 1 390 7953-004 . O-RING
005 1 390 7953-005 . O-RING
006 2 390 7953-006 . O-RING
007 4 390 7953-007 . SCREW MC6S 12 x 30 -10.9
008 4 390 7953-009 . SCREW M20 x 80 -8.8

2011-08-17 9.2 625-5740.040 1 (2)
OIL COOLER
3 22 16
4
1
100
1198527
625-5740.040 /0
Weight 88 kg
2011-08-17 9.2 625-5740.040 2 (2)
OIL COOLER
000 1 1198527 OIL COOLER
001 1 1221116 . FAN WHEEL COVER
002 1 1221112 . ELEMENT COVER
003 1 1221110 . COOLER ELEMENT
004 1 1221115 . FAN WHEEL
006 1 1221118 . ELECTRIC MOTOR
007 2 1221125 . FOOT
016 2 2183 2022-122 . LIFTING EYE BOLT M12; DIN 580
022 2 1221124 . SEALING STRIP
100 1 1221119 . ASSEMBLY KIT Incl. screws, nuts and washers

2013-03-18 9.3 625-5740.048A 1 (2)
OIL COOLER ASSEMBLY
5 10 12
4 9
16
11
7
4x
1236187
625-5740.048
2013-03-18 9.3 625-5740.048A 2 (2)
OIL COOLER ASSEMBLY

001 1 1236187 . OIL COOLER ASSEMBLY
002 1 1240432 . BRACKET
003 1 1236188 . BRACKET
004 4 2126 2634-122 . LOCKING NUT M6LM 12 - A2-70
004 1 2121 2034-540 . SCREW M6S 12 x 40 -A2-70
005 1 2121 2034-501 . SCREW M6S 10 x 50 -A2-70
006 3 2121 2034-455 . SCREW M6S 8 x 30 -A2-70
007 7 2151 2027-178 . WASHER BRB 13 x 24 -A2
008 6 2151 2027-164 . WASHER BRB 8.4 x 16 -A2
009 1 2151 2054-178 . WASHER TBRSUB 13 x 36 FZB
010 4 2151 2054-173 . WASHER TBRSUB 10.5 x 28 FZV
012 2 2126 2634-120 . LOCKING NUT M6LM 10 - A2-70
013 2 2126 2634-118 . LOCKING NUT M6LM 8 - A2-70
016 4 2121 2034-542 . SCREW M6S 12 x 50 -A2-70

2012-12-13 9.3 625-5740.049 1 (2)
OIL COLER ASSEMBLY
1219505
625-5740.049
2012-12-13 9.3 625-5740.049 2 (2)
OIL COLER ASSEMBLY

000 1 1219505 OIL COLER ASSEMBLY
001 1 1198527 . OIL COOLER SEE FIG. 625-5740.040
002 1 2528 2512-635 . COUPLING

2006-09-18 9.3 625-5865.033A 1 (2)
OIL TANK ASSEMBLY

2006-09-18 9.3 625-5865.033A 2 (2)
OIL TANK ASSEMBLY

000 1 189 3870-801 OIL TANK ASSEMBLY
004 1 5692 4700-803 . LEVEL AND TEMPERATURE GUARD
005 1 289 1598-801 . DIRECTION VALVE
006 1 390 5254-801 . HEATER
007 1 389 2828-801 . AIR FILTER WITH DIPSTICK
008 1 2529 2563-151 . HOSE CONNECTION
009 1 390 3178-801 . COVER
011 1 5695 1000-063 . THERMOMETER Glued w. Bostic 10 or similar
013 1 490 3471-801 . VALVE PLATE
032 6 2152 2151-228 . SEAL RING
035 1 2515 6044-220 . HYDRAULIC HOSE L= 2200 mm
053 1 2541 2506-117 . VEDGE VALVE 1 1/4"
054 1 2541 4129-113 . BALL VALVE
055 1 2541 4130-050 . BALL VALVE

2013-03-18 9.3 625-6102.609A 1 (2)
CRANE HOUSE ASSEMBLY
21
17
16 15
20
18 19
14
13
9
5 6
8
4
10 11
2
7
12
1236391 22
625-6102.609
2013-03-18 9.3 625-6102.609A 2 (2)
CRANE HOUSE ASSEMBLY

000 1 1236391 CRANE HOUSE ASSEMBLY
002 X . HOISTING WINCH ASSEMBLY SEE TABLE OF CONTENTS SECTION 9.1
003 X . LUFFING WINCH ASSEMBLY SEE TABLE OF CONTENTS SECTION 9.1
004 1 289 1944-801 . WINCH MOUNTING SET SEE FIG. 625-2250.008
005 1 289 3393-801 . SLACK WIRE DEVICE, MOUNT.
006 1 289 3396-801 .. SLACK WIRE DEVICE SEE FIG. 625-6250.023
007 1 289 5323-801 . LIMIT SWITCHES BOX SEE FIG. 625-6245.635
008 1 289 5449-801 . LIMIT SWITCHES BOX SEE FIG. 625-6245.643
009 X . OIL TANK ASSEMBLY SEE TABLE OF CONTENTS SECTION 9.3
010 X . SLEWING GEAR ASSEMBLY SEE TABLE OF CONTENTS SECTION 9.1
011 2 391 0247-801 . SLEWING GEAR ASSEMBLY SET SEE FIG. 625-3254.024
012 X . JIB BEARING MOUNTING SEE TABLE OF CONTENTS SECTION 9.3
013 X . PUMP UNIT SEE TABLE OF CONTENTS SECTION 9.2
014 1 289 6807-801 . CAB INSTALLATION SEE FIG. 625-6540.034
015 X . OIL COOLER ASSEMBLY SEE TABLE OF CONTENTS SECTION 9.2
016 1 1236187 . OIL COOLER ASSEMBLY SEE FIG. 625-5740.048
017 X . CRANE TOP MOUNTING SEE TABLE OF CONTENTS SECTION 9.3
018 X . VENTILATION FAN SEE TABLE OF CONTENTS SECTION 9.3
019 1 1239312 . VENTILATION FAN ASSEMBLY SET SEE FIG. 625-6625.028
020 1 390 3274-801 . COVER MOUNTING SEE FIG. 625-6169.005
021 1 390 7581-801 . PROTECTIVE PLATE MOUNT. SEE FIG. 625-6459.051
022 X . SLEWING BEARING MOUNTING SEE SLEWING SPECIFICATION

2011-11-25 9.3 625-6122.048A 1 (2)
SLEWING SPECIFICATION
CRANE
FOUNDATION
490 8453-801
625-6122.048
2011-11-25 9.3 625-6122.048A 2 (2)
SLEWING SPECIFICATION
000 1 490 8453-801 SLEWING SPECIFICATION
001 1 1189737 . SLEWING BEARING 20 x greasing nipples. Roller bearing
004 1 1189942 . SLEWING BEARING MOUNTING SEE FIG. 625-6123.004
005 1 1189965 . SLEWING BEARING YARD MOUNTING SEE FIG.625-6124.004

2012-08-07 9.3 625-6123.004A 1 (2)
SLEWING BEARING MOUNTING
1189942
625-6123.004
2012-08-07 9.3 625-6123.004A 2 (2)
SLEWING BEARING MOUNTING

000 1 1189942 SLEWING BEARING MOUNTING
001 115 1184927 . STUD M30x285; Special requirements
002 115 2126 2039-130 . NUT M6M 30; Special requirements.

2013-03-11 9.3 625-6124.004B 1 (2)
SLEWING BEARING YARD MOUNTING
1189965
625-6124.004
2013-03-11 9.3 625-6124.004B 2 (2)
SLEWING BEARING YARD MOUNTING

000 1 1189965 SLEWING BEARING YARD MOUNTING
001 115 390 9268-011 . STUD M30x300; Special requirements.
002 115 1205599 . WASHER
003 115 2126 2039-130 . NUT M6M 30; Special requirements.

2010-05-24 9.3 625-6169.005A 1 (2)
COVER MOUNTING
2010-05-24 9.3 625-6169.005A 2 (2)
COVER MOUNTING
000 1 390 3274-801 COVER MOUNTING
001 1 390 3282-801 . COVER ASSEMBLY SEE FIG. 625-6169.006
002 4 2121 2034-455 . SCREW M6S 8 x 30 -A4 -80
003 4 2151 2027-164 . WASHER RB 8.4 x 16 -A4
004 4 2126 2634-118 . LOCKING NUT M6M 8 -A4-80

2003-01-30 9.3 625-6169.006 1 (2)
COVER ASSEMBLY
2003-01-30 9.3 625-6169.006 2 (2)
COVER ASSEMBLY
000 1 390 3282-801 COVER ASSEMBLY
001 1 390 3282-001 . COVER
002 1 389 1581-802 . HANDLE
003 1 1856 2160-001 . SEAL STRIP L= 2010
004 2 389 1903-004 . HINGE
005 6 2121 2034-451 . SCREW M6S 8 x 20 -A4-80
006 6 2151 2027-164 . WASHER RB 8.4 x 16 -A4
007 6 2126 2634-118 . NUT M6M 8 -A4-80

2008-07-10 9.3 625-6170.045A 1 (2)
JIB BEARING MOUNTING
8
6
4
3
2
5
390 6852-801
625-6170.045
2008-07-10 9.3 625-6170.045A 2 (2)
JIB BEARING MOUNTING

