Crane Instruction Manual

INSTRUCTION MANUAL Date Project No.
Page
Dept. 230 2005-03-09 LO04062 1 (6)
TABLE OF CONTENTS
Manual No. 11139 (3 pcs), 2 CD
Certificate for
crane issued by: ILO
Certificate for
foundation issued by: LR
IMO No. L8809189
Name of ship KIRIBATI CHIEF
Newbuilding No. 1348
Shipyard Wenchong SY
Owners CNCO
Project No. LO04062
Mfg. No. 62506198 - Crane 1
Type of crane GL 6019/5022/4524/4027/3630-2
Collecting list
Crane specification
Order specification 490 4637-801/ F; El. spec 490 4643-801/ D
SAFETY DOCUMENTS
Document names written with bold letters are documents with safety aspects.
INSTRUCTION NO. REV NAME OF INSTRUCTION
GENERAL 1 1.000.2 E b SAFETY INSTRUCTIONS

1.005 E e PREFACE
1.009 E a GENERAL INSTRUCTIONS, CLEANLINESS IN HYDRAULIC SYSTEMS
1.102 E c CONVERSION FACTORS
1.518.3 ED a HYDRAULIC AND ELECTRIC SYMBOLS
TECHN. DESCRIP. 2 LO04062 TECHNICAL DATA

2.007.61 E c TECHNICAL DESCRIPTION
FUNCTION 3 3.110.102 E - HYDRAULIC FUNCTION

3.131.19 E - STARTING AND STOPPING, ELECTRIC SAFETY FUNCTIONS, SINGLE CRANES
3.142.27 E - CRANE CONTROL SYSTEM CC2000, Single Cranes with More than One Outreach
3.155 E a THERMOSTATIC CONTROLLED VENTILATION FAN
OPERATION 4 PM40 1857-E00 - CREW CHECKLIST

PM40 5500-E00 b OPERATING INSTRUCTION
PM40 6062-E00 d OPERATING INSTRUCTION
PM40 6370-E00 - CONTROLS AND INDICATORS
PM41 0001-E - EMERGENCY ESCAPE INSTRUCTIONS
PM41 0014-E00 - EMERGENCY ESCAPE INSTRUCTIONS, ROPE LADDER/FIXED LADDERS
4.620.1 E n PARKING THE CRANE, SEA STOWING, GENERAL INSTRUCTION
4.630 E - HANDLING HATCHES BY DECK CRANE
MAINTENANCE 5 5.005.58 E - MAINTENANCE CHART

5.018 E b INSPECTION OF STRESSED COMPONENTS AND STRUCTURES
5 025.2 E - CONTAMINATION SWITCH - CHIP DETECTOR
5.127.1 E - AUTOMATIC LUBRICATION SYSTEM, SLEWING BEARING
PM51 1712-E00 - LUBRICATION CHART
The Original Manufacturer of HÄGGLUNDS Cranes

INSTRUCTION MANUAL Date Project No. Page
Dept. 230 2005-03-09 LO04062 2 (6)
TABLE OF CONTENTS
MAINTENANCE 5 5.150.1 E b LUBRICATING AND MAINTENANCE

5.301.8 E - FILTERS
5.301.16 E - FILTER - EXTRA OFF LINE FILTRATION
5.302.16 E d HYDRAULIC OIL TANK
5.315 E a SAMPLING OF OIL TO VERIFY THE CLEANLINESS IN HYDRAULIC SYSTEM
5.320.2 E a EXTRA OFF-LINE FILTRATION OF HYDRAULIC SYSTEM
5.421.40 E - LUBRICANTS FOR DECK MACHINERY
SERVICE 6
6.0 6.000 E b HOW TO ORDER SPARE PARTS

6.000.1 E b STATEMENT REGARDING DELIVERY OF SPARE PARTS TO SWIVELS, LIFTING B
6.000.2 E - RETURN FORM
6.003.1 E l GLOBAL SERVICE
6.004.1 E av MacGREGOR GLOBAL SERVICES
6.005.5 E - INTRODUCTION
6.1 6.100 E b MEASURES BEFORE STARTING, DURING AND AFTER COMPLETED SERVICE/M
6.106.3 E a TROUBLE-SHOOTING CHART, OVERHEATING
6.117 E b TROUBLE SHOOTING, PUMPS
6.120.15 E c SLEWING GEARSET (PINION MODULE 14 AND 16)
6.120.64 E i HYDRAULIC MOTORS, HOISTING, LUFFING AND SLEWING CIRCUITS
6.120.89 E a WINCHES, HOISTING/LUFFING
6.121.3 E a TROUBLE-SHOOTING CHART, HYDRAULIC HIGH SPEED MOTORS
6.125.14 E - FEED PUMP UNIT
6.127.40 E b HIGH PRESSURE PUMPS
6.142.5 E a RECOMMENDATION FOR INSPECTION AND REPLACEMENT OF HYDRAULIC HO
6.189 E e HYDRAULIC PISTON ACCUMULATOR 388 0362-801, -802, -803
6.2 6.214 E h TIGHTENING TORQUES, STUDS/SCREWS AND BOLTS

6.216.64 E e ROPE REEVING DIAGRAM CRANES TYPE GL-2 (new version)
6.222.1 E a HANDLING, INSTALLATION AND MAINTENANCE OF STEEL WIRE ROPES
6.223.12 E b REPLACEMENT OF WIRES, ONE OR TWO FALL RIGGING
625/1473 E a WEAR ON WIRE SHEAVES
625/1532 E a REPLACEMENT OF WIRE ROPE TYPES
625/1560 E b LIFTING BLOCK
625/1579 E c MEASURING PROCEDURE FOR WEAR IN SLEWING BEARINGS
6.3 6.300.1 E - EMERGENCY OPERATION CARD CC2000

6.303.33 E - ELECTRONIC TROUBLESHOOTING FOR CRANE CONTROL SYSTEM CC2000, SI
414 6848 f SIGNAL OVERVIEW, CRANE CONTROL SYSTEM CC2000
414 7012 j ERROR MESSAGES, SINGLE AND TWIN CRANES, CRANE CONTROL SYSTEM C
424 0606 - CONTAMINATION LEDs, CONTAMINATION SWITCH - FUNCTION
6.305.1 E b ELECTRICAL EQUIPMENT, GENERAL MAINTENANCE
6.307.11 E b SLIP-RING UNIT
6.311.4 E - OIL LEVEL FLOAT SWITCH AND OVERHEATING PROTECTOR
6.320.288 E - LIMIT SWITCHES IN HOISTING AND LUFFING WINCH SYSTEMS
6.321.13 E a SLACK WIRE SAFETY SWITCH HOISTING AND LUFFING WINCHES
6.990.49 E - EMERGENCY LOWERING IN CASE OF COMPLETE POWER FAILURE, OPERA
EXTRA EQUIPMENT 7

INSTRUCTION MANUAL Date Project No. Page
Dept. 230 2005-03-09 LO04062 3 (6)
TABLE OF CONTENTS
APPENDICES 8
SPARE PARTS 9 SEE SEPARATE TABLE OF CONTENTS

PARTS MANUAL Date Project No. Page
Dept. 230 2005-03-09 LO04062 4 (6)
TABLE OF CONTENTS
GROUP DESCRIPTION PART NUMBER FIG
9 E 625-0014
9.0 HOW TO ORDER SPARE PARTS b 6.000 E
9.1 HOISTING WINCH, C 189 4211-801 -/ 625-1440.070

HOISTING WINCH 189 2663-801 -/ 625-1450.052A
DRIVE IN, COMPLETE 875 13004-058 -/ 625-1451.016
GEAR, COMPLETE 875 13019-066 -/ 625-1451.017
FLANGE, COMPLETE 875 13021-021 -/ 625-1451.015
HYDRAULIC MOTOR 188 1222-801 B/ 625-2205.008
LUFFING WINCH, C 189 3516-801 -/ 625-1440.064
LUFFING WINCH 189 2669-801 A/ 625-1450.058A
HYDRAULIC MOTOR 188 1221-801 B/ 625-2205.009A
WINCH MOUNTING SET 288 2710-801 B/ 625-2250.001C
SLEWING GEAR MOUNTING 390 2587-801 -/ 625-3254.011
SLEWING GEAR 289 1546-801 -/ 625-3255.013A
HYDRAULIC MOTOR 188 1223-801 A/ 625-2205.010
9.2 PUMP UNIT 189 4212-801 C/C 625-4935.137

PUMP UNIT 289 3458-801 C/ 625-4935.138
GEAR BOX 390 3433-801 B/ 625-4940.024B
HYDRAULIC PUMP 289 1833-801 B/ 625-4945.025
HYDRAULIC PUMP 289 1834-801 B/ 625-4945.026A
TANDEM ASSEMBLY KIT 388 5167-801 E/ 625-4963A
FEED PUMP UNIT 388 0364-801 H/H 625-5176C
OIL COOLER 287 8763-801 K/ 625-5738G
OIL COOLER ASSEMBLY 389 2804-801 B/ 625-5740.002A
9.3 OIL TANK ASSEMBLY 188 1591-801 G/G 625-5865.014E

CRANE HOUSE ASSY. 189 4232-801 A/ 625-6102.305
COVER MOUNTING 390 0191-801 B/ 625-6169.003A
JIB BEARING MOUNTING 389 1452-801 B/ 625-6170.020A
JIB BEARING HOUSING 389 1453-801 B/ 625-6170.021
JIB TOP MOUNTING 289 3495-801 -/ 625-6244.044
LIMIT SWITCHES BOX, HOISTING 289 2375-801 C/ 625-6245.166
LIMIT SWITCHES BOX, LUFFING 289 2377-801 C/ 625-6245.223
SLACK WIRE DEVICE 289 3396-801 -/ 625-6250.023
CRANE JIB, YARD MOUNTING 489 5409-801 A/ 625-6275.004B
CRANE JIB MOUNTING 289 3494-801 -/ 625-6408.085
CRANE TOP MOUNTING 289 3490-801 -/ 625-6459.037
INCLINOMETER, C 388 0176-801 B/B 625-6509A
CAB MOUNTING 289 2249-801 -/ 625-6540.009
CAB ASSEMBLY 189 2357-801 -/ 625-6545.048
EMERGENCY DOOR ASSY 390 4053-801 -/ 625-6546.001
CAB CUPOLA ASSEMBLY 289 2251-801 -/ 625-6560.007
WINDSCREEN CLEANER 387 6227-802 F/F 625-6561.001B
VENTILATION FAN 390 2115-801 B/ 625-6625.014
VENTILATION FAN, ASSEMBLY 289 1348-801 A/ 625-6625.016
LIFTING BLOCK 288 1423-803 C/ 625-7013.080
JIB WELDING 189 4355-801 -/ 189 4355
SLEWING BEARING 289 3491-801 -/ 289 3491