000 1 390 6852-801 JIB BEARING MOUNTING
001 1 289 1905-001 . SHAFT
002 1 390 6853-801 . JIB BEARING HOUSING SEE FIG. 625-6170.046
003 12 487 2826-002 . WASHER
004 1 489 6412-001 . COVER
005 1 490 3578-001 . SPACER
006 12 2121 2030-630 . SCREW M6S 16 x 50 -10.9
007 2 2152 2115-529 . O-RING
008 1 2545 2110-003 . GREASE NIPPLE AM 10 x 1 -A2-50

2004-09-14 9.3 625-6170.046 1 (2)
JIB BEARING HOUSING

2004-09-14 9.3 625-6170.046 2 (2)
JIB BEARING HOUSING

000 1 390 6853-801 JIB BEARING HOUSING
001 1 289 1904-001 . BEARING HOUSING
002 2 388 9574-001 . RING
003 2 388 9575-001 . WASHER
004 24 487 2826-002 . WASHER
005 6 489 3362-001 . CLIP
006 1 490 4616-801 . BEARING
009 12 2121 2030-648 . SCREW M6S 16 x 150 -10.9
010 12 2126 2038-124 . NUT M6M 16 -10; 235 Nm
011 2 2152 2115-543 . O-RING
012 2 2186-2187-170 . V-RING V-170A

2010-08-10 9.3 625-6244.070 1 (2)
JIB TOP MOUNTING
18
9
22
22
9
18
12
10
Notice!
Shaft must be mounted correctly,
grease holes downwards.
1194150
625-6244.070
2010-08-10 9.3 625-6244.070 2 (2)
JIB TOP MOUNTING

000 1 1194150 JIB TOP MOUNTING
006 1 390 5330-001 . SHAFT
008 2 118 5110 . SPACER
009 4 489 5334-002 . LOCK WASHER
010 7 490 4086-801 . WIRE SHEAVE
012 1 1185527 . SPACER
018 4 2121 2034-628 . SCREW M6S 16 x 40 -A2-70
022 7 2545 2110-003 . GREASE NIPPLE AM 10 x 1 -A2-50

2011-12-07 9.3 625-6245.635B 1 (2)
LIMIT SWITCHES BOX
22 26 27
23 24
31
14 15
16 17
32
18 19 20 21
25
289 5323-801
625-6245.635 /B
2011-12-07 9.3 625-6245.635B 2 (2)
LIMIT SWITCHES BOX

000 1 289 5323-801 LIMIT SWITCHES BOX
001 1 875 15017-012 . CAM DISC WITH ARM, COMPLETE 30° - 55°
014 6 875 15001-001 . MICRO SWITCH 1A
015 2 875 15001-002 . THREADED STUD WITH NUTS M3. Cut to right length.
016 1 875 15003-023 . COVER, COMPLETE Incl. screws and sealing.
017 1 875 15003-002 .. SEALING L = 2000 mm
018 4 2121 2034-457 .. SCREW M6S 8 x 35 -A2-70
019 4 2126 2034-118 .. NUT M6M 8 - A2-70
020 4 2151 2027-164 .. WASHER BRB 8.4 x 16 -A2
021 4 2126 2432-118 .. CAP NUT MHM 8 -6 FZB
022 1 875 15012-013 . WORM GEAR, COMPLETE Incl. screws. Ratio 50:1.
023 1 875 15006-008 . SHAFT COUPLING, COMPLETE
024 1 875 15008-005 . KEY 4 x 4 x 16
025 2 875 15002-003 . CABLE GLAND WITH NUT
026 2 875 15009-003 . SCREW T6SS 4 x 6 -A2
027 1 875 15006-013 . SHAFT
031 1 ENCODER Ordered separately.

2007-12-13 9.3 625-6245.643 1 (2)
LIMIT SWITCHES BOX
22 33
23 24
32
1
14 15
2
16 17 5
8
18 19 20 21
9
289 5449-801 25 31 10
625-6245.643 /0
2007-12-13 9.3 625-6245.643 2 (2)
LIMIT SWITCHES BOX

000 1 289 5449-801 LIMIT SWITCHES BOX
014 10 875 15001-001 . MICRO SWITCH 1A
015 2 875 15001-002 . THREADED STUD WITH NUTS M3. Cut to right length.
016 1 875 15003-028 . COVER, COMPLETE Incl. screws and sealing.
017 1 875 15003-002 .. SEALING L = 2000 mm
018 4 2121 2034-457 .. SCREW M6S 8 x 35 -A2-70
019 4 2126 2034-118 .. NUT M6M 8 - A2-70
020 4 2151 2027-164 .. WASHER BRB 8.4 x 16 -A2
021 4 2126 2432-118 .. CAP NUT MHM 8 -6 FZB
022 1 875 15012-005 . WORM GEAR, COMPLETE Incl. screws. Ratio 50:1.
023 1 875 15006-008 . SHAFT COUPLING, COMPLETE
024 1 875 15008-002 . KEY 4 x 4 x 20
025 2 875 15002-002 . CABLE GLAND WITH NUT
031 1 875 15018-001 . PLAIN BEARING

2009-06-15 9.3 625-6248.001B 1 (2)
LIMIT SWITCHES BOX, MOUNT.

2009-06-15 9.3 625-6248.001B 2 (2)
LIMIT SWITCHES BOX, MOUNT.

000 1 489 6415-801 LIMIT SWITCHES BOX, MOUNT.
002 3 2122 2519-378 . SCREW MSK6SS 6 x 40 -A4
003 3 2151 2027-156 . WASHER BRB 6.7 x 14 -A2
004 3 2126 2034-116 . NUT NYLOC - M6M 6 -A4-80

2004-10-13 9.3 625-6250.023 1 (2)
SLACK WIRE DEVICE

2004-10-13 9.3 625-6250.023 2 (2)
SLACK WIRE DEVICE

000 1 289 3396-801 SLACK WIRE DEVICE
001 1 288 2344-801 . SUPPORT
002 1 288 2345-801 . BRACE
003 1 288 2346-801 . BRACE
004 2 388 3290-004 . LIMIT SWITCH PART
005 2 489 5947-001 . SPRING
006 2 489 4601-001 . SCREW
007 2 489 4604-001 . SPACER
008 18 490 4586-001 . ROLLER
009 4 490 4587-001 . WASHER
010 2 490 4591-001 . SCREW
011 20 488 8518-014 . WASHER
012 2 489 6172-001 . SHAFT
013 2 2184 4024-546 . LINK SCREW M12 x 80 FZB
014 2 2121 2032-544 . SCREW M6S 12 x 60 -8.8 FZB
015 8 2121 2532-339 . SCREW MC6S 5 x 40 -8.8 FZB
016 4 2121 2032-331 . SCREW M6S 5 x 20 -8.8 FZB
017 6 2126 2032-122 . NUT M6M 12 -8 FZB
018 6 2126 2636-124 . LOCKING NUT M6M 16 -8 FZB; DIN 982
019 4 2151 2022-185 . WASHER BRB 17 x 30 FZB
020 8 2151 2022-196 . WASHER BRB 23 x 40 FZB
021 4 2114 2014-201 . SPLIT PIN SP 4 x 40 -A4
022 1 5661 4116-512 . LIMIT SWITCH, HOISTING
023 1 5661 4126-001 . LIMIT SWITCH

2006-03-06 9.3 625-6275.004C 1 (2)
CRANE JIB, YARD MOUNTING
489 5409-801
625-6275.004
2006-03-06 9.3 625-6275.004C 2 (2)
CRANE JIB, YARD MOUNTING

000 1 489 5409-801 CRANE JIB, YARD MOUNTING
001 8 388 7147-009 . SCREW M6S 30 x 210 -10.9 spec.
002 8 490 3816-008 . WASHER

2010-08-10 9.3 625-6408.112 1 (2)
CRANE JIB MOUNTING
1194148
625-6408.112
2010-08-10 9.3 625-6408.112 2 (2)
CRANE JIB MOUNTING

000 1 1194148 CRANE JIB MOUNTING
002 1 1194150 . JIB TOP MOUNTING SEE FIG. 625-6244.070

2010-10-01 9.3 625-6459.070 1 (2)
CRANE TOP ASSEMBLY
19
16
25
13
2
9
18 7
15
9
7 12
25
19
16
12
20
17 16
19
25
14
9
25
10
11
16
19
1195411
625-6459.070
2010-10-01 9.3 625-6459.070 2 (2)
CRANE TOP ASSEMBLY

000 1 1195411 CRANE TOP ASSEMBLY
001 1 289 1841-001 . SHAFT
002 1 289 1842-001 . SHAFT
007 6 490 4086-801 . WIRE SHEAVE
009 3 1184786 . SPACER
010 1 1184788 . SPACER
011 1 490 3620-001 . COVER
012 2 490 3621-001 . COVER
013 1 489 5323-001 . COVER
014 1 489 4345-004 . LOCKING PLATE
015 4 489 5334-001 . LOCK WASHER
016 8 489 5334-002 . LOCK WASHER
017 2 2154 2233-192 . LOCK WASHER
018 4 2121 2034-495 . SCREW M6S 10 x 30 -A4-80
019 8 2121 2034-628 . SCREW M6S 16 x 40 -A4-80
020 2 2121 2034-672 . SCREW M6S 20 x 40 -A4-80
025 8 2545 2110-003 . GREASE NIPPLE A-M 10 x 1 -A2-50

2007-01-17 9.3 625-6459.051 1 (2)
PROTECTIVE PLATE MOUNT.
4 3 2
390 7581-801
625-6459.051
2007-01-17 9.3 625-6459.051 2 (2)
PROTECTIVE PLATE MOUNT.

000 1 390 7581-801 PROTECTIVE PLATE MOUNT.
001 1 390 7582-001 . PROTECTIVE PLATE
002 6 2121 2034-542 . SCREW M6S 12 x 50 -A2 -70
003 6 2151 2054-178 . WASHER TBRSUB 13 x 36 FZB
004 6 2126 2634-122 . NUT M6M 12 -A2 -70

92-02-19 9.3 625-6509A 1 (2)
INCLINOMETER, C
92-02-19 9.3 625-6509A 2 (2)
INCLINOMETER, C
000 1 388 0176-801 INCLINOMETER, C
001 1 488 7233-001 . INCLINOMETER
002 3 2121 2254-378 . SCREW MCS 6 x 40 -5.8 G
003 11 2126 2032-116 . NUT M6M 6 -8 FZB
004 1 488 7511-001 . BRACKET
005 5 2151 2022-153 . WASHER BRB 6.4 x 12 G
006 2 2121 2034-370 . SCREW M6S 6 x 20 -A2-70
007 2 2151 2025-153 . WASHER BRB 6.4 x 12 SSt

2009-04-09 9.3 625-6540.034 1 (2)
CAB INSTALLATION
5
1
3 7 8
289 6807-801
625-6540.034
2009-04-09 9.3 625-6540.034 2 (2)
CAB INSTALLATION
000 1 289 6807-801 CAB INSTALLATION
001 1 190 0115-801 . CAB ASSEMBLY SEE FIG. 625-6545.068
002 3 489 5395-801 . BRACKET
003 3 489 5154-003 . SHAFT
004 1 488 9225-001 . WASHER
005 1 489 2844-001 . RUBBER MOULDING L = 9000 mm
006 1 2121 2034-536 . SCREW M6S 12 x 30 -A4 -80
007 3 2151 2027-192 . WASHER RB 21 x 37 -A4
008 6 2114 2014-201 . SPLIT PIN SP 4 x 40 -A4

2009-04-09 9.3 625-6545.068 1 (2)
CAB ASSEMBLY
190 0115-801
625-6545.068
2009-04-09 9.3 625-6545.068 2 (2)
CAB ASSEMBLY
000 1 190 0115-801 CAB ASSEMBLY
004 1 289 2251-801 . CAB CUPOLA ASSEMBLY SEE FIG. 625-6560.007
005 1 390 8573-801 . CAB DOOR ASSEMBLY SEE FIG. 625-6546.008
013 1 390 4053-801 . EMERGENCY DOOR ASSY SEE FIG. 625-6546.001
016 1 488 3152-801 . VENTILATOR, C
020 2 490 3825-801 . LOCKING PLATE
021 12 489 3492-001 . SHIM
039 12 2121 2550-339 . SCREW MC6S 5 x 40 -A4-80
041 11 2121 2550-370 . SCREW MC6S 6 x 20 -A4 -80
042 6 2121 2550-374 . SCREW MC6S 6 x 30 -A4-80
047 18 2126 2634-114 . LOCKING NUT M6M 5 -A4 -80
048 17 2126 2634-116 . LOCKING NUT M6M 6 -A4-80
056 18 2151 2027-146 . WASHER RB 5.3 x 10 -A4
057 8 2151 2027-156 . WASHER BRB 6.7 x 14 -A4

2012-05-07 9.3 625-6560.007B 1 (2)
CAB CUPOLA ASSEMBLY
/B
2012-05-07 9.3 625-6560.007B 2 (2)
CAB CUPOLA ASSEMBLY

000 1 289 2251-801 . CAB CUPOLA ASSEMBLY
001 1 189 2327-001 .
002 1 387 6167-803 . SLIDE WINDOW
003 1 388 0223-001 . GLASS
004 1 388 0145-002 . GLASS
005 1 388 0145-003 . GLASS
006 2 388 0145-004 . GLASS
007 X 487 2152-001 . RUBBER MOULDING L=16000mm
008 X 487 2153-001 . LOCKING LIST L=16000mm
009 1 488 7400-001 . HOLDER
010 4 488 7601-001 . HOLDER
012 17 2126 2034-116 . NUT M6M 6 -A4-80
013 15 2121 2844-374 . SCREW MVBF 6 x 30 -A4-80
015 X 1236 2273-001 . SEALING

2006-10-30 9.3 625-6546.008 1 (2)
CAB DOOR ASSEMBLY

2006-10-30 9.3 625-6546.008 2 (2)
CAB DOOR ASSEMBLY

000 1 390 8573-801 CAB DOOR ASSEMBLY
001 1 289 4337-001 . DOOR
003 1 390 8574-801 . DOOR LOCK

2002-06-26 9.3 625-6546.001 1 (2)
EMERGENCY DOOR ASSY

2002-06-26 9.3 625-6546.001 2 (2)
EMERGENCY DOOR ASSY

000 1 390 4053-801 EMERGENCY DOOR ASSY
001 1 390 4054-001 . WINDOW
002 2 389 1581-801 . HANDLE
003 2 489 5392-801 . HINGE
004 6 2121 2636-331 . SCREW MFS 5 x 20 -A4-80
005 6 2126 2634-114 . NUT M6M 5 -A4 -80
006 6 2151 2027-146 . WASHER BRB 5.3 x 10 -A4
007 1 489 2006-801 . EYE BOLT WITH WIRE
008 X 1236 2135-021 . SEALING COMPOUND

2005-05-10 9.3 625-6561.001C 1 (2)
WINDSCREEN CLEANER
2005-05-10 9.3 625-6561.001C 2 (2)
WINDSCREEN CLEANER
000 1 387 6227-802 WINDSCREEN CLEANER
010 1 6179 2151-280 . WIPER MOTOR
011 1 387 6227-920 .. MOUNTING SET For shaft ø20
012 1 387 6227-916 .. MOUNTING SET For shaft ø16
030 1 6179 2153-700 . WIPER BLADE L = 700 mm
090 1 6179 2152-600 . ARM L = 600 mm
101 2 2126 2032-118 . NUT M6M 8 -8 FZB
102 2 2154 2016-164 . SPRING WASHER FBB 8,2 FZB

2013-01-28 9.3 625-6625.028 1 (2)
VENTILATION FAN ASSEMBLY SET
3 4 5 6
2 4 5 6
1239312
625-6625.028
2013-01-28 9.3 625-6625.028 2 (2)
VENTILATION FAN ASSEMBLY SET

000 1 1239312 VENTILATION FAN ASSEMBLY SET
002 1 288 0945-801 . TUB FOR FAN
003 8 2121 2032-459 . SCREW M6S 8 x 40 -8.8 FZB
004 20 2126 2636-118 . LOCKING NUT M6M 8 -8 FZB; DIN 982
005 20 2151 2058-165 . WASHER TBRSB 8.4 x 26 FZB
006 XX 1236 2296-020 . SEAL STRIP 19 x 2

2010-10-22 9.3 625-6625.015A 1 (2)
VENTILATION FAN
388 9464-801
625-6625.015
2010-10-22 9.3 625-6625.015A 2 (2)
VENTILATION FAN
000 1 388 9464-801 VENTILATION FAN

2012-10-22 9.3 625-7013.126A 1 (2)
LIFTING BLOCK
Important!
When replacing genuine parts,
an overload test of the complete
unit has to be done.
New certificate to be issued. 12
See instruction 6.000.1 E.
13
1, 2, 3
5, 6
16
15
14
17
15
20, 21
18
22, 23
7, 8
11 10
1205161
625-7013.126 /A
Weight 1.170 kg
2012-10-22 9.3 625-7013.126A 2 (2)
LIFTING BLOCK
000 1 1205161 LIFTING BLOCK SWL 36 tonnes.
001 1 875 12401-022 . SHEAVE, COMPLETE Incl. bearing and lock rings.
002 1 875 12054-004 .. BEARING
003 2 875 12062-003 .. LOCK RING
004 2 875 12009-007 . SPACER
005 1 875 12404-021 . SHAFT, COMPLETE Incl. retainer, screw, nipple.
006 1 2545 2011-025 .. GREASE NIPPLE A-M10 x 1 FZB; DIN 71412
007 1 875 12413-010 . SWIVEL, COMPLETE
009 2 875 12073-007 . SHACKLE
010 1 875 12001-027 . HOOK, COMPLETE Incl.safety latch kit.
011 1 875 12064-003 .. SAFETY LATCH KIT Incl. spring, screw, nut.
012 1 875 12408-011 . PROTECTION CAP, COMPLETE Incl. screws.
013 2 875 12406-029 . SPACER, COMPLETE Incl. spacer tube, screw, nut.
014 1 875 12409-011 . CABLE LEADER, COMPLETE Incl. screws, nuts.
015 4 1223541 . SPACER, COMPLETE Incl. spacer tube, screw, nut.
016 2 2183 2022-126 . LIFTING EYE BOLT M20 FZV; DIN 580
017 1 875 12407-003 . CASING, COMPLETE Incl. screws.
018 1 1238136 . CROSSLINK