Dept. 230 2005-03-09 LO04062 5 (6)
TABLE OF CONTENTS
9.3 SLEWING BEARING YARD MOUNT. 390 0405-801 A/ 390 0405

SLEWING BEARING MOUNTING 390 6900-801 -/ 390 6900
LOAD WIRE ROPE; SEE TECHNICAL DATA 390 3922-821 V/ -
LUFFING WIRE ROPE; SEE TECHNICAL DATA 390 4274-815 M/ -
LIMIT SWITCH, HOISTING 5661 4116-512 -
LIMIT SWITCH 5661 4126-001 -
9.4 VALVE UNIT 289 1639-801 A/ 625-7207.006

VALVE UNIT 289 3269-801 -/ 625-7207.009
FLUSHING VALVE 388 3579-801 F/F 625-7287C
UNLOADING UNIT 388 3576-801 B/B 625-7291C
FILTER UNIT, INLET 188 0117-801 C/ 625-7314.001A
FILTER UNIT, OUTLET 188 0118-801 D/ 625-7314.002A
FILTER UNIT 289 3459-801 A/ 625-7314.010
DIRECTION VALVE 288 2553-801 -/ 625-7322.014
DIRECTION VALVE 289 1597-801 A/ 625-7322.047
DIRECTION VALVE 289 1598-801 -/ 625-7322.048
FLUSH AND UNLOADING UNIT 388 3580-801 C/C 625-7449B
HAND PUMP 188 0366-801 J/ 625-7454E
UNLOADING UNIT 388 3576-803 B/B 625-7802.004
ACCUMULATOR 388 0362-801 F/ 625-7951E
HYDRAULIC HOSES 625-7970G
FILTER ELEMENT 489 3104-801 C/ -
TUBING OIL COOLER 189 1011-801 -/ 189 1011
HYDRAULIC CIRCUIT DIAGRAM 189 4214 D/D 189 4214
TUBING EXTRA OVERLOAD 289 2624-801 -/ 289 2624
TUBING LOAD INDICATOR 289 3623-801 -/ 289 3623
9.5 POWER SUPPLY 324 0440-801 B/B 625-8562.008

DRIVER'S DESK 124 0239-801 B/B 625-8563.009
EL. INST. CRANE JIB LIGHT 124 0231-801 A/ 625-8567.017A
EL. INST. JIB LIGHT 124 0255-801 B/ 625-8567.019B
CONTROLLER 314 2005-802 D/ 625-8591C
CONTROLLER 314 2006-802 D/ 625-8592C
CONTROLLER PANEL 414 6792-801 A/A 625-8596
CONTROL PANEL 224 0117-801 A/ 625-8597.008
CABINET CT1/CT2 224 0166-801 -/- 625-8598.038
ASSY PLATE, CABINET CT2 (MB) 324 0212-801 C/C 625-8600.002B
SLIPRING UNIT 314 3985-801 A/ 625-8750.005B
MPC CARD W. SOFTWARE 314 3603-814 F/ -
INST.POWER/CABLE CONNECTION 324 1044-801 C/ 324 1044
ELECTRIC SYSTEM 324 1047 D/ 324 1047
9.7 LIFE LINE 388 0962-801 -/ -

EL INST ANGLE ENCODER (HOIST.) 124 0375-801 A/ 624-2195.002
EL INST ANGLE ENCODER (LUFFI.) 124 0460-801 -/ 624-2195.003
EL. INST. AUTO-PLUSSING CRANE 124 0291-801 D/ 624-2195.004
LUBRICATION SYSTEM 189 4356-801 B/ 624-2484.001
GREASE PUMP 289 3592-801 A/ 624-2484.002
LUBRICATION PUMP 390 7036-801 -/ 624-2484.003

Dept. 230 2005-03-09 LO04062 6 (6)
TABLE OF CONTENTS
9.7 FIRE EXTINGUISHER, MOUNT 490 4074-801 A/ 624-2524

EL.INST CRANE FORCE LIMIT 124 0475-801 -/ 124 0475
EL.INST.CARD RELAY (CT2) 224 0248-801 -/ 224 0248
EL INST DECK LIGHT, CAB 324 1096-801 -/- 324 1096
ADDITION SLIPRING DEVICE 324 1109-801 -/ 324 1109
EXTRA OFFLINE FILTRATION 189 4213-801 C/ 189 4213
AUTOMATIC LUBRICATION 189 4341-801 A/ 189 4341
EL INST OILFILTER PUMP (CRANE) 124 0457-801 -/ 124 0457
EL.INST OIL FILT. PUMP(CABINET) 224 0235-801 A/ 224 0235
EL INST OIL FILT. PUMP (CABIN) 324 1049-801 B/ 324 1049
EL INST AUTO GREASING,CRANE 124 0459-801 A/ 124 0459
EL INST AUTO GREAS.CABINET CT1 224 0237-801 C/ 224 0237
EL INST AUTOGREAS. ,CABIN 324 1064-801 -/ 324 1064
EL INST HAWK SENSOR, CRANE 124 0483-801 A/ 124 0483
EL INST HAWK SENSOR,CT2CABINET 224 0217-801 A/ 224 0217
EL. INST. PRESS ENCODER, CRANE 124 0323-801 -/ 124 0323
EL INST EXTRA LIGHTNING, CRANE 124 0476-801 -/ 124 0476
EMERGENCY STOPS (PACKS) 124 0477-801 -/ 124 0477
EL. INST. IMPULSE RELAY CT1 224 0116-801 -/ 224 0116
EL INST SAFETY RELAY, CT1 224 0249-801 A/ 224 0249
EL. INST. CABIN VENTILATOR 324 0609-801 B/ 324 0609
EL. INST. AIC-CARD, CT2-CABNET 324 0648-801 -/ 324 0648
EL INST HIGH SPEED LAMP,CABIN 324 0714-801 A/ 324 0714
EL INST RESET EMERG.STOP,CABIN 324 1093-801 A/ 324 1093
EL.INST OVERLOAD LAMP,CABIN 324 1171-801 -/ 324 1171
EL.INST LOAD STEP LIMIT,CABIN 324 1172-801 -/ 324 1172
COVER PLATE W. MOUNTED BUTTON,CT2 424 0400-801 D/ 424 0400

GENERAL 1.000.2 E rev.: b 2004-02-10
Safety Instructions
Cargo Handling Equipment only for its own professional services. Our product
The MacGREGOR crane is a cargo handling de- 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 signifi- tested for this application and are supplied with our
cant 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
and certified by a competent person after any of the crane systems, nor for the safe use of the crane,
substantial repair. unless original spare parts are used.
Supervision, Instructions, Signs and Warnings

Safe Operating Conditions, Proper Instructions
Proper use of this crane and its equipment is possi-
and Precautions
ble as long as the owners, users and operators main-
The responsible officer on board shall ensure that tain the crane to meet full operational standards. This
the crane is operated under safe conditions, by per- includes the replacement of signs, instructions and
sonnel familiar with its functions and operating instruc- warnings as per delivery. MacGREGOR does not ac-
tions. All safety and precautionary issues contained cept responsibility for any party who fails to ensure
in this manual must be observed. Proper instructions that this manual, signs, instructions, and warnings are
and 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.
2. Exposing persons to the risks of falling cargo.
The crane operator, authorized by the responsible
3. Overloading.
officer on board, must be familiar with all safety is-
4. Unlocking the crane or crane jib or operating the
sues contained in this Chapter and with preparation
equipment at sea without full acceptance and con-
for use and operating instructions before work is
trol of personnel and equipment safety.
started.
5. Unprofessional, intended or unintended, adjustment
of safety locks, hydraulic or electric settings.
6. Disregard of occupational and safety standards of
Maintenance and Service
work.
Prerequisite for proper use is regular maintenance
(see Chapter 5) and service (see Chapter 6).
MacGREGOR are available for full service of this

cargo crane. MacGREGOR will take responsibility
The Original Manufacturer of HÄGGLUNDS Cranes 1 (16)

GENERAL 1.000.2 E rev.: b 2004-02-10
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 equip-
and installations to allow for safe normal use, opera- ment is responsible to ensure that safety functions,
tion, care and control. This is applicable to instructed installations and equipment are maintained to opera-
personnel without specific professional education or tional standards and are not being removed, by-
certification, but working according to this manual. passed or worn to non-working condition.
Specific service and repair of the electrical, hydrau- This manual features important presentations of
lic and the mechanical functions, controls and settings safety functions, installations and equipment. A
require professional service personnel knowledgeable summary is 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 button is loacated in cabin. This action ac-
tion, e.g.: tivates safety stops and automatic lock posi-
tions.
Chapter 4 contains: 2. At twin crane operation the crane movements
Safety Precautions Checklist for Single and Twin automatically stop and Synchronizing failure
Cranes. indicator lamp lights if the hooks or jibs get
out of syncronizing position.
Chapter 5 contains, if applicable: 3. The crane has several fail-safe functions for
Inspection of Stressed Components and Structures. over-ruling or stopping the operator’s
Lubrication chart; Crane. maneuvring in the event that normal hydraulic
Lubrication chart; Twin Platform. or electrical functions fail, a sudden uncon-
Lubrication chart; Cable Winch and Stabilizing Equip- trolled movement occurs or during overspeed
ment. operation (see below).
Lubrication chart; Power Swivel. 4. There are limit switches for reducing speed of
Filters. or stopping all dangerous motions.
Handling and Checking Steel Wire Ropes.
Checking brake settings. (Valid for winches equipped b. Hydraulic functions:
with low speed motors.) 1. Hydraulic valve functions are set for exact pres-
sure. Any change in the settings adversely af-
Before maintenance and service work is started, cer- fects crane operation and must exclusively be
tain measures and procedures must be followed. set by professional service personnel (see in-
structions Hydraulic function and High pressure
Chapter 6 contains: pumps).
Measures before Starting Service/Maintenance Work. 2. Hydraulic oil pressure sensor automatically in-
Electrical Equipment, General Maintenance. dicate an overload. For safe hoisting or lower-
ing, the system automatically switch from a
highspeed movement to a lowspeed movement
or may stop the hoisting movement.
2 (16) The Original Manufacturer of HÄGGLUNDS Cranes