2003-03-18 9.4 625-7207.006 1 (2)
VALVE UNIT
2003-03-18 9.4 625-7207.006 2 (2)
VALVE UNIT
000 1 289 1639-801 VALVE UNIT
001 1 189 1665-801 . VALVE BLOCK
002 2 289 1598-801 . DIRECTION VALVE SEE FIG. 625-7322.048
003 1 488 9601-802 . JOINT COUPLING
006 8 2121 2541-341 . SCREW MC6S 5 x 30 -12,9
007 1 2152 2118-217 . O-RING
010 2 2528 2512-615 . COUPLING
011 1 2528 2512-617 . COUPLING
012 1 2528 2512-622 . COUPLING
013 1 2528 2512-623 . COUPLING
014 2 2528 3426-151 . COUPLING
015 1 2528 3632-222 . COUPLING
016 1 2528 3633-215 . COUPLING
017 2 2528 3633-222 . COUPLING
018 1 2528 3634-210 . COUPLING
019 1 2528 3635-151 . COUPLING
020 1 2528 3635-220 . COUPLING
021 1 2529 2558-111 . CONNECTING NIPPLE R 3/8
022 1 2541 4129-113 . BALL VALVE VBS-R 1/2
023 4 2522 2105-018 . PLUG VSTI G1/8-ED

2003-02-06 9.4 625-7207.007 1 (2)
VALVE UNIT
2003-02-06 9.4 625-7207.007 2 (2)
VALVE UNIT
000 1 289 2557-801 VALVE UNIT
001 1 189 1665-001 . VALVE BLOCK
004 1 489 2571-803 . MANOMETER CONNECTION
006 8 2121 2541-341 . SCREW MC6S 5 x 30 -12,9
008 1 2528 2512-609 . COUPLING
009 2 2528 2512-615 . COUPLING
010 1 2528 2512-617 . COUPLING
011 1 2528 2512-623 . COUPLING
012 1 2528 2592-622 . COUPLING
013 1 2528 2592-615 . COUPLING
014 1 2528 3421-150 . COUPLING
015 2 2528 3426-151 . COUPLING
016 1 2528 3426-221 . COUPLING
017 1 2528 3633-215 . COUPLING
018 1 2528 3635-220 . COUPLING
019 1 2529 2558-111 . CONNECTING NIPPLE
020 1 2541 4129-113 . BALL VALVE
024 1 2528 3634-215 . ADJUSTABLE COUPLING

94-09-15 9.4 625-7287C 1 (2)
FLUSHING VALVE
94-09-15 9.4 625-7287C 2 (2)
FLUSHING VALVE
000 1 388 3579-801 FLUSHING VALVE
001 1 489 3705-802 . GASKET SET
002 2 2152 2151-206 .. SEAL RING INCLUDED IN GASKET SET
003 2 2152 2118-406 .. O-RING INCLUDED IN GASKET SET

94-09-15 9.4 625-7291C 1 (2)
UNLOADING UNIT
94-09-15 9.4 625-7291C 2 (2)
UNLOADING UNIT
000 388 3576-801 UNLOADING UNIT
001 1 388 3575-001 . SPRING SLEEVE CAN NOT BE SUPPLIED SEPARATELY
002 1 287 8772-001 . VALVE HOUSING CAN NOT BE SUPPLIED SEPARATELY
003 2 388 3574-001 . PISTON CAN NOT BE SUPPLIED SEPARATELY
004 388 3576-005 . SPRING CAN NOT BE SUPPLIED SEPARATELY
005 1 489 3061-001 . SPRING SEAT CAN NOT BE SUPPLIED SEPARATLY
006 1 2152 2151-215 . SEAL RING
007 1 2522 4502-111 . PLUG
008 1 2522 4502-110 . PLUG
009 1 2522 4502-113 . PLUG

2005-11-22 9.4 625-7314.007A 1 (2)
FILTER UNIT, INLET

2005-11-22 9.4 625-7314.007A 2 (2)
FILTER UNIT, INLET

000 1 189 1558-801 FILTER UNIT, INLET
001 1 . FILTER
002 1 390 2604-001 . BLOCK OUTLET
003 1 . COVER
004 4 . SCREW UC6S 1/2 x 4"
005 1 389 1673-801 . CHECK VALVE 0,2 bar
006 1 . WASHER
007 2 . O-RING
008 1 875 22002-002 . SEAL KIT

2005-11-22 9.4 625-7314.008A 1 (2)
FILTER UNIT OUTLET

2005-11-22 9.4 625-7314.008A 2 (2)
FILTER UNIT OUTLET

000 1 189 1559-801 FILTER UNIT OUTLET
001 1 . FILTER
002 1 390 2689-801 . BLOCK INLET
003 1 390 2691-801 . BLOCK OUTLET
004 1 390 2690-801 . BLOCK PILOT
005 2 . COVER
006 4 . SCREW UC6S 1/2 x 4"
007 4 . SCREW UC6S 1/2 x 1 1/2"
008 4 . SCREW UC6S 1/2 x 7"
009 1 . PRESSURE RELIEF VALVE
010 1 . DIN-CARTRIDGE
011 4 . SCREW UC6S 1/2 x 2"
012 1 389 1673-801 . CHECK VALVE 0,2 bar
013 1 389 1673-802 . CHECK VALVE 7 bar
014 4 . O-RING
015 1 . SEAL
016 1 875 22002-002 . SEAL KIT

2003-02-11 9.4 625-7322.047 1 (2)
DIRECTION VALVE
2003-02-11 9.4 625-7322.047 2 (2)
DIRECTION VALVE
001 1 289 1597-801 DIRECTION VALVE
002 2 490 3450-801 . COIL
003 1 490 3452-801 . GASKET SET

2003-02-11 9.4 625-7322.048 1 (2)
DIRECTION VALVE
2003-02-11 9.4 625-7322.048 2 (2)
DIRECTION VALVE
001 1 289 1598-801 DIRECTION VALVE
002 1 490 3450-801 . COIL
003 1 490 3452-801 . GASKET SET

1996-09-30 9.4 625-7449B 1 (2)
FLUSH AND UNLOADING UNIT

1996-09-30 9.4 625-7449B 2 (2)
FLUSH AND UNLOADING UNIT

000 1 388 3580-801 FLUSH AND UNLOADING UNIT
001 1 388 3579-801 . FLUSHING VALVE SEE FIG 625-7287
002 1 388 3576-801 . UNLOADING UNIT SEE FIG 625-7291
003 4 2121 2541-497 . SCREW MC63 10 x 35 -12.9
004 1 2521 2135-205 . COUPLING
005 1 2152 2151-194 . SEAL RING INCLUDED IN GASKET SET
006 1 2152 2151-181 . SEAL RING INCLUDED IN GASKET SET
007 1 489 3059-801 . CHECK-RESTRICTION VALVE
008 1 2528 2512-610 . COUPLING
009 1 2522 4506-191 . PROTECTIVE PLUG
010 1 489 3705-803 . GASKET SET

1999-04-22 9.4 625-7802.004 1 (2)
UNLOADING UNIT
1999-04-22 9.4 625-7802.004 2 (2)
UNLOADING UNIT
000 1 388 3576-803 UNLOADING UNIT
001 1 388 3575-001 . SPRING SLEEVE CAN NOT BE SUPPLIED SEPARATELY
002 1 287 8772-001 . VALVE HOUSING CAN NOT BE SUPPLIED SEPARATELY
003 1 388 3574-001 . PISTON CAN NOT BE SUPPLIED SEPATATELY
004 1 388 3576-005 . SPRING CAN NOT BE SUPPLIED SEPARATELY
005 1 489 3061-001 . SPRING SEAT CAN NOT BE SUPPLIED SEPARATELY
006 1 2152 2151-215 . SEAL RING
007 2 2522 4502-111 . PLUG
008 1 2522 4502-110 . PLUG
009 1 2521 2135-205 . COUPLING
010 1 2152 2151-194 . SEAL RING
011 1 2152 2151-181 . SEAL RING
012 1 489 3059-801 . CHECK-RESTRICTION VALVE
013 1 2528 2512-610 . COUPLING
014 1 2522 4506-191 . PROTECTIVE PLUG

2007-08-06 9.4 625-7951.005 1 (2)
ACCUMULATOR
Old design
New design
1 2
388 0362-803
625-7951.005
2007-08-06 9.4 625-7951.005 2 (2)
ACCUMULATOR
000 1 388 0362-803 ACCUMULATOR Charge Press. 2.0 MPa (20 bar)
001 1 488 7888 . GASKET SET Valid for old design
002 1 490 3956 . GASKET SET Valid for new design

2003-06-10 9.4 625-7970G 1 (2)
HYDRAULIC HOSES
When ordering hydraulic hoses, see marking on each

hose
Article number for hydraulic hoses
Quality demands hydraulic hoses, see page 2

2003-06-10 9.4 625-7970G 2 (2)
HYDRAULIC HOSES
MacGREGOR Cranes
Quality and Manufacturing Demands - Hydraulic Hoses
MacGREGOR Cranes are certified holders according to ISO 9001, and therefore the
hydraulic hoses with couplings supplied by us must have type approval on all ma-
terial.
Standard rubber hose for our 1" high pressure hoses are made for a working
pressure of 380 bar.
The hoses are pressure-proof tested according to the DIN norms.
100% of the high pressure hoses are proof tested and leakage tested at 450 bar
during minimum 30 seconds and maximum 60 seconds. This pressure corresponds
to 1.3 times the working pressure.
100% of the hoses are marked with MacGREGOR Cranes part numbers, for quick
and correct identification.
100% of all high pressure hoses are, furthermore, marked with manufacturing date.
100% of all hoses are carefully cleaned after testing. They are cleaned by means of
cavitation with a mixture of water and an anti-corrosive agent.
The cleanliness after washing is equal to, or better than, class 9 according to NAS
norm 1638.
Factors Influencing the Lifetime of Hydraulic HOSES

Pressure - temperature - bending radius - damage caused by outside factors.
Sunlight and artificial light are also harmful to hydraulic hoses.