GENERAL 1.000.2 E rev.: b 2004-02-10
3. In case of a ruptured high-pressure oil pipe/ 4. Heat sensors located in the main electric mo-
hose or other feed pressure drops, the oil feed tors and feed pump motor stops all crane ope-
pressure will collapse. A feed pressure switch rations and activates all brakes.
stops the crane and the mechanical brakes are 5. The overcurrent protections on all electric mo-
automatically applied. tors prevent the electric motors from overload-
4. Each winch has a hydraulic motor brake valve ing.
flanged to the motor. Mounted directly to the The main electric motor and feed pump elec-
motor it also provides hydraulic braking in case tric motor overcurrent protections stop all crane
of a pipe rupture. (Valid for winches equipped operations and activates all brakes.
with low speed motors.) 6. A separate electrical feed for the cranehouse
5. If there is brake band failure, e.g. caused by lights operator’s cab and on jib, maintains func-
worn-out lining, hydraulic braking capacities by tion of lights even during feed disruption to the
the pump and motor brake systems are still a- crane operating functions. As there is not a
vailable. (Valid for winches equipped with low separate emergency illuminating system for
speed motors.) the crane (this is dependent on the ship’s sys-
6. If there is a multiple-disc failure caused by worn tems) the owner of the crane must provide a
out brake discs, sticking cylinder, brake pilot battery type flash-light for the operator’s cab.
valve or valve spool, hydraulic braking by
pumps and motor is still avaiable. (Valid for d. Mechanical functions:
winches equipped with high-speed motors). 1. Automatic sensors recognize dangerous wire
7. In case of overheating oil, a temperature sen- slacks and stop hoisting and luffing movements
sor stops the main electric motor, locking crane that threaten safe control and the equipment
operation. itself.
8. Efficient oil filters with exclusive bypass to the 2. Each working circuit has at least two inde-
hydraulic oil reservoir protects the system from pendent brake systems.
harmful oil conditions. A warning light on the Dynamic braking, deceleration, is achived by
operator's panel indicates if the filter has to be the regenerative function of motor and pump.
changed. Dirty filter might cause mal function (hydraulic braking).
to the system. True static braking (parking brakes) is pro-
9. If the hydraulic oil tank oil level drops below vided by multiple disc-brakes or band brakes.
the minimum permissible level. There are band brakes for low speed winches
A warning light on the operator’s panel is acti- and an extra mechanical pawl-brake for luffing.
vated. The mechanical brakes are automatically ac-
An indicator stops the main electric motor and tivated in the event of dangerous oil pressure.
crane functions are closed while all brake sys- High speed winches are provided with multi-
tems are automatically activated. ple disc brakes. One for each gear unit.
Each slewing gear unit is equipped with one
c. Electrical functions: multiple disc brake.
1. The crane control system protects the crane
from overload by using pressure sensors. See 2. Safety Installations
also section 3. Crane Control System CC2000..
a. Warning lights, measuring instruments and meters:
2. During a complete power failure all solenoid
1. The operator’s panel is provided with warning
valves are de-energized, causing brakes to be
lights which indicate clogged filters or low oil
activated.
level in the oil tank.
3. The electronic cabinets have power failure in-
2. During crane start-up a warning light on the
dicators. This function closes the electronic sig-
operator’s panel indicates that starting proce-
nals down which automatically activates all
dures are still running and that working condi-
mechanical brakes.

GENERAL 1.000.2 E rev.: b 2004-02-10
tions are not acceptable before the lamp goes b. Safety belt, rescue line, safety chains:
out. Maneuvres are not to be ordered before 1. For work or entry to the open-air crane top,
the warning light goes out. authorized personnel must wear a safety belt.
3. A pushbutton siren is located in the crane op- The connector hook should be anchored to rails
erator’s cabinet, allowing the operator to alert and fixed position while staying or working on
persons in the working area (e.g. against pro- crane top.
hibited riding on the load or against load move- 2. The rescue line and equipment for emergency
ments). evacuation of the crane operator must always
4. Measuring instruments and meters (e.g. for be easily accessible on the interior wall-side
checking the crane functions, adjusting valve of the crane cabin. The equipment status and
positions, and setting functional positions) are completeness must be inspected regularly by
supplied as per agreement with the crane the responsible officer onboard.
buyer/owner. Tools and equipment which are 3. The safety chains on the open-air crane top
eliminated from the original order to and work platforms inside the crane, must be
MacGREGOR are delivered at the discretion used for attendant’s safety during stay and
of the owner. work.
b. Covers and houses: c. Firefighting equipment:

1. Unauthorized visitors in the cranehouse, es- A fire extinguisher shall be made available by
pecially during crane operation, is prohibited. owner in the operator’s cabin.
The crane is a dangerous working area, and
requires special permission to enter. Instruc- The fire extinguisher is for emergency use in-
tions given by the superintendent or responsi- side the crane.
ble officer must be followed.
2. Covers for electric boxes must be opened only The equipment must be regularly inspected for
by authorized personnel. proper pressure reading at the meter and must
be serviced annually. This is to be supervised
c. Alert and warning signs: by the responsible officer on board.
The crane is equipped with a system of dan-
ger, warning, caution and notice signs. These d. Test device:
signs are presented on pages 6 - 15. At delivery, the MacGREGOR crane is
equipped 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 person-
nel.
2. Safety valves for hydraulic pressure settings
and switches for electric safety circuits are
sealed to secure correct position and trim.
Sealed equipment may be opened and posi-
tions changed only after consulting the
MacGREGOR service organization for proper
handling.

GENERAL 1.000.2 E rev.: b 2004-02-10
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 national standards. Signs of non-MacGREGOR de-
a life-threatening danger (e.g. high voltage elec- sign are not allowed. MacGREGOR does not ac-
tricity). cept responsibility for unauthorized signs.
Safety installations, covers or houses prevent ex-

Specific Presentation of Signs and Their Message
posure during normal working conditions, but can-
All signs attached to the crane are illustrated on the
not eliminate the imminent risk for any unprofes- following pages. Each sign is given a specific number
sional/non-certificated person, should the danger to which it is referred.
sign not be followed.
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 person-
nel 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 se-
vere 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.

GENERAL 1.000.2 E rev.: b 2004-02-10
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. 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
NOTICE SIGN
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 ...
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.
WARNING SIGN

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

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

PM40 7105-E00 RISK 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
wire. A safe distance from wire and drums must be maintained and adequate caution must be
regarded.
WARNING SIGN
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

GENERAL 1.000.2 E rev.: b 2004-02-10
PM40 7107-E00 RISK OF GETTING CAUGHT BETWEEN BRAKE CYLINDER AND WALL - WATCH OUT!
During service or replacement work, the serviceman may be exposed to the power of released
brake cylinders.
WARNING SIGN
Attached at brake cylinders, narrow spaces near them, at work platforms

PM40 7108-E00RISK 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.
WARNING SIGN The authorized visitor must be aware of the risk and be cautious to avoid being seriously hurt.
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 7110-E00 UNIT UNDER CONSTANT SPRING TENSION. USE PRESCRIBED TOOL FOR SERVICE
The label warns of the release of tension power of brake cylinders.
The exposed force of cylinders might expose personnel to specific risk.
CAUTION SIGN The risk is exposed only during service or replacement work.
Attached at brake cylinders.

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.
The crane operator is obliged to stop operation and to alert any person riding to keep off. The
DANGER SIGN
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 cranehouse, close to pumps, valves, pipes and manifold blocks.
Also in the foundation close to oil tank and pipes.

GENERAL 1.000.2 E rev.: b 2004-02-10
PM40 7114-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-
vice work, exchange of parts or equipment, the exposure may be dangerous for unqualified or
WARNING SIGN
uninformed personnel.
Instructions for service must be followed and must be restricted to qualified personnel only.
Attached to surfaces close to pipes inside the cranehouse.

PM40 7115-E00 SLIPPERY SURFACES - WATCH OUT!
Also under normal working conditions, all walking surfaces are slippery fromdirt, oil spill, etc.
The responsible officers onboard must have the crane ladders and work platform surfaces
cleaned regularly. Any person who is admitted to the area must be aware of the risk of slippery
WARNING SIGN
surfaces.
This sign is attached generally to the walls of work platforms.

PM40 7116-E00 FAN 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
qualified personnel only.
NOTICE SIGN
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 co-
vers 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
DANGER SIGN vers or hoses are removed. Access is restricted to qualified and authorized personnel only.
Attached to electrical equipment e. g. electric main motor.

GENERAL 1.000.2 E rev.: b 2004-02-10
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.
WARNING SIGN The crane operator must stop operation and alert personnel.
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.
DANGER SIGN
This sign is attached to the steel bracket side of the open-air crane top entry.
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.
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.

GENERAL 1.000.2 E rev.: b 2004-02-10
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-
vice work, exchange of parts or equipment, the exposure may be dangerous for unqualified or
WARNING SIGN
uninformed personnel.
Instructions for service must be followed and must be restricted to qualified personnel only.
Attached to surfaces close to pipes inside the cranehouse.

This sign warns the visitor about the risk of getting jammed when the drum is rotating.
Adequate caution must be exercised.
WARNING SIGN
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
operation. When service personnel are working on such equipment (e.g. checking and setting
NOTICE SIGN valves) 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.
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.

This sign warns the visitor about the risk of getting jammed when the drum is rotating.
Adequate caution must be exercised.
WARNING SIGN
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.
WARNING SIGN Authorized visitors must be aware of the risk and be very cautious to avoid serious injury.
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.
DANGER SIGN vers or hoses are removed.
Boxes with this sign are powered even if main switch has shut off other electrical power. Ac-
cess is restricted to qualified and authorized personnel only.
Attached to electric cabinet CT1.

GENERAL 1.000.2 E rev.: b 2004-02-10
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
electrical supply.
DANGER SIGN
Access is restricted to qualified and authorized personnel only.
Attached to the cover of slipring device in the foundation.

GENERAL 1.000.2 E rev.: b 2004-02-10
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 7107-E00 Fig. 8. PM40 7108-E00

GENERAL 1.000.2 E rev.: b 2004-02-10
Fig. 9. PM40 7109-E00 Fig. 10. PM40 7110-E00
Fig. 11. PM40 7111-E00 Fig. 12. PM40 7112-E00
Fig. 13. PM40 7113-E00 Fig. 14. PM40 7114-E00
Fig. 15. PM40 7115-E00 Fig. 16. PM40 7116-E00

GENERAL 1.000.2 E rev.: b 2004-02-10
Fig. 17. PM40 7117-E00 Fig. 18. PM40 7118-E00
Fig. 19. PM40 7119-E00 Fig. 20. PM40 7122-E00
Fig. 21. PM40 7123-E00 Fig. 22. PM40 7124-E00
Fig. 23. PM40 7125-E00 Fig. 24. PM40 7127-E00

GENERAL 1.000.2 E rev.: b 2004-02-10
Fig. 25. PM40 7129-E00 Fig. 26. PM40 7130-E00
Fig. 27. PM40 7131-E00 Fig. 28. PM40 7132-E00
Fig. 29. PM40 7134-E00 Fig. 30. PM40 7135-E00
Fig. 31. PM40 7136-E00 Fig. 32. PM40 7140-E00

GENERAL 1.000.2 E rev.: b 2004-02-10
Fig. 33. PM40 7142-E00

GENERAL 1.005 E rev.: e 2003-09-09
Preface
This instruction manual covers the MacGREGOR Spare parts

hydraulic deck crane. We hope that it will prove a General advice how to order spare parts; spare parts
valuable companion to everyone concerned with the lists and illustrations.
operation of the crane 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

sections 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 equip-
ment.
Appendices
Other information, which cannot be referred to any of
the above mentioned sections.

PAGE INTENTIONALLY LEFT BLANK
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 or-
astrous effect on the function of a hydraulic sys- der 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 nection. Clean all covers before reinstallation.
or 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
2. Barrels, hoses and pump must be carefully han-
was 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.,
for inspection is not defective at all, and will be
damped 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.

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
1 kp/cm² = 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/cm²
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

GENERAL/ALLGEMEINES 1.518.3 ED rev.: a 2002-12-10
Hydraulic and Electric Symbols
Hydraulische und elektrische Bildzeichen
This section covers a part of the symbols and port markings commonly
used in MacGREGOR Cranes hydraulic and electric circuits, divided into
three parts:
Diese Sammlung umfaßt einen Teil der allgemeinen Bild- und

Anschlußzeichen, die in MacGREGOR Cranes 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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

Pump for hoisting winch.

Pumpe für Lastwinde.



Pump for luffing winch.

Pumpe für Einziehwinde.

Pump for luffing winch.

Pumpe für Einziehwinde.
Pump for luffing or slewing.

Pumpe für Einziehwinde oder Schwenkantrieb.

Pump for slewing or luffing.

Pumpe für Schwenkantrieb oder Einziehwinde.
Pump for slewing.

Pumpe für Schwenkantrieb.

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.

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.

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.

Valve unit for stabilizing winch.

Ventileinheit für Stabilisierungswinde.
Unloading unit for feed pump.

Entlastungsventil für Speisepumpe.

Valve unit, cylinder luffing.

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

Ventileinheit, Zylinder-Einziehung.

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.

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.

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).

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).

Diode.
Diode.
ää
Light emitting diode.
Leuchtdiode.
Pilot lamp.
Meldeleuchte.
Light.
Beleuchtung.
Flood light.
Scheinwerfer.
Alarm signal.
Alarmsignal.
Alarmsiren.
Alarmhupe.
Single-phase outlet.
Steckdose, einphasig.

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

Condenser.
Kondensator.
Heater, cabin.
Heizkörper in der Fahrerkabine.
Air condition.
Klimaanlageapparat.
VL . . . .
Solenoid valve.
Magnetventil.

Controller, hoisting.
Steuerknüppel, Lastwinde.
Controller, luffing and slewing.

Steuerknüppel, Einziehwinde und Schwenkantrieb.

TECHNICAL DATA
(2.001 E) LO04062 2005-01-24
TECHNICAL DATA
GENERAL
Type of crane GL6019/5022/4524/4027/3630-2
Work order LO04062
Serial number 62506198 - CRANE No. 1
Weight 58 ton
Type of current 3 ~ 60 Hz
Supply voltage 440 V
Control voltage 220 V
MECHANICAL DATA
Lifting height H 10 m
Lifting height K 20 m
Hoisting Jib radius Jib radius Hoisting Hoisting Luffing time Slewing
capacity Minimum Maximum speed speed Max – min speed
(ton) (m) (m) low high radius (rev/min)
(m/min) (m/min) (sec)
60 3 19 15 0.7
50 3 22 20 0.7
45 3 24 20 0.7
40 3 27 20 0.7
36 3 30 20 88 0.7
24 3 30 40 0.7

TECHNICAL DATA
(2.001 E) LO04062 2005-01-24
ELECTRICAL DATA
MAIN ELECTRICAL MOTOR No. 390 5128-801
Type of frequency 3 ~ 60 Hz
Rated power, cont. 184 kW
Rated power, S6 40% int. 290 kW
Speed 1788 rev/min
Rated voltage 440 V
Starting current 710 A
ELECTRIC MOTOR, OFF-LINE OIL FILTRATION No. 289 3458-001
Type of frequency 60 Hz
Rated power, cont 1,5 kW
Speed 1700 rev/min
Rated voltage 230 V
GEAR BOX DATA

GEAR BOX No. 390 3433-801
Gear ratio i = 0.692
Speed 2583 rev/min
FEED AND CONTROL CIRCUIT

ELECTRICAL MOTOR No. 388 0369-801
Type of frequency 3 ~ 60 Hz
Rated power, 2-pole 20 kW
Rated power, 4-pole 13 kW
Speed, 2-pole 3360 rev/min
Speed, 4-pole 1680 rev/min
Starting current, 2-pole 141 A
Starting current, 4-pole 107 A
FEED PUMP No. 388 1669-801
Displacement 49.1 cm³/rev.

TECHNICAL DATA
(2.001 E) LO04062 2005-01-24
AUTOMATIC LUBRICATION SYSTEM – SLEWING BEARING
Grease pump No. 289 3592-801
Lubrication output 2.1 – 8.3 cm3 /min
ELECTRIC MOTOR
Type of frequency 60 Hz
Rated power, cont 0.21 kW
Speed 1800 rev/min
Rated voltage 230 V
HYDRAULIC DATA - HOISTING CIRCUIT

PUMP No. 289 1833-801 (2×)
Displacement 125 cm³/rev.
MOTOR, HOISTING No. 188 1222-801 A6 VM
Displacement Vg 160-0 cm³/rev.
HYDRAULIC DATA - LUFFING CIRCUIT

PUMP No. 289 1833-801 (1×)
MOTOR No. 188 1221-801 A2 FM
HYDRAULIC DATA - SLEWING CIRCUIT

PUMP No. 289 1834-801 (1×)
MOTOR No. 188 1223-801 (3×)

TECHNICAL DATA
(2.001 E) LO04062 2005-01-24
HYDRAULIC DATA – OFF - LINE FILTRATION
PUMP No. 390 6830-801 (1x)
WIRE ROPE
Wire rope, hoisting winch Ø 38 mm x 287.5 m
No. 390 3922-821
Wire rope, luffing winch Ø 32 mm x 187.5 m

No. 390 4274-815
OIL VOLUME / OIL FILLING

Oil tank 560 litres
Planetary gear box, module 16 15.5 litres (x3)
Hoisting winch gear 39.0 litres
Luffing winch gear 10.5 litres

TECHNICAL DESCRIPTION 2.007.61 E rev.: c 2002-06-13
Technical Description
Jib top
Jib top
Lifting block
Lifting block
Main electric
motor
Pump unit
Crane operator's cab
Oil tank with feed

pump unit
Slack wire
device
Luffing winch
Crane jib
Hoisting winch
Slewing gear
Fig. 1. Crane type GL-2

MacGREGOR hydraulic deck cranes are self- An oil cooler removes heat developed in the oil during
contained units with all machinery enclosed in the its work cycle. If the oil temperature exceeds a certain
crane house and, thus, well protected against external level, a thermostat operates a contactor to stop the
abuse. main drive electric motor.
When delivered, the cranes are mechanically, Various pressure limits are provided to protect the
hydraulically, and electrically complete in every crane against overload. All moving parts in the
respect and ready to be installed on a suitable hydraulic system are lubricated by the hydraulic oil
foundation fixed in the ship’s deck or on a crane which minimises mechanical wear and ensures the
carriage travelling on deck. added advantage of silent operation.
The crane house is an all-welded structure on a rigid

Construction
baseplate, and encloses all mechanical and
All crane movements - hoisting, luffing, and slewing -
hydraulical machinery and associated electric
are driven by hydraulic motors. These are supplied
equipment for adequate protection against rain, sleet,
with high pressure oil by a pump unit comprising
and waves breaking over the ship. Catwalks, ladders,
separate pumps for each hydraulic circuit. The high
platforms, and handrails facilitate maintenance of the
pressure pumps are mounted in the same pump unit
crane.
and are geardriven by a flange mounted electric motor.
The tops of the crane house and of the jib head are
The hoisting winch is driven by a hydraulic motor via
fitted with sheaves for the hoisting and luffing wire
a planetary gear box. A brake is integrated in the winch
ropes. All sheaves run on sealed ball bearings, and
gear set. When the winch is running, the brake is
their shafts are secured by lockplates.
automatically released by a hydraulic unit.
Various limit switches are provided.
Limit switches operate if the wire slackens and to
preclude the complete unwinding of the wire from the
The cranes are supplied with test certificates to the
wire drums.
requirements of National Swedish Board of Shipping
and Navigation. The design meets the requirements
The crane jib is raised and lowered by the luffing winch
of ILO and the relevant classification societies whose
whose general design is similar to that of the hoisting
certificates will be furnished if specially ordered.
winch.
The slewing drive of the crane uses a high-speed Crane operator’s cab
hydraulic motor, installed onto a planetary gearbox The crane operator’s cab affords an excellent allround
and fitted with a drive pinion. The pinion meshes with view of the entire work area from the comfortable seat,
the internal gear teeth of the slewing ring which and ready access to the two control levers, one
supports the crane house. On customer’s order limit controlling the hoisting winch, and the other, the luffing
switches can be provided to define the slewing range and slewing movements.
of the crane.
The cab also contains control panels with various
To heat the oil to a suitable operating temperature, switches, control buttons, and signal lamps.
the separately driven feed pump of screw type Jib
generates the heat by circulating the oil in the system.
For most crane types the jib is made of two box
girders, joined by transverse tubular steel struts. The
foot of the jib mounts on two trunnion journals at the
sides of the crane house skirt. A mercury-lamp or
sometimes Halogen floodlight is also mounted on the
jib.

Electric equipment For twin operation, all movements of the two cranes
Certain electric cables outside of the crane house, are synchronised through the use of transmitters and
e.g. on the jib, are carried in steel conduit. All cables receivers. The slewing of the twin combination is
and electric accessories are specifically designed for driven by hydraulic motors in the twin platform.
marine use.
The slip-ring unit linking the crane network with the

shipboard network, is in single cranes placed in the
foundation and at the bottom centre of the twin
platform in twin cranes, and is bolted to the bottom of
the crane.
The electric cabinet is placed on the inside wall of the

crane house. The cabinet contains contactors, relays,
fuses, and various other components of the electric
installation. The main power switch is placed on the
CT1-cabinet (A-cabinet).
Hydraulic hoses
The hydraulic hoses are high-pressure tested and
carefully cleaned and inspected before assembly.
Cargo handling gear

The swivel, hook, shackles, rings, and chains all have
ample safety margins for the maximum load to be
handled by the crane. The non-rotatory, langs lay wire
ropes are galvanised and oiled.
Surface treatment
All surfaces of the crane are carefully prepared by
sandblasting before being given a coat of Primer. As
standard the crane is painted with an anticorrosive
system basically based on two-component epoxy
paint and an acrylic finishing coat.
Twin cranes
A MacGREGOR hydraulic twin crane set consists of
two single cranes mounted on a commmon platform.
The cranes may be operated independently, or
interconnected for twin operation. When operated in
single, they function exactly like ordinary single
cranes.