2011-01-21 9.4 625-7994.001 1 (2)
PRES. SWITCHES EXTRA OVERLOAD
288 1436-801
625-7994.001
2011-01-21 9.4 625-7994.001 2 (2)
PRES. SWITCHES EXTRA OVERLOAD

000 1 288 1436-801 PRES. SWITCHES EXTRA OVERLOAD
001 2 388 3600-801 . PRESSURE SWITCH, C

2012-02-09 9.5 625-8563.059A 1 (2)
DRIVER´S DESK
7 8
14 72 73 9 10
15 74
11 12
13
124 0827-801
625-8563.059
2012-02-09 9.5 625-8563.059A 2 (2)
DRIVER´S DESK
000 1 124 0827-801 DRIVER´S DESK
002 1 390 8558-001 . DRIVER SEAT
003 1 224 0483-801 . CONTROL PANEL RIGHT CT3 SEE FIG. 625-8597.041
004 1 414 6792-801 . CONTROLLER SEE FIG. 625-8596
006 1 314 3980-801 . SIREN
007 1 5915 4262-002 . ARMATURE 60 W
008 1 5911 4145-060 . LAMP BULB 220 V 60 W E27
009 1 387 6227-802 . WINDSCREEN CLEANER SEE FIG. 625-6561.001
010 1 388 9799-001 . COVER
011 3 5217 4837-240 . SCREW CONNECTION
012 3 5217 4838-240 . BULKHEAD HOUSING
013 1 314 4244-801 . CABIN HEATER
014 1 287 4867-002 . ARM REST
015 1 288 1058-001 . ARM REST
072 1 488 7461-001 . SIGN
073 1 488 6906-001 . SIGN
074 1 490 6220-001 . SIGN

2012-03-07 9.5 625-8564.029 1 (2)
EL INST. CRANE HOUSE
93 95
93 95
93 95
90
124 0438-801
625-8564.029
2012-03-07 9.5 625-8564.029 2 (2)
EL INST. CRANE HOUSE

000 1 124 0438-801 EL INST. CRANE HOUSE
090 1 5375 4231-024 . SWITCH
093 4 5912 4102-020 . FLUORESCENT TUBE 18 W
095 2 5915 4315-001 . ARMATURE 2 x 18 W

2012-05-30 9.5 625-8567.045B 1 (2)
EL. INST. JIB LIGHT, CRANE
124 0647-801
625-8567.045
2012-05-30 9.5 625-8567.045B 2 (2)
EL. INST. JIB LIGHT, CRANE

000 1 124 0647-801 EL. INST. JIB LIGHT, CRANE
001 1 1189971 . CABLE L=7m
002 2 2121 2550-370 . SCREW MC6S 6 x 20 -A2-70
003 2 2126 2634-116 . LOCKING NUT M6LM 6 - A2-70
004 2 2151 2027-156 . WASHER BRB 6.7 x 14 -A2
005 1 2166 2051-823 . CABLE GLAND Pr 22.5
007 1 5388 4121-002 . CONNECTION BOX

2012-05-16 9.5 625-8567.046D 1 (2)
EL. INST. JIB LIGHT (PACKING)
25 26
2 14 13 12
124 0648-801
625-8567.046
2012-05-16 9.5 625-8567.046D 2 (2)
EL. INST. JIB LIGHT (PACKING)

000 1 124 0648-801 EL. INST. JIB LIGHT (PACKING)
002 2 1233451 . SCREW
005 1 1190048 . CABLE L = 40m
012 2 2126 2634-122 . LOCKING NUT M6LM 12 - A2-70
013 2 2151 2027-178 . WASHER BRB 13 x 24 -A2
014 10 2151 2027-185 . WASHER BRB 17 x 30 -A2
025 1 5911 4529-410 . HALOGEN LAMP 1000W
026 1 5921 2141-101 . FLOOD LIGHT

2011-06-27 9.5 625-8567.065 1 (2)
EL. INST.WARN. LIGHT JIB PACK
18 19
124 0652-801
625-8567.065
2011-06-27 9.5 625-8567.065 2 (2)
EL. INST.WARN. LIGHT JIB PACK

000 1 124 0652-801 . EL. INST.WARN. LIGHT JIB PACK
018 1 5911 4528-066 . BULB 60W
019 1 5915 4251-021 . ARMATURE

2011-06-27 9.5 625-8567.066 1 (2)
EL.INST.WARN.LIGHT JIB (CRANE)
124 0651-801
625-8567.066
2011-06-27 9.5 625-8567.066 2 (2)
EL.INST.WARN.LIGHT JIB (CRANE)

000 1 124 0651-801 EL.INST.WARN.LIGHT JIB (CRANE)
006 1 5388 4121-002 . CONNECTION BOX

2012-01-05 9.5 625-8567.074 1 (2)
EL. INST. WARNING LIGHT TOP
124 0654-801
625-8567.074
2012-01-05 9.5 625-8567.074 2 (2)
EL. INST. WARNING LIGHT TOP

000 1 124 0654-801 EL. INST. WARNING LIGHT TOP
012 1 5911 4528-066 . BULB 60W
013 1 5915 4251-021 . ARMATURE

91-12-10 9.5 625-8591C 1 (2)
CONTROLLER, HOISTING
91-12-10 9.5 625-8591C 2 (2)
CONTROLLER, HOISTING
000 1 314 2005-802 CONTROLLER, HOISTING
001 1 414 5396-801 . POTENTIOMETER WITH CARD
002 1 414 2081-801 BELLOWS WITH BRACE SPARE PART NO: 662 0034-000
91-11-14 9.5 625-8592C 1 (2)
CONTROLLER, LUFFING/SLEWING
91-11-14 9.5 625-8592C 2 (2)
CONTROLLER, LUFFING/SLEWING
000 1 314 2006-802 CONTROLLER, LUFFING/SLEWING
001 2 414 5396-801 . POTENTIOMETER WITH CARD
002 1 414 2081-801 BELLOWS WITH BRACE SPARE PART NO: 662 0034-000
1997-10-07 9.5 625-8596 1 (2)
CONTROLLER
1997-10-07 9.5 625-8596 2 (2)
CONTROLLER
000 1 414 6792-801 CONTROLLER
001 1 414 7054-001 . COVER
002 1 314 2006-802 . CONTROLLER, LUFFING/SLEWING SEE FIG. 625-8592
003 1 2152 2067-018 . COVER PLATE
004 1 2121 2550-331 . SCREW MC6S 5 x 20 A4-80
005 2 2126 2634-114 . NUT M6M 5 -A4 -80
006 1 2151 2027-146 . WASHER RB 5.3 x 10 -A4

2008-12-04 9.5 625-8597.041 1 (4)
CONTROL PANEL RIGHT CT3
224 0483-801
625-8597.041
2008-12-04 9.5 625-8597.041 2 (4)

000 1 224 0483-801 CONTROL PANEL RIGHT CT3
001 1 224 0206-001 . COVER
002 1 314 2005-802 . CONTROLLER, HOISTING SEE FIG. 625-8591
005 1 424 0640-801 . SWITCH WITH KEY
006 1 424 0641-801 . SWITCH WITH HANDLE
011 1 424 0643-001 . LENS WITH SYMBOL
012 1 424 0643-002 . LENS WITH SYMBOL
013 1 424 0643-003 . LENS WITH SYMBOL
014 1 424 0643-004 . LENS WITH SYMBOL
015 1 424 0643-005 . LENS WITH SYMBOL
016 1 424 0643-006 . LENS WITH SYMBOL
018 1 424 0643-022 . LENS WITH SYMBOL
028 1 424 0646-001 . SIGN
030 1 424 0644-002 . SIGN
032 1 424 0644-005 . HEADLINE SIGN
033 1 424 0644-006 . HEADLINE SIGN
038 7 5298 2070-100 . PILOT LAMP RED
045 1 5372 2206-003 . CONTACT BLOCK
046 1 5372 2206-002 . CONTACT BLOCK
048 1 5372 2203-001 . PUSH BUTTON
049 1 5372 2204-102 . PUSH BUTTON
050 1 5372 2202-101 . EMERGENCY STOP
053 2 5375 4340-102 . SWITCH
056 1 5375 4341-112 . SWITCH WITH KEY

2008-12-04 9.5 625-8597.041 3 (4)
224 0483-801
625-8597.041
2008-12-04 9.5 625-8597.041 4 (4)

058 1 5672 4245-002 . CIRCUIT BREAKER
062 11 2152 2069-225 . BLANKING PLUG
063 1 2152 2067-018 . COVER PLATE
064 1 2121 2550-331 . SCREW MC6S 5 x 20 -A4-80
066 2 2126 2634-114 . LOCKING NUT M6M 5 -A4 -80
068 1 2151 2027-146 . WASHER RB 5.3 x 10 -A4