FUNCTION 3.110.102 E rev.: - 2005-01-18
Hydraulic Function
General
The following description refers to the standard hydraulic in the crane. The first digit of each number signifies the
system of MacGREGOR hydraulic deck cranes, normal circuit to which the component belongs:
version.
1... Hoisting circuit
Minor variations in the hydraulic system may occur in 2... Luffing circuit
individual cranes of the same type, and the objective of 3... Slewing circuit
this description is only to provide a general orientation 4... Feed and control-pressure circuit
concerning the arrangement of the hydraulic system. 5... Additional programming equipment *)
6... Twin crane hydraulic equipment
A complete hydraulic circuit diagram relating 7... Other additional hydraulic equipment *)
specifically to your crane will be found in the
instruction manual, section “Spare Parts”, Group *) Equipment installed at request of customer.
9.4.
Legend
Three separate hydraulic work circuits, ie, the hoisting,
MHO Hydraulic motor, hoisting circuit
luffing, and slewing circuits, plus feed and control-
MLU Hydraulic motor, luffing circuit
pressure circuits, make up the complete crane operating
MSL Hydraulic motor, slewing circuit
system.
PHO Pump, hoisting circuit
PLU Pump, luffing circuit
Each of these work circuits may have one or more
PSL Pump, slewing circuit
pumps located in the pump unit, in Figure 1 marked
PF Pump, feed circuit
PHO, PLU, PSL. Pump PF for the feed and control-
pressure system is located inside the hydraulic
reservoir.
HOISTING LUFFING SLEWING
CIRCUIT CIRCUIT CIRCUIT
Identifying circuits in the hydraulic diagram
Figure 1 shows the arrangement of the three work
circuits, hoisting, luffing, and slewing circuits, together MHO MLU MSL
with the feed and control-pressure circuit. The circuits
appear in the same order in the hydraulic diagram.
Symbols
Every hydraulic component is represented by a
special symbol in the circuit diagram. The meaning PHO PLU PSL
of the symbols is explained in section “General” in
the Manual. The symbol for the reservoir is shown in
several places in the diagram for greater simplicity of
drawing; but there is naturally only one reservoir in
actual fact. PF
Component identification FEED AND CONTROL CIRCUIT

The main components are identified by four-digit
numbers in the diagram and on the actual components Fig. 1. Identifying hydraulic circuits.

FUNCTION 3.110.102 E rev.: - 2005-01-18
Feed and control circuits
Feed pressure circuit Contamination switches (optional)

The function of this circuit is mainly to replace the hot All pumps are equipped with a contamination switch
fluid leaking from the closed work circuits. The feed which indicates if there is too much dirt in the pump. The
fluid is introduced through non-return valves into the contamination switches are:
low-pressure side of the system. The feed circuit Hoisting - 1234, 1244
operates at a pressure of approx. 2.5 MPa (25 bar), Luffing - 2243
which is set at valve 4148 and is measured at test Slewing - 3243
point 1.
Control pressure circuit Extra off-line filtration circuit (optional)

The function of this circuit is to supply fluid to the
Equipment in order to achieve extra filtration in the
brakes and pump servos, ie, to control winch speed,
hydraulic system.
slewing speed and working direction. The system
operates at approx. 3.0-3.3 MPa (30-33 bar), and is
The hydraulic system is fitted with an off-line filtration
measured at test point 2. Control fluid is provided to the
circuit consisting of an extra filter, with increased grade
pump servos via servo valves.
of filtration, and a pump unit.
NOTE. The equipment consists of:

For exact pressure settings, see pressure list in the 1. Extra filter, 4137, with increased grade of filtration
hydraulic diagram. 2. Pump unit 4114
3. Warning light, H6, in cabin
4. Hydraulic equipment in crane housing.
1 Feed pressure, inlet

2 Control pressure
Pump case drain Feed pressure outlet
Filter
indicator
Fig. 2. Feed and control circuit, example.

FUNCTION 3.110.102 E rev.: - 2005-01-18
Hoisting winch circuit Lowering
Introduction
Low speed High speed
Figure 6 shows a hoisting winch circuit diagram, with
the following main components:
Pumps 1111, 1112 Hoisting Control lever

Hydraulic motors 1141
Brakes 1211, (1212) Fig. 3. Control lever in neutral, hoisting.
The brake is mounted inside the winch gearbox.
Function
With the control lever in neutral, Figure 3 or 7, and
the pump running, the hoisting circuit performs no
actual work. A continuous supply of fluid from the
feed circuit, flushes the circuit. Lowering
Low-speed range, brake release

When the control lever is moved to the left for low-
speed operation of the winch, Figure 4, valve 1221
and 1226 in the actuated mode, "b", (1226 slightly
Control lever Hoisting
delayed in relation to 1221) and connects full control
pressure to the brake valve 1226 which releases the
Fig. 4. Control lever, hoisting, brake release position.
brake, and also to valve 1128-1 which shifts from its
unloading mode.
With no load on the cargo hook and the control lever

in brake release position, Figure 4, the hoisting winch
should produce a slow hoisting movement, so called
plussing. See instruction under section 6.1 "High
pressure pumps".
Lowering
Control lever Hoisting
Fig. 5. Control lever, hoisting, low-speed hoisting.

FUNCTION 3.110.102 E rev.: - 2005-01-18
HOISTING CIRCUIT
2
1
5
2
4
1. Feed pressure, inlet

2. Control pressure
4. Pump case flushing
5. Pump case drain
Fig. 6. Hoisting winch circuit, example.

FUNCTION 3.110.102 E rev.: - 2005-01-18
High speed range, brake release

When the control lever is moved to the right, Figure 8, Shifts to low-speed when running in the high-speed
valves 1221 (a) and 1226 (b) are actuated, (1226 mode.
slightly delayed in relation to 1221). Control pressure - Pressure switch 1381 stops the crane in the event
is connected to the brake valve 1226 which releases of insufficient feed pressure.
the brake, and also to valve 1128-1 which shifts from
its unloading mode. Note! It is not allowed to adjust sealed safety valves
without contacting MacGREGOR Cranes, Service
The brakes are released and the motor assumes the Department.
high-speed position (min. displacement). The motor
rotates at double speed, and the lifting capacity of
the winch is reduced to approximately 40 % of its Lowering
maximum rate.
With no load on the cargo hook and the control lever Low speed High speed
in brake release position, Figure 8, the hoisting winch
should produce a slow hoisting movement.
Hoisting Control lever

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 Fig. 7. Control lever in neutral, hoisting.
will cause valve 1221 to shift to low-speed range. (Full
displacement)
Lowering
Hoisting and lowering, high speed or low speed

Pulling the control lever backwards from the brake
release position will start the winch to lift the load,
Figure 5 low speed and Figure 9 high speed. The
servo valves 1111-9 and 1112-9 affect the servo and
thus the pump displacement. The pumps 1111 and Hoisting Control lever
1112 thereby produce a flow of fluid that is
proportional to deflection of the control lever.
Fig. 8. Control lever, hoisting, brake release position.
If, instead, the control lever is moved forward, the
load will be lowered, ie, the function is the same as Lowering
for hoisting, except for the direction of flow.
Safety functions Low speed High speed

The hoisting winch circuit embodies four safety
features:
Hoisting Control lever
- Main pressure limiting valves 1111-2; 1111-3,
1112-2, 1112-3.
- Pressure cut-off valves 1111-10, 1112-10. Fig. 9. Control lever, hoisting, high-speed hoisting.
- Pressure switch 1311 (overload valve) stops the
crane in the event of overloading at low speed.

FUNCTION 3.110.102 E rev.: - 2005-01-18
LUFFING CIRCUIT
1 Feed pressure, inlet

2 Control pressure
3 Feed pressure, outlet
4 Pump case flushing
5 Pump case drain
2
1
3
5
2
4
1
Fig. 10. Luffing circuit, example.

FUNCTION 3.110.102 E rev.: - 2005-01-18
Luffing winch circuit
Introduction
Figure 10 shows a luffing winch circuit diagram, with the Note! It is not allowed to adjust sealed safety valves
following main components: 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 11.
Brake release
Moving the control lever from neutral, eg, rearward
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 and to valve 2127 which shifts position from the Luffing-in (raising jib)
unloading mode.
With the control lever in the brake release position, Fig. 11. Control lever, luffing/slewing.
the luffing winch should produce a slow movement of
the crane jib.
Raising and lowering the jib

Moving the control lever further backward starts
operation of the luffing winch. The servo valve 2111-
9 affects the servo and thus the pump displacement.
The pump 2111 thereby produces a flow of fluid at a
rate that is proportional to 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 three safety
features:
- Pressure limiting valves 2111-3, 2111-2.

- Pressure switch 2481; stops the crane in the event
of insufficient feed pressure.
- Pressure cut-off valve 2111-10.

FUNCTION 3.110.102 E rev.: - 2005-01-18
SLEWING CIRCUIT
2
1
3 1 Feed pressure, inlet
5
2 2 Control pressure
4 3 Feed pressure, outlet
4 Pump case flushing
5 Pump case drain
Fig. 12. Slewing circuit, example.

FUNCTION 3.110.102 E rev.: - 2005-01-18
Slewing circuit
Introduction
Figure 12 shows a slewing circuit diagram for the crane,
with the following main components:
Slewing left Slewing right
(Anti-clockwise) (Anti-clockwise)
Variable displacement pump 3111
Hydraulic motors 3141, 3142, 3143
Valve unit 3127
Brakes 3211, 3212, 3213
Fig. 13. Control lever, luffing/slewing.
The luffing and slewing movements are generally
operated by a common control lever, Figure 13.
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 valve 3111-9 affects the servo 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 two safety features:
- Main pressure limiting valves 3111-2, 3111-3.

- Pressure cut-off valve 3111-10.

FUNCTION 3.131.19 E rev.: - 2005-01-13
Starting and Stopping, Electric Safety Functions

Single Cranes
Introduction
The following description refers to the starting and N.B. - The hydraulic oil must be warm before the
stopping, and electric safety functions, of a standard- crane may be started.
type single crane. A complete electric circuit diagram
relating specifically to the particular crane will be
found in the section SPARE PARTS of the Manual. Starting and stopping the crane
Start sequence
The purpose of the present description is to furnish a
- Press button S10 "1" (Start)
general idea of the design and function of the electric
- Warning lamp H1 "Do not operate" goes on
system. The crane is supplied with electric power via
- Feed pump motor M2 is started in 2-pole configu-
the slip-ring unit and the main switch in the
ration by contactors K13 and K11. The motor runs
cranehouse. Cables lead from the main switch to: a
at its full speed of 2900 rpm (50 Hz) or 3500 rpm
transformer supplying power for all control circuits; a
(60 Hz).
switch for the oil cooler fan motor; a Y/D switch for
the main electric motor; a pole switch for the feed
The feed circuit pressure build up its operating pres-
pump electric motor; and a thermostat switch for the
sure. Pressostats BP1 - hoisting circuit, BP2 - luffing
ventilation fan in cranehouse.
circuit, close and start a delayed closing 8s time relay
K71.
All components are marked by symbols in the dia-
gram, making it easier to follow the various stages of
- After 8s, Y contactor K2 switches on N contactor
the starting sequence, e.g.
K1; the main motor M1 starts in Y connection.
- At the same time as the Y contactor was switched
- Contactors: K1 (N); K3 (D); K2 (Y)
on, an 8s delayed-opening double relay K9 was
- Contactors: K12; K13; K11
started.
- Time relays: K9; K71
- After 8s, the Y contactor drops, and D contactor
K3 is switched on by double time relay K9 closing
after 0.1s.
Preparing for starting the crane
The D contactor and self-holding N contactor switch
Summer main motor M1 to delta configuration.
Outside temperature above +5oC - Pushbutton "1" (Start) energize the motor switch
Q5 and the COOL FAN MOTOR M3 starts.
- Set ”WINTER/SUMMER” switch S50 to SUMMER.
Motor M3 is also activated by thermostat BLT1 if
- Close main switch Q1 - ON
the temperature of the hydraulic oil exceeds +10oC.
- Warning light H1 goes out. The crane is
Winter operational.
Outside temperature below +5oC
- Set ”WINTER/SUMMER” switch S50 to WINTER. Stop sequence
- Close main switch Q1 - ON. - Press button S10 "0" (Stop)
- Feed pump motor M2 starts in 4-pole configura- - All contactors of Y/D switches and all other motor
tionvia contactor K12 and runs at its lower speed contactors are de-energized. All motors stop.
of 1450 rpm (50 Hz) or 1750 rpm (60 Hz).
- Wait 24 hours.

FUNCTION 3.131.19 E rev.: - 2005-01-13
- If the switch S50 is in ”winter” connection, feed The crane house lighting is operated by switches
pump motor M2 does not stop but is switched to 4- under the bottom plate. The cabin lighting and the jib
pole configuration and continues to run at its lower light are operated by switches in the cabin.
speed of 1450 rpm (50 Hz) or 1750 rpm (60 Hz).
- The feed pump motor and the ventilation fan mo-
Control system error
tor stops only when the main switch Q1 is switched
If an error is detected by the crane control system in
OFF.
the CT2-cabinet pilot light H4 illuminates. Check the
CT2-cabinet according to instruction "Crane Control
System CC2000" in Section 6.3.
Other electric functions
Interlocking of start circuit

Overheating protection
An interlocking contact prevents the crane from star-
A thermostat BT2 in the hydraulic system of the crane
ting, if there is not enough supply of electric power
opens the control circuits of the main electric motor
from the ship's generators.
and the oil cooler fan motor when the oil temperature
exceeds +85oC.
The interlocking contact is connected in series with
the emergency stop circuit. The interlocking contact
The oil is cooled by setting the S50 switch to position
must be closed, i.e. the power supply must be
"TEST" and depressing the START button on the
suffiecient, before the safety relay K99 can be reset.
control panel in the cabin. The feed pump motor starts
The safety relay K99 is reset by pressing the RESET
together with the cooler fan.
EMERGENCY STOP button H14.
Oil level switch

If the oil level in the hydraulic oil tank drops below
the minimum permissible level, an alarm system is
switched 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 the feed pump electric motor M2
and 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.

FUNCTION 3.142.27 E rev.: - 2005-01-24
Crane Control System CC2000

Single Cranes with More than One Outreach
General
The following description refers to the microcomputer For detailed information about the control system a
based crane control system CC2000 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 ìSpare Partsì, 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 ìSpare Partsì, 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

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

Brake valve
Slewing gear
SLEWING
MPC Hydraulic Hydr.

"SL" pump motor
Unloading valve Limit switch box
Fig. 1. Crane control system with interfaces to control levers and hydraulic system.

FUNCTION 3.142.27 E rev.: - 2005-01-24
Crane control system - interfaces and

principle of operation
Control levers (joysticks) Hydraulic pumps

The right control lever controls the hoisting winch and The hydraulic pumps are variable displacement
the left control lever controls the luffing and slewing pumps (e.g., the flow is steplessly variable from zero
movements. The control lever linear potentiometers to max. rated flow). The pump oil flow is controlled by
are fed with 0V, +6V and +12V. The output level is a 24V pulse width modulated (PWM) current signal.
approx. +6V with the control lever in neutral. The out- The direction of the oil flow is dependent on which
put signal is controlled by the lever and is decreased one of the two solenoid valves is activated.
to approx. +1.5V and increased to approx. +10.5V,
depending on the lever movement. The speed of the winch, the pump displacement, the
current through the solenoid coil and the lever
The control lever for hoisting also gives 24V signals movement are proportional to each other.
for selection of low speed/high speed and hoisting/
lowering.
Hydraulic motors
The control lever for luffing/slewing also gives 24V
The hydraulic motors may be reversed by changing
signals for selecting luffing in/luffing out and slewing
the direction of the hydraulic pump oil flow. Each
left/slewing right.
motor also has a low and a high speed range selected
by the operator's control lever.
Crane control system cabinet
The crane control system consists mainly of four MPC
Overload protection, Auto Loadstep
cards - Micro Processor Cards. One MPC card is used
To prevent the crane from being overloaded, i.e. lifting
for internal communication between the cards and a
too heavy a load, the hydraulic system is equipped
parameter memory card. Three of the MPC cards are
with an electro-hydraulic overload system. Pressure
controlling all input and output signals for each crane
sensing switches, which normally enable the opera-
movement, hoisting, luffing and slewing. Each MPC
tion, stop the hoisting movement if a too heavy load
card feeds a potentiometer in the control lever for the
is lifted at the current jib outreach. The pressure switch
crane movement in control. Potentiometer and control
gives a signal to the control system overload logic,
lever direction signals go to a microprocessor with a
which senses the overload input signal and switches
software control program that handles brake release
over from high speed to low speed or from low speed
logic, overload logic and rampforming. The output
to stop.
from the microprocessor is fed to a voltage to current
amplifier on the card.
Interlocking cams on the luffing limit switch box are
used to select the pressure switch corresponding to
The rampformer gives smooth acceleration and re-
the jib outreach.
tardation to the crane movements.
Additional functions in the Auto Loadstep system

The brake release logic circuit releases and applies
automatically adjust the hoisting speed and the mini-
the brake in the correct sequence with the displace-
mum and maximum outreach on the basis of the
ment/unloading signals when the hydraulic motor is
actual hook load, see Fig. 2.
started and stopped.
The crane is equipped with ìMulti SWL plussingî, a

The voltage to current amplifier feeds the hydraulic
type of load-dependent leakage compensation that
pump solenoids.
is less dependent on the load than normal mechanical
plussing. It is a combination of mechanical offset on

FUNCTION 3.142.27 E rev.: - 2005-01-24
the pump and a load-dependent electrical signal to Limit switch box, luffing
the pump servo. Together with a speed sensor on The limit switch box controls speed reduction and stop
the hoisting limit switch box, they guarantee that the function for all max. and min. outreach, and stop
load is not lowered when the brake is released. parking, if fitted.
Instead, the load is hoisted at creep speed, indepen-
dent of the load. The Multi SWL plussing is also used Additional cams are used to select the hydraulic
for hoisting during a luffing operation. However, a pressure switch corresponding to the actual outreach.
couple of exceptions occur when only the mechanical
plussing is active, namely, when the hoisting winch
Limit switches, slackwire
reaches empty or full drum and in an overload situa-
tion. The limit switch for hoisting slackwire stops the
lowering movement, and the limit switch luffing slack-
wire stops the luffing out movement when a wire is
Limit switch box, hoisting
slack.
The limit switch box controls speed reduction and stop
function for full or empty drum. It also contains a
Limit switches, slewing
speed-encoder used for plussing control.
If fitted, the limit switches for slewing controls speed
reduction and stop function for each direction at maxi-
mum slewing range.
Fig. 2. Auto loadstep, principle.

FUNCTION 3.142.27 E rev.: - 2005-01-24
Computer system cabinet, CC2000
Two versions of cabinet are used, MB and CT2.
5 3 1 2
STEP STEP STEP STEP
07 33 07 33 07 33 07 33
36 36 36 36
39 39 39 39
08 34 08 34 08 34 08 34
37 37 37 37
40 40 40 40
09 31 09 31 09 31 09 31
30 30 30 30
10 32 10 32 10 32 10 32
11 14 11 14 11 14 11 14
12 15 12 15 12 15 12 15
13 16 13 16 13 16 13 16
17 19 17 19 17 19 17 19
18 20 18 20 18 20 18 20
TX 28 TX 28 TX 28 TX 28
42 42 42 42
PC COM PC COM PC COM PC C OM
4
9
10
Fig. 3. Computer system CC2000 in cabinet MB.
5 3 1 2 7
4
8 9
10
1. Cabinet
2. 19" rack with electronic cards
3. MPC cards (Micro Processor Cards)
6 4. Parameter list 625 XXXXX
5. Parameter memory card
(mounted on the backplane card)
6. Cables from MPC cards to plinths
7 Plinths
8. Anti-condensation heating
9. Sign: Signal overview
10. Sign: Error messages
Fig. 4. Computer system CC2000 in cabinet CT2.

FUNCTION 3.142.27 E rev.: - 2005-01-24
Computer system cabinet

The Crane control system CC2000 is protected New versions of the crane control software can be
against humidity by a casing with protection class IP54 loaded/programmed into the MPC cards using a stan-
(dust proof and splash water proof). dard notebook PC.
19" subrack with electronic cards Parameter list

All electronic cards are mounted in a standard 19" The parameter list specifies all information details
aluminium subrack. A backplane card is used for about the crane needed for the control system. It sta-
connecting power 8V and 24V to the MPC-cards. It tes the software version and software configuration
also provides communication lines between the MPC- parameters such as number of pumps, type of pumps,
cards and between one MPC-card and the parameter maximum speed, extra equipment etc.
memory card.
The parameter list identification number 625XXXXX,
MPC - Micro Processor Card is the same as the crane manufacturing number seen
on the sign in the operator's cabin (Mfg. No.). All para-
Hardware meters are stored on the parameter memory card.
The control system consists mainly of four MPC cards.
All four cards are identical and are 100% Parameter memory card
interchangeable.
All parameter values from the parameter list are sto-
red on the parameter memory card. The information
Each MPC card is a complete stand-alone
is stored in electronic memories on the card. Stored
microprocessor system with processor, several types
parameter values are not dependent on power supply
of memories and communication channels, analogue
or battery. There is, however, a battery on the card
and digital inputs as well as analogue and digital out-
used for a calendar, giving all MPC cards date and
put current drivers.
time information. The card is located inside the rack
Each card can fully handle all input and output sign-
and is mounted on the backplane card that also holds
als needed for one hydraulic circuit, i.e. one crane
all the MPC card connectors.
movement. A separate safety system on each card
The lifetime of the battery is 10 years.
gives processor-independent protection against
hazardous operation at low feed pressure and
overload pressure as well as ensuring the stopping Cables from MPC cards
of the crane movement due to activated limit switches. Each MPC card has a maximum of 42 cables
connecting all the inputs and outputs between the card
Software and its part of the plinth row. Cables are numbered 1
to 42 and brought together in a cable loom.
All four MPC cards are programmed with the same
crane control software. Each card senses which rack
position and therefore which crane movement it is Plinths
controlling. All external connections are made to a row of plinths
in the lower part of the enclosure.
All MPC cards identify themselves by showing a two-
character abbreviation of the function/movement- Each MPC card has its own series of plinths: 101 -
name on the front panel display: Sc - supervisor, Ho 142 for the MPC ìScì, 201-242 for the MPC ìHoì,
- hoisting, Lu - luffing, SL - slewing. 301-342 for the MPC ìLuì and 401-442 for the MPC
The leftmost MPC card, the MPC ìScì, is only used ìSLì. Note that not every number has a corresponding
for supervisory functions such as communication with plinth and that a particular crane does not necessarily
other MPC cards and distribution of control system use every plinth for external connections.
parameters from the parameter memory card.