2011-01-26 9.5 625-8597.061 1 (2)
EL. INST JIB LIGHT (CABIN)
324 2043-801
625-8597.061
2011-01-26 9.5 625-8597.061 2 (2)
EL. INST JIB LIGHT (CABIN)

000 1 324 2043-801 EL. INST JIB LIGHT (CABIN)
001 1 5372 2207-011 . CONTACT BLOCK
003 1 5372 2205-142 . PUSH BUTTON

2011-01-27 9.5 625-8597.062 1 (2)
EL. INST. DECK LIGHT (CABIN)
2 3
14 15
324 1722-801
625-8597.062
2011-01-27 9.5 625-8597.062 2 (2)
EL. INST. DECK LIGHT (CABIN)

000 1 324 1722-801 EL. INST. DECK LIGHT (CABIN)
002 1 5372 2205-143 . PUSH BUTTON
003 1 5372 2207-011 . CONTACT BLOCK
014 2 5921 2141-101 . FLOOD LIGHT
015 2 5911 4529-410 . HALOGEN LAMP 1000W

2011-01-27 9.5 625-8597.063 1 (2)
EL. INST. FORCE LIMIT GRAB (CA
324 1724-801
625-8597.063
2011-01-27 9.5 625-8597.063 2 (2)
EL. INST. FORCE LIMIT GRAB (CA

000 1 324 1724-801 EL. INST. FORCE LIMIT GRAB (CA
001 1 5375 4340-131 . SWITCH
002 1 424 0644-014 . SYMBOL

2011-01-28 9.5 625-8597.064 1 (2)
EL. INST. PMS (CABIN)
324 1723-801
625-8597.064
2011-01-28 9.5 625-8597.064 2 (2)
EL. INST. PMS (CABIN)

000 1 324 1723-801 EL. INST. PMS (CABIN)
001 1 5372 2207-003 . CONTACT BLOCK
003 1 5372 2205-112 . PUSH BUTTON

2011-06-27 9.5 625-8597.081 1 (2)
CABIN DISPLAY ASSEMBLY
1182879
625-8597.081
2011-06-27 9.5 625-8597.081 2 (2)

000 1 1182879 CABIN DISPLAY ASSEMBLY
004 1 1183160 . CABLE

2011-06-08 9.5 625-8597.088 1 (2)
EL. INST. TILT SWITCH (CAB)
324 2260-801
625-8597.088
2011-06-08 9.5 625-8597.088 2 (2)
EL. INST. TILT SWITCH (CAB)

000 1 324 2260-801 EL. INST. TILT SWITCH (CAB)
001 1 424 0643-018 . LINS WITH SYMBOL
003 1 5298 2070-102 . PILOT LAMP YELLOW

2011-10-04 9.5 625-8597.090 1 (2)
EL.INST.AIR CIRCULAT FAN (CAB)
8 9
1213193
625-8597.090
2011-10-04 9.5 625-8597.090 2 (2)
EL.INST.AIR CIRCULAT FAN (CAB)

000 1 1213193 EL.INST.AIR CIRCULAT FAN (CAB)
001 1 1213220 . FAN
004 1 5388 2131-020 . CONNEXION BOX
008 1 5375 4340-102 . SWITCH
009 1 424 0644-008 . SIGN

2012-01-04 9.5 625-8597.100 1 (2)
EL. INST. WARNING LIGHT (CAB)
324 1791-801
625-8597.100
2012-01-04 9.5 625-8597.100 2 (2)
EL. INST. WARNING LIGHT (CAB)

000 1 324 1791-801 EL. INST. WARNING LIGHT (CAB)
001 1 5375 4340-102 . SWITCH
002 1 424 0644-009 . HEADLINE SIGN

2012-12-11 9.5 625-8598.170 1 (6)
EL CABINET (C1/C2)
1236710
625-8598.170
2012-12-11 9.5 625-8598.170 2 (6)
EL CABINET (C1/C2)
000 1 1236710 EL CABINET (C1/C2)
001 1 224 0351-801 . CABINET BASIC
002 1 4762 4221-200 . POWER SUPPLY
003 1 4762 4202-102 . POWER SUPPLY
004 1 324 1165-801 . TRANSFORMER 1-PHASE
006 1 324 1656-801 . ASSEMBLY CT2-PLATE SEE FIG. 625-8607.010
008 1 2152 2069-225 . BLANKING PLUG
010 1 414 1941-801 . THERMISTOR
012 1 5639 4161-202 . IMPULSE RELAY
013 2 2638 3100-160 . COPPER BRAID
014 2 2638 3100-224 . COPPER BRAID
015 2 2638 3100-288 . COPPER BRAID
019 6 2121 2550-329 . SCREW MC6S 5 x 16 -A4-80
020 4 2121 2032-453 . SCREW M6S 8 x 25 -8.8 FZB
024 4 2126 2032-118 . NUT M6M 8 -8 FZB
028 4 2151 2022-164 . WASHER BRB 8.4 x 16 FZB; DIN 125A
029 4 2151 2027-146 . WASHER BRB 5.3 x 10 -A4
032 1 5632 4209-003 . TIME RELAY
036 1 2663 4660-001 . CONNECTION PLINTH
040 5 2669 4160-015 . END HOLDER
044 2 5218 3107-111 . AUXILIARY CONTACT
047 3 5354 4130-220 . CONTACTOR RELAY
050 1 5237 4190-035 . FLANGE
054 1 5340 2011-501 . CIRCUIT BREAKER

2012-12-11 9.5 625-8598.170 3 (6)
EL CABINET (C1/C2)
1236710
625-8598.170
2012-12-11 9.5 625-8598.170 4 (6)
EL CABINET (C1/C2)
058 1 5349 2002-105 . CONNECTOR
062 1 5349 2011-105 . COVER
066 2 5354 4130-400 . CONTACTOR RELAY
070 5 5354 4137-501 . AUXILIARY CONTACT BLOCK
074 3 5354 4273-009 . CONTACTOR
080 1 5372 2202-101 . EMERGENCY STOP
082 1 5381 4280-001 . ELECTRICAL OUTLET
083 1 5672 4212-140 . FUSE
084 1 5572 4105-063 . MOTOR SWITCH
085 1 5572 4105-630 . MOTOR SWITCH
086 3 2669 4180-060 . FUSE TERMINAL
087 1 5672 4212-120 . FUSE 5x20 2A
090 1 5591 2153-150 . STAR DELTA STARTER
091 2 5347 4262-116 . CIRCUIT BREAKER
092 1 5632 4209-002 . TIME RELAY
093 1 5632 4209-004 . TIME RELAY
095 1 5347 4262-106 . CIRCUIT BREAKER
096 1 5347 4262-202 . CIRCUIT BREAKER
097 1 5347 4262-306 . CIRCUIT BREAKER
099 1 7635 4113-200 . THERMOSTAT
101 1 5349 2021-102 . KNOB
103 1 5692 4740-024 . HOUR METER

2012-12-11 9.5 625-8598.170 5 (6)
EL CABINET (C1/C2)
1236710
625-8598.170
2012-12-11 9.5 625-8598.170 6 (6)
EL CABINET (C1/C2)
105 3 2689 4121-009 . SLEEVE
106 1 5354 4133-221 . CONTACTOR RELAY
107 1 7426 4200-050 . SURGE SUPPRESSOR

2000-03-28 9.5 625-8599.020 1 (2)
RELAY CARD WITH LEDs

2000-03-28 9.5 625-8599.020 2 (2)
RELAY CARD WITH LEDs

000 1 324 0089-801 RELAY CARD WITH LEDs
006 4 414 4667-007 . SPACER
007 4 2121 2254-220 . SCREW MCS 3 x 6 -5.8 FZB
008 4 2126 2636-110 . NUT NYLOC-M6M 3 -8 FZB
009 4 2154 2022-124 . WASHER AZ 3.2 FZB