FUNCTION 3.142.27 E rev.: - 2005-01-24
Plinth numbers from 1 to 99 are used for power and Error messages
cross-connections for external limit switches, key
switches, overload switches etc.
Built-in diagnostics system
The CC2000 control system has its own built-in
Anti-condensation heating diagnostics system. The system is capable of
To avoid condensation on the electronic cards, the detecting several types of malfunction.
temperature inside the enclosure is kept a few
degrees above the temperature outside. Heating The system checks itself and external input and out-
elements are therefore mounted behind the row of put signals. Internal problems such as loss of
plinths. They are powered with 24V AC when the communications are continuously checked. Loose
control system is switched off or when the crane is connections to pumps and valves are detected when
not operational. the output is activated. Signal levels that do not
correspond to normal levels, e.g. the potentiometer
input from the operator handle, are also detected.
Signal overview CC2000
When any type of malfunction is detected, the MPC
card flashes with its error LED, no. 28. All MPC card
Coloured LEDs
error LEDs are wired together to an error lamp in the
Signals to and from each MPC-card are indicated by
operator's cabin, the ìcontrol system error" lamp. To
green, yellow and red LEDs (Light-Emitting Diodes)
get the corresponding error message number, push
on the front panel of each MPC card.
the STEP push-button on the MPC card with the
flashing LED.
Green is used for normal input and outputs. Yellow
indicates that the crane motion concerned is driven
If there are several errors, they are shown one at a
with slower speed. Red indicates that the motion is
time for each push on the STEP push-button. When
stopped.
there are no more error messages to read, the dis-
play shows two hyphens ì- -ì. The error LED is now
Signal overview sign either on or off.
All signals indicated by LEDs are listed on the SIG- - If it is on, the error is still present but has been
NAL OVERVIEW sign inside the cabinet, see section acknowledged.
îServiceî, Group 6.3. - If it is off, the errors are no longer present.
Identifying the plinth number corresponding to a When a new error is detected, the error LED starts
LED flashing again to indicate that a new error exists.
The plinth number is identified by a three-digit
number. The first digit of each number signifies the Error message sign
MPC card to which the signal is connected:
The corresponding error message text can be found
on the ERROR MESSAGES sign in the cabinet, see
1. Supervisory MPC card, ìScì
section îServiceî, Group 6.3.
2. Hoisting MPC card, ìHoì
3. Luffing MPC card, ìLuì
4. Slewing MPC card, ìSLì
The last two digits signify the LED number on each

MPC card front panel, showing the status of the 24V
input and output signals for the card. The same two-
digit number is used on the cables from the plinth to
each MPC card.

FUNCTION 3.155 E rev.: a 1998-05-19
Thermostatic Controlled Ventilation Fan
General
The ventilation fan is thermostatic controlled and

situated inside the cranehouse top, see Fig. 1.
Function
With the main switch in position "1" (on-position)
Thermostat
the ventialtion fan starts via a thermostat, posi-
tioned in the A-cubicle, see Fig. 2. The thermostat
bulb is situated outside the cubicle.
The thermostat is activated at +25°C. The thermo-

stat can be adjusted, see Fig. 3.
Fan
Fig. 2. Thermostat installed in A-cubicle
95°
50°
25°
Fig. 1. Crane house Fig. 3. Thermostat

OPERATION PM40 1857-E00 rev.: - 2005-01-13
CREW CHECKLIST
BEFORE TAKING CRANE INTO OPERATION

Note! When the crane is rigged ready for operation, all keys for all lockable switches must be stored in a safe place
by the officer responsible on board.
Read sections Operation and Maintenance in the instruction manual and make sure that maintenance is performed
according to Maintenance Chart.
Make sure nobody enters the crane without permission from responsible officer on board.
Make sure that there is nobody in the crane house who might be caught in the machinery or strangled by the wire
ropes.
The following checks and procedures must be performed before taking crane into operation:
Note! To ensure lubrication of the slewing bearing slew crane at least one whole revolution before operation.
Summer Oil level and oil temperature

Verify hydraulic oil level and that
FEED PUMP MOTOR
the oil temperature is above
SUMMER
+5oC in oil tank.
R
TE
Also check oil level in slewing

TE
ST
IN
W
gearcase.
When outside selector shall Switch main switch

Unclamp jibs and loose gear
temperature is be set to SUM- to position "1".
above +5∞C... MER. Unclamp jib and loose gear from
its parking position.
Winter
FEED PUMP MOTOR

SUMMER
TE M P
R
PU
TE
ST
IN
Wires and sheaves

W
Verify that wires run cor-

rectly in the sheaves and
that the wire ends are
securely clamped.
When outside selector shall Switch main switch
temperature is be set to to position "1" some
below +5oC... WINTER. 24 hours before
operation.

IF CRANE DOES NOT START IF CRANE STOPS

Interlocking of start circuit Check the following:
An interlocking contact prevents the crane from starting, a. Crane overheated
if there is not enough supply of electric power from the
1. Set FEED PUMP MOTOR FEED PUMP MOTOR
ship's generators.
switch in TEST PUMP posi- SUMMER
TE M P
TE
tion.
PU
ST
IN
Check the following:
W
2. Press START button (to start
- Check that the emergency stops are not activated.
feed pump unit in high
The emergency stops are located in the crane, in
speed).
the pedestal and on port side of the ship.
3. Check that oil cooler fan is run-
- Reset the RESET EMERGENCY STOP
ning.
pushbutton.
4. After approx. 30 min. set FEED PUMP MOTOR
- If the pilot light goes out start the crane.
switch in SUMMER position.
- If the pilot light still lights check if the power supply
5. Try to start the crane by pressing START button.
is enought to crane.
b. Oil level
DURING OPERATION 1. Check oil level in oil tank.
2. Fill oil if necessary. (See Lubricating Chart).
List/trim
Verify that ship does not list more than 5 degrees and
does not trim more than 2 degrees. c. Current setting list
1. Check current setting list inside the electric cabinet
Max. 5∞
door CT1.
2. Change current setting, if necessary.
AFTER SEA STOWING

Anti-condensation heating (if electronic cabinet CT2
fitted).
Check that the heating elements (two large or three
small) in electronic cabinet CT2 are working, i.e. get
AFTER OPERATION warm.
Park the crane

Park the crane according to separate instruction in section
4 of the instruction manual.
Heating
elements
Also see instr. "Crane control system", section 3.

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.

OPERATION PM40 6062-E00 rev.: d 2003-06-23
OPERATING INSTRUCTION
START - STOP
MacGREGOR cranes are designed for operation in harbour or sheltered water environments where there is no
significant movement of the ship due to wave action.
WARNING!
Only ship's crew is allowed to operate key switches. Keys must be stored in a safe place by responsible officer.
Notify responsible officer onboard before taking crane into operation.

Make sure that there is nobody in the crane house who might be caught in the machinery or strangled by the
wire ropes.
When using 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.
BEFORE STARTING START
Set switch (automatic return)

into position 1
Read instructions carefully Check that control levers are in The crane is operational when
before taking crane into neutral. If not, notify responsible the red warning light goes out.
operation. officer. Do not operate on red light.
EMERGENCY STOP STOP
If the crane gets out of control... - LET GO both control levers;

they will return automatically to
their neutral positions. Set switch into position 0
- Press Emergency Stop button! (automatic return)

OPERATION PM40 6062-E00 rev.: d 2003-06-23
CRANE OPERATION
CONTROL LEVER, CONTROL LEVER, CONTROL LEVER,

SLEWING / LUFFING HOISTING / LOWERING HOISTING / LOWERING
Luffing out Lowering Lowering
Neutral Low speed High speed

Slew Slew Low speed High speed
left right
Hoisting
Lowering
Luffing in Hoisting
With the slewing/luffing control lever Low speed High speed

in neutral, the brakes are engaged.
Moving the lever a short distance
from neutral releases the brakes. Hoisting
Moving the lever left or right starts With the hoisting winch control
the crane to slew in the direction lever in neutral, the winch brake
chosen. is engaged and holds the load. To be able to hold the load at
Moving the lever forwards or constant height move the hoisting
backwards starts operation of the Moving the hoisting winch lever winch control lever to one of the
luffing winch. to one of the grid slots for high or positions shown above. The brake
Note! When operating luffing the low hoisting speed releases the will then be realeased and the
hoisting brake is released and the winch brake; the winch starts load will be held at constant height.
hoisting winch starts hoisting at hoisting at creep speed. This The position of the lever is
creep speed. speed is depending on the load. depending on the load on the hook.
LIST / TRIM DRAGGING LOADS SHORT BREAKS IN

OPERATION
1,5 m
Verify that ship does not list more Dragging loads is not permitted! ... or if a technical malfunction
than 5 degrees and does not trim has developed:
more than 2 degrees. Do not drag loads - lift them.
- Raise swivel to approx. 1.5 m
below jib head, if possible.
- Return control levers to neu-
tral.
- Press STOP button.