2008-11-17 9.5 625-8607.010 1 (2)
ASSEMBLY CT2-PLATE
6 4 3
50 50
50
459
458 457
455 453
451 449
Hardware Hardware Hardware Hardware 448 438
xxx xxxx-xxx xxx xxxx-xxx xxx xxxx-xxx xxx xxxx-xxx 437 436
435 434
Error MP SP Error MP SP Error MP SP Error MP SP 433 432
431 430
Input Output Input Output Input Output Input Output
07 18 27 33 36 33 36 33 36 429 427
07 07 07 426 425
08 19 28 39 43 39 43 39 43
09 20 29 34 37 34 37 34 37 420 419
08 08 08 418 417
10 26 30 40 45 40 45 40 45
415 414
11 49 31 09 31 09 31 09 31
30 30 30 412 411
12 51 32 10 32 10 32 10 32
408 407
13 56 33 19 Sw19 19 Sw19 19 Sw19
404 403
Encoder 14 57 34 20 Sw20 55 20 Sw20 55 20 Sw20 55
402 401
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
50 50
24V 38 26 27 26 27 26 27
42 359
Com 39 58 59 58 59 58 59
358 357
C1 R1 40 49 17 29 49 17 29 49 17 29
356 355
C2 R2 53 51 18 53 51 18 53 51 18 53
353 349
C3 R3 61 52 54 52 54 52 54
348 338
C4 MP 57 C1 R1 57 C1 R1 57 C1 R1
337 336
C2 MP C2 MP C2 MP
335 334
Com Com Com
333 332
331 330
CC MC MC MC
329 327
326 325
320 319
318 317
315 314
Sc Ho Lu Sl
312 311
308 307
Select / Info Select / Info Select / Info Select / Info 304 303
Normal 302 301
Up Up Up Up
Rigg OL-Test
Down / Exit Down / Exit Down / Exit Down / Exit
50 50
50 50
259 258
257 256
50 42
255 254
PC COM PC COM PC COM PC COM 50 42
253 252
50 42
251 249
50 42
248 247
50 42
Software Software Software Software 245 243
98 97
241 240
96 95
239 238
94 93
237 236
92 91
235 234
90 89
233 232
SC IO SC Supervisory HO Hoisting LU Luffing SL Slewing AU Auxiliary IO Input/Output 88 87
231 230
C28
C36
C44
C52
C17
C6
86 85
C3 C3 A1 C1 A1 C1 A1 C1 A1 C1 A1 C1 A1 C1 229 227
SC_C3 1
IO_C3 1
SC_C1 1
HO_C1 1
LU_C1 1
SL_C1 1
AU_C1 1
IO_C1 1
84 83
226 225
82 81
HO_A1
AU_A1
SC_A1
LU_A1
SL_A1
IO_A1
220 219
80 79
218 217
78 77
P115 P1115 P108 P208 P308 P408 P508 P1108 215 214
76 75
P101 P201 P301 P401 P501 P1101 212 211
C29
C37
C45
C53
C18
74 73
C7
C4 C4 A2 C2 A2 C2 A2 C2 A2 C2 A2 C2 A2 C2 210 209
72 71
1
SC_C2 1
HO_C2 1
LU_C2 1
SL_C2 1
AU_C2 1
IO_C2 1
208 207
70 69
HO_A2
SC_C4
AU_A2
SC_A2
LU_A2
SL_A2
IO_C4
IO_A2
204 203
68 67
202 201
66 65
P109 P209 P309 P409 P509 P1109 50 50
64 63
P116 P1116 P102 P202 P302 P402 P502 P1102 50 50
62 61
485.2 485.2 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1 42 42
60 23
SC_485.2 1
IO_485.2 1
SC_485.11
HO_485.11
LU_485.11
SL_485.11
AU_485.11
IO_485.1 1
42 42
22 21
HO_A3
AU_A3
SC_A3
LU_A3
SL_A3
161 160
IO_A3
20
158 157
19
P103 P110 P210 P310 P403 P410 P510 P1110 153 151
P203 P303 P503 P1103 18
149 143
P117 P1117
C12
C34
C33
C42
C41
C50
C49
C58
C57
C23
C22
C11
17
141 137
485.3 485.3 Sp SSI Sp SSI Sp SSI Sp SSI Sp SSI Sp SSI 16
SC_485.3 1
IO_485.3 1
136 135
15
134 133
14 13
HO_SSI
AU_SSI
SC_SSI
LU_SSI
SL_SSI
HO_Sp
IO_SSI
132 131
AU_Sp
SC_Sp
LU_Sp
SL_Sp
IO_Sp
12 11
130 128
10 9
127 126
P118 P1118 8 7
125 119
6 5
118 117
P107 P106 P207 P206 P307 P306 P407 P406 P507 P506 P1107 P1106 4 3
116 115
2 1
114 113
112 111
110 109
108 107
104 103
102 101
324 1656-801
625-8607.010
2008-11-17 9.5 625-8607.010 2 (2)
ASSEMBLY CT2-PLATE
000 1 324 1656-801 ASSEMBLY CT2-PLATE CC-3000
003 3 . MC-CARD See table of contents section 9.5
004 1 . CC-CARD See table of contents section 9.5
006 1 324 1663-X . MEMORY CARD X = Crane manufacturing No.

2010-10-08 9.5 625-8650.001 1 (2)
EL. INST. IMPULS RELAY
224 0116-801
625-8650.001
2010-10-08 9.5 625-8650.001 2 (2)
EL. INST. IMPULS RELAY

000 1 224 0116-801 EL. INST. IMPULS RELAY
002 1 5639 4161-202 . IMPULSE RELAY

2011-01-24 9.5 625-8650.002 1 (2)
EL. INST. CARD RELAY (CT2)
224 0118-801
625-8650.002
2011-01-24 9.5 625-8650.002 2 (2)
EL. INST. CARD RELAY (CT2)

000 1 224 0118-801 EL. INST. CARD RELAY (CT2)
002 1 324 0089-801 . RELAY CARD WITH LED’S SEE FIG. 625-8599.020
2012-09-20 9.5 625-8650.003A 1 (2)
EL. INST. PMS ELECTRIC CABINET
2 6
224 0119-801
625-8650.003
2012-09-20 9.5 625-8650.003A 2 (2)
EL. INST. PMS ELECTRIC CABINET

000 1 224 0119-801 EL. INST. PMS ELECTRIC CABINET
002 1 5354 4130-220 . CONTACTOR RELAY
006 1 2669 4160-015 . END HOLDER

2011-02-01 9.5 625-8650.004 1 (2)
EL.INST.OIL TANK HEATER (CT1)
15
3
14
2 15
224 0474-801
625-8650.004
2011-02-01 9.5 625-8650.004 2 (2)
EL.INST.OIL TANK HEATER (CT1)

000 1 224 0474-801 EL.INST.OIL TANK HEATER (CT1)
001 1 5354 4273-009 . CONTACTOR
002 1 5354 4130-220 . CONTACTOR RELAY
003 1 5572 4105-250 . MOTOR SWITCH
014 1 5218 3107-111 . AUXILIARY CONTACT
015 2 2669 4160-015 . END HOLDER

2011-02-02 9.5 625-8650.005 1 (2)
EL. INST. FORCE LIMIT GRAB CT1
1, 2
4
224 0547-801
625-8650.005
2011-02-02 9.5 625-8650.005 2 (2)
EL. INST. FORCE LIMIT GRAB CT1

000 1 224 0547-801 EL. INST. FORCE LIMIT GRAB CT1
001 1 5354 4133-221 . CONTACTOR RELAY
002 1 7426 4200-050 . SURGE SUPPRESSOR
004 1 2669 4160-015 . END HOLDER

2011-02-03 9.5 625-8650.006 1 (2)
ELECRICAL HEATER ASSEMBLY
1194462
625-8650.006
2011-02-03 9.5 625-8650.006 2 (2)
ELECRICAL HEATER ASSEMBLY

000 1 1194462 ELECRICAL HEATER ASSEMBLY
001 2 324 1353-801 . HEATING FAN

2011-02-10 9.5 625-8650.007 1 (2)
ELECTRICAL HEATER ASSEMBLY
3, 4
6
6 2 2
1194464
625-8650.007
2011-02-10 9.5 625-8650.007 2 (2)
ELECTRICAL HEATER ASSEMBLY

000 1 1194464 ELECTRICAL HEATER ASSEMBLY
001 2 5672 4248-216 . CIRCUIT BREAKER
002 2 5354 4273-016 . CONTACTOR
003 1 5375 4340-122 . SWITCH
004 1 424 0644-006 . HEADLINE SIGN
006 3 2669 4160-015 . END HOLDER

2011-03-14 9.5 625-8650.009 1 (2)
EL. INST. CT1 AMMETER
224 0110-801
625-8650.009
2011-03-14 9.5 625-8650.009 2 (2)
EL. INST. CT1 AMMETER

000 1 224 0110-801 EL. INST. CT1 AMMETER
001 1 4762 4108-400 . CURRENT TRANSFORMATOR
002 1 5697 4336-400 . AMMETER

2011-02-03 9.5 625-8655.001 1 (2)
CABIN DISPLAY
424 0715.801
625-8655.001
2011-02-03 9.5 625-8655.001 2 (2)
CABIN DISPLAY
000 1 424 0715-801 CABIN DISPLAY
001 1 5730 1003-101 . DISPLAY
002 1 424 0632-801 . USB CABLE
003 1 424 0786-801 . BUZZER CABLE

2012-12-08 9.5 625-8655.009 1 (2)
Cut cable in suitable length
1182916
625-8655.009
2012-12-08 9.5 625-8655.009 2 (2)

000 1 1182916 CABIN DISPLAY ASSEMBLY
007 1 2623 4132-101 . CAN BUS CABLE
008 1 424 0754-801 . CONNECTOR

2011-04-19 9.5 625-8750.005D 1 (2)
SLIPRING UNIT
2011-04-19 9.5 625-8750.005D 2 (2)
SLIPRING UNIT
000 1 314 3985-801 SLIPRING UNIT
011 20 875 17202-001 . SIGNAL BRUSH, COMPLETE 20 A
012 22 875 17203-001 . HOLDER
021 3 875 17201-001 . POWER BRUSH, COMPLETE 400 A
022 1 875 17201-002 . POWER BRUSH, COMPLETE 400 A, earth
101 1 875 17207-006 . POWER CABLE Slipring #101, earth
102 1 875 17207-001 . POWER CABLE Slipring #102

2012-12-07 9.5 625-8760.001 1 (2)
MC-SPARE CARD
XXXXXXX
1194171
625-8760.001
2012-12-07 9.5 625-8760.001 2 (2)
MC-SPARE CARD
000 1 1194171 MC-SPARE CARD Includes hardware and software

2012-12-07 9.5 625-8760.002 1 (2)
CC-SPARE CARD
XXXXXXX
1194172
625-8760.002
2012-12-07 9.5 625-8760.002 2 (2)
CC-SPARE CARD
000 1 1194172 CC-SPARE CARD Includes hardware and software

2008-10-30 9.7 624-2180.014 1 (2)
MOUNTING ENCODER
390 9851-801
624-2180.014
2008-10-30 9.7 624-2180.014 2 (2)
MOUNTING ENCODER
000 1 390 9851-801 MOUNTING ENCODER
001 1 490 4982-001 . TORQUE ARM
002 3 2121 2550-220 . SCREW MC6S 3 x 6 -A2-70

2008-10-30 9.7 624-2180.015 1 (2)
MOUNTING ENCODER
390 9852-801
624-2180.015
2008-10-30 9.7 624-2180.015 2 (2)
MOUNTING ENCODER
000 1 390 9852-801 MOUNTING ENCODER
001 1 490 4982-001 . TORQUE ARM
002 3 2121 2550-220 . SCREW MC6S 3 x 6 -A2-70

2012-04-10 9.7 624-2180.023A 1 (2)
ABSOLUTE ENCODER
324 1408-801
624-2180.023
2012-04-10 9.7 624-2180.023A 2 (2)
ABSOLUTE ENCODER
000 1 324 1408-801 ABSOLUTE ENCODER

2012-04-10 9.7 624-2180.025A 1 (2)
INCREMENTAL ENCODER
324 1409-801
624.2180-025
2012-04-10 9.7 624-2180.025A 2 (2)
INCREMENTAL ENCODER
000 1 324 1409-801 INCREMENTAL ENCODER

2011-05-30 9.7 624-2195.015 1 (2)
EL. INST. LOAD STEP LIMIT
1
4
7
17
2
5
7
17
1205622
624-2195.015
2011-05-30 9.7 624-2195.015 2 (2)
EL. INST. LOAD STEP LIMIT

000 1 1205622 EL. INST. LOAD STEP LIMIT
001 1 324 1408-801 . ABSOLUTE SINGLETURN ENCODER
002 1 324 1409-801 . INCREMENTAL ENCODER 5000
004 1 390 9852-801 . MOUNTING ENCODER SEE FIG. 624-2180.015
005 1 390 9851-801 . MOUNTING ENCODER SEE FIG. 624-2180.014
007 2 2623 4130-102 . SENSOR CABLE
017 2 424 0756-801 . CONNECTOR 6-POL

2011-06-08 9.7 624-2195.018 1 (2)
EL. INST. TILT SWITCH
124 0679-801
624-2195.018
2011-06-08 9.7 624-2195.018 2 (2)
EL. INST. TILT SWITCH

000 1 124 0679-801 EL. INST. TILT SWITCH
001 1 324 1648-001 . TILT SWITCH

2011-04-12 9.7 624-2196.008 1 (2)
EL. INST. EMERG. STOP PEDESTAL
1202955
624-2196.008
2011-04-12 9.7 624-2196.008 2 (2)
EL. INST. EMERG. STOP PEDESTAL

000 1 1202955 EL. INST. EMERG. STOP PEDESTAL
001 1 1200949 . SWITCH

2012-12-13 9.7 624-2460.001 1 (2)
EMERGENCY BOX
1237995
624-2460.001
2012-12-13 9.7 624-2460.001 2 (2)
EMERGENCY BOX
000 1 1237995 EMERGENCY BOX

2011-09-01 9.7 624-2492C 1 (2)
HAND PUMP
50
22 13
9
49
8
6
19
27
2
28
21
52
7
3 10
20
36
189 1952-801
624-2492
2011-09-01 9.7 624-2492C 2 (2)
HAND PUMP
000 1 189 1952-801 HAND PUMP
002 1 389 1507-801 . SINGLE ACTING PUMP
003 1 389 3862-801 . RELIEF VALVE
004 1 389 3864-801 . NEEDLE VALVE
006 1 489 3126-801 . FLOW CONTROL VALVE
008 1 489 5662-801 . NEEDLE VALVE
009 1 489 5663-001 . BUSHING
010 1 489 5901-801 . COUPLING
013 1 2121 2033-463 . SCREW M6S 8 x 60 H -8.8 FZB
027 1 2528 2773-100 . NUT
028 1 2528 2763-100 . PLUG
036 1 2522 2170-100 . PLUG
049 1 2529 2458-111 . QUICK COUPLING G 3/8"
050 1 2529 2458-116 . QUICK COUPLING G 1"
052 1 5693 4121-060 . MANOMETER

2012-12-07 9.7 624-2501 1 (2)
LIFE LINE
388 0962-801
624-2501
2012-12-07 9.7 624-2501 2 (2)
LIFE LINE
000 1 388 0962-801 LIFE LINE

2010-08-13 9.7 624-2524A 1 (2)
FIRE EXTINGUISHER, MOUNT
490 4074-801
624-2524
2010-08-13 9.7 624-2524A 2 (2)
FIRE EXTINGUISHER, MOUNT

000 1 490 4074-801 FIRE EXTINGUISHER, MOUNT
003 1 6956 2020-060 . FIRE EXTINGUISHER POWDER

GLB3030-2 2430gr NB 2253 212012.01LMW Crane 1 2 3 4

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GLB3030-2 2430gr NB 2253 212012.01LMW Crane 1 2 3 4

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Assembly and Installation Manual

IMO No.: L9576961

GENERAL 1 1.000.4 E e SAFETY INSTRUCTIONS

TECHN. DESCRIP. 2 2/12012.01LMW - TECHNICAL DATA

FUNCTION 3 3.110.122 E - HYDRAULIC FUNCTION

OPERATION 4 PM40 1879-E00 - CREW CHECKLIST BEFORE AND AFTER OPERATION

MAINTENANCE 5 5.005.55 E g MAINTENANCE CHART

MAINTENANCE 5 5.018 E c INSPECTION OF STRESSED COMPONENTS AND STRUCTURES

6.0 6.000 E e HOW TO ORDER SPARE PARTS

6.3 6.303.49 E e TROUBLESHOOTING, CRANE CONTROL SYSTEM CC3000, GLB-CRANE

6.3 6.324.1 E b PREPARATION FOR OVERLOAD (OL) TEST MODE

EXTRA EQUIPMENT 7 7.075.12 E - MacHEAVYVISOR RELEASE 3.6

SPARE PARTS 9 SEE SEPARATE TABLE OF CONTENTS

9.0 HOW TO ORDER SPARE PARTS e 6.000 E

9.1 HOISTING WINCH 189 2796-801 E/ 625-1440.047

9.2 PUMP UNIT 1196619 B/ 625-4935.217A

9.3 OIL TANK ASSEMBLY 189 3870-801 A/ 625-5865.033A

9.3 CAB ASSEMBLY 190 0115-801 A/ 625-6545.068

9.4 VALVE UNIT 289 1639-801 A/ 625-7207.006

9.5 DRIVER´S DESK 124 0827-801 B/ 625-8563.059A

9.5 EL. INST. IMPULSE RELAY 224 0116-801 A/ 625-8650.001

9.7 MOUNTING ENCODER 390 9851-801 A/ 624-2180.014

Cargo Handling Equipment

Supervision, Instructions, Signs and Warnings

Preparation for Use and Operation According to

MacGREGOR are available for full service of this

Functions, Installations and Equipment Safety Functions and Equipment

Specific safety equipment is installed and delivered

4. If there is a multiple-disc failure caused by worn d. Mechanical functions:

b. Safety belt, rescue line, safety chains:

Danger, Warning, Caution and Notice

Principles of Risk Classification

Those risks classified as DANGER sign are pre-

2. WARNING SIGNS are attached to equipment or

The danger does not exist unless protection instal-

3. CAUTION SIGNS are attached to equipment or

Any person should be able to avoid the danger.

4. NOTICE SIGNS are attached to equipment and

Responsible officers onboard must ensure that the

Alert / Warning signs

PM40 7101-E00 REPORT TO SUPERINTENDENT OR OPERATOR’S ROOM FOR PERMIT TO ENTER

This sign is at the bottom entrance to the crane foundation.

This sign is at the bottom entrance to the crane foundation.

This sign is at the bottom entrance to the crane foundation.

This sign is at the bottom entrance to the crane (twin) platform.

Attached to the crane wall surfaces close to winches.

Attached to brackets and walls of work platforms inside crane

Attached on the wall side of the crane operator’s cabin.

Attached to surfaces close to pipes inside the crane house.

PM40 7115-E00 SLIPPERY SURFACES - WATCH OUT!

Attached to electrical equipment e. g. electric main motor.

Applied on the wall side of the crane operator’s cabin.

Attached outside and inside the cabin.

Attached to surfaces close to pipes inside the crane house.

Attached to brackets and walls of work platforms inside the crane.

Attached to the crane wall surfaces close to winches.

Attached to brackets and walls of work platforms inside the crane.

Attached to the cover of slipring device in the foundation.

Fig. 1. PM40 7101-E00 Fig. 2. PM40 7102-E00

Fig. 3. PM40 7103-E00 Fig. 4. PM40 7104-E00

Fig. 5. PM40 7105-E00 Fig. 6. PM40 7106-E00

Fig. 7. PM40 7108-E00 Fig. 8. PM40 7109-E00

Fig. 9. PM40 7111-E00 Fig. 10. PM40 7112-E00