OPERATING INSTRUCTION PM40 6370-E00 rev.: - 2005-01-13
Controls and Indicators

Luffing out Lowering
Slew CT3 CT3 Low High

Slew
left speed speed
right
32 31
Luffing in Hoisting
1 2 3
4 5 6
7 8 9
10 11 12
13 14 15
16 17 18
19 20 21
22 23 24
Fig. 1. Controls and indicators
25
in the crane cabin.
Warning! detected by the crane control system in the

Only ship's crew is allowed to operate key switches. electronic cabinet CT2.
WARNING!
H5 LOW GREASE LEVEL
Store Keys Safely Pilot light. Illuminates when the grease tank
When the crane is rigged ready for operation, all keys is empty. Illuminates only when the crane is
for all lockable switches must be stored in a safe place in operation.
by the responsible officer on board.
H6 CONTAMINATION
Pilot light. Illuminates and indicates con-
H1 DO NOT OPERATE tamination in the hydraulic system. See
Pilot light. Illuminates during starting separate instruction 5.025.2 E.
sequence of the crane (feed pump motor,
main electric motor and supply to electronics). H7 OVERLOAD
Pilot light. Illuminates at overload.
H2 LOW OIL LEVEL
Pilot light. Illuminates as a pre-warning for H8 LOAD STEP LIMIT
low oil level in crane and the siren or bell, Pilot light. Illuminates when permitted jib
which is mounted under the crane cabin will outreach for actual load is reached.
sound. Refill oil tank. The pilot light and the - Flashing light for jib in speed reduce area.
siren/bell can be switched off by selecting - Fixed light when jib has stopped.
the key float switch S12 in position ”Bell off”.
H9 HIGH SPEED
H3 CHECK OIL FILTER Pilot light. Illuminates when the control lever,
Pilot light. Illuminates when the oil pressure hoisting/lowering, is in high speed position.
over the oil filter is more than 5 bar.The oil Actual load in hook, SWL, is shown by the
filter is saturated and ought to be changed or load indicator in the cabin. The load indicator
hydraulic system is to be checked. has two scales:
- Low speed - blue colour.
H4 CONTROL SYSTEM ERROR - High speed - red colour.
Pilot light. Illuminates when an error is

S10 1 / 0 (Start/Stop) are pushed. When all emergency stops are

Pushbutton with two positions: reset push the button to switch off the pilot
- Position "1" starts the complete crane. light.
During the starting sequence the ”Do not If the pilot light still does not go out the
operate” pilot light illuminates. interlocking contact is activated due to less
- Position "0" stops the complete crane. The power supply to the crane.
power supply to the main electric motor,
the feed pump motor, running in normal S15 DECK LIGHT
speed "Summer" position, and electronics Pushbutton. On/Off. Activates an impulse
will be broken. When the feed pump is relay that activates the deck light.
running in low speed, ”Winter” position
(advised at an outside temperature lower S16 HEATER CABIN
than +5°C), then after stopping the crane, Switch. On/Off. Starts and stops the cabin
the feed pump continues to run. heater.
S11 SIREN S17 CABIN LIGHT

Pushbutton. The siren sounds when the Switch. 0 / I. On/Off.
pushbutton is activated.
S18 FLOOD LIGHT
S12 FLOAT SWITCH Pushbutton. Activates an impuls relay that
This four position key switch is normally in activates the flood light.
position "1".
Normal oil level is between MIN and MAX. If S19 WIPER
the oil level drops the indicator lamp ”Low oil Switch. Normally in position "0". Switch in
level” illuminates and the alarm will sound. position "1" starts the wiper.
A key is needed to select the following three
positions: F20 RESET WIPER
1) The ”TEST” position is used to check the Pushbutton. Resets the wiper motor
function of the siren/bell, as well as if the (automatic fuse), when the wiper motor has
”Low oil level” and the ”Do not operate” lamps stopped due to a too high current.
illuminate.
2) The ”BELL OFF” position is used in an S21 EMERGENCY STOP
emergency. The siren/bell will be silent and Pushbutton. Stops the complete crane in
the indicator lamp ”Low oil level” goes out. case of emergency. The pushbutton has to
The operation of the crane may be continued be reset, otherwise the crane cannot be re-
for a short time. Check why oil level has started.
dropped!
3) The ”BY-PASS” position is in Extreme S22 VENTILATION FAN
Emergency to lower a load which is hanging Switch. Starts and stops ventilation fan in
in the hook. The ”Low oil level” lamp continues cabin.
to illuminate and the crane siren/bell sounds.
S23 LUBRICATION SLEWING BEARING
S13 PARKING OF JIB Key switch. Is normally in position AUTO.
Key switch. Is normally in position "0". - AUTO position: The greasing starts and
When luffing out is stopped due to the maxi- stops at intervals, which are set and
mum outreach limit switch, further lowering of controlled by a time relay.
the jib is possible (for parking purposes of jib) - MANUAL position: The greasing pump is
only if the key switch is turned to position "1". running continously.
When the key switch is turned to position "1"
the movements luffing and slewing operate in The greasing pump is running even if the
speed reduce. crane is stopped or main switch Q1 is in
position "OFF".
H14 RESET EMERGENCY STOP
Pushbutton with pilot light. The pilot light S24 OIL FILTRATION
illuminates when the emergency stop(s) is/ Switch. ON/OFF.
Starts and stops the filtration.

Filtration can be switched on/off indepen- S32 CONTROL LEVER, LUFFING/SLEWING

dent of main switch Q1 is switched on or off. With the control lever in neutral position the
brakes are engaged.
H25 ALARM Moving the control lever short distance from
Buzzer. Sounds for 20 sec. and indicates neutral releases the brake for luffing winch
contamination in the hydraulic system. See or/and slewing machinery.
separate instruction 5.025.2 E. Moving the control lever furthermore in luffing
or slewing direction means continued speed
S31 CONTROL LEVER, HOISTING/LOWERING increase from zero to max. speed.
When control lever is in neutral position the To give a smooth acceleration and retarda-
brake is engaged and holds the load. tion to the luffing winch movement and the
Moving control lever in low speed or high slewing movement the control system is fitted
speed position releases the winch brake. with a ramp former with a special ramp time.
Moving control lever in hoisting or lowering The ramp time is the same as it takes the
direction means continued speed increase luffing winch speed or the slewing machin-
from zero to max. speed. ery to increase from standstill to maximum
To give a smooth acceleration and retarda- speed when the control lever is moved rap-
tion to the winch movement the control sys- idly from zero to maximum speed position.
tem is fitted with a ramp former with a special In the same way it also takes the
ramp time. corresponding ramp time to decrease the
The ramp time is the time it takes to increase winch speed from max. to standstill if the
the winch speed from standstill to maximum control lever will be dropped.
speed, when the control lever is moved The ramp time for luffing is 2 sec. and for
rapidly from zero to maximum speed posi- slewing 4 sec. See Fig. 3 and 4.
tion. In the same way it also takes the corre-
sponding ramp time to decrease the winch Power swivel, slewing CCW *
speed from maximum speed to standstill, if Press pushbutton on the top of the control
the control lever will be dropped. lever.
The ramp time for the hoisting system is 2
sec. See Fig. 2.
Power swivel, slewing CW *

Press pushbutton on the top of the control
lever.
Control lever movement

Start - acceleration Retardation - stop

Speed
Speed max.
max.
Time
Time 2 sec. 2 sec.
2 sec. 2 sec.
Acceleration Retardation
Fig. 2. Hoisting/lowering. Fig. 3. Luffing.
* Pushbuttons on top of the control lever to be used only when operating extra equipment e. g. power swivel.

Speed
max.
Time
4 sec. 4 sec.
Fig. 4. Slewing.
CT1 Electric Cabinet
S50 FEED PUMP MOTOR

Switch.
Summer
When outside temperature is above +5°C
set switch in SUMMER position. Set main
switch in position "ON" (1).
Winter
When outside temperature is below +5°C
set switch in WINTER position. Set main
switch in position "ON" (1) some 24 hours
before operation.
Test
This switch position is used when servicing
hydraulic system.
Also when overheating occurs this switch is
set in TEST position.
Only cool fan and feed pump start and oil
circulates in the system.
S51 EMERGENCY STOP

Pushbutton. Stops the complete crane in
case of emergency. The pushbutton has to
be reset, otherwise the crane cannot be re-
started.
Q1 MAIN SWITCH
Cuts off the main power to CT1-cabinet.
DANGER! Separate feed in CT1-cabinet!

Powered even when main switch is switched
off.

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.

EMERGENCY ESCAPE INSTRUCTIONS

Rope Ladder / Fixed Ladders
Leaving Crane Operator's Cabin Using Leaving Crane Operator's Cabin Using
Rope Ladder Emergency Ladders
1. Exit through the window to the escape ladder on 1. Exit through the window to the emergency ladder
the outside of the cabin. on the outside of the cabin.
2. Release the rope ladder by removing the strops
and pull the rope ladder out of the console and let
it fall down towards the deck.
1
Emergency
ladder
Rotating
ladder
Strops
Hand rail
2
Foot rail
Fixed ladder
Deck level

OPERATION 4.620.1 E rev.: n 2004-12-16
Parking the Crane, Sea Stowing

General Instruction
Introduction Sea stowing with cargo hook/block

hoisted to jib top, see Fig. 6
Prior to sea voyage, the jib/jib extension should be
put on its parking support (see Fig. 1). The hook is 1. Lower the jib into parking support, using the key
to be stowed to deck, fibrestrops with low ultimate switch "Parking of jib". See Fig. 2.
load or manual stretching screw must be used (see 2. Run the block up against the jib. Do NOT tighten
Fig. 6). If the hook is not secured to deck a jib safety to hard. (The jib must still be resting on the
lock is recommended to lock the crane jib in the support).
parking support. See Fig. 7. 3. We recommend to secure the hook to the deck
with a rope otherwise the hook will be swinging
Sea stowing with cargo hook secured during sea voyage. See Fig. 3.
to deck, see Fig. 1
When parking the jib with the hook block hoisted to
1. Lower the jib into parking support, using the key jib top it is important that the parking support is
switch "Parking of jib". See Fig. 2. provided with an arrangement to lock the crane jib/jib
2. Run the block up to suitable height. extension. See Fig. 7.
3. Secure hook to deck as shown in Fig. 6.
Fig. 1. Jib/jib extension on parking support.
PARKING OF JIB
0
1
Fig. 2. Switch in cabin.

OPERATION 4.620.1 E rev.: n 2004-12-16
Important! Prior to cargo handling

The wire ropes must not be tightened. The crane
structure, wire ropes, sheaves, and winches are Make sure the hook and the crane jib are loosened
subject to heavy stress during sea voyage. before raising the jib from the parking support.
Also ensure that the crane jib is luffed-in to its
Note! Releasing the hook from sea stowing position working area (e.g. within max. outreach).
must be done manually as the hook will start
hoisting when the brake is released.
Rope
Fig. 3. Block secured to deck by using a rope.

OPERATION 4.620.1 E rev.: n 2004-12-16
Crane jib parked on next crane housing

or foundation, see Fig. 4 and 5. (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.
Crane No. 2 Crane No. 1
Fig. 4. Jib parked on crane housing.
Example:
Before operating the crane carefully check that the Jibs parked in their jib supports on the foundation
crane jib has been removed from its parking towards each other. Hook secured to deck, see
support. Fig. 6.
Crane No. 2 Crane No. 3
Fig. 5. Jib parked on foundation.

OPERATION 4.620.1 E rev.: n 2004-12-16
Rope connection
Stretching screw
turnbuckle
Notice! Hand-tighten only to the

Deck
extent that the tightening gear is
not slack.
Fig. 6. Hook secured to deck.

OPERATION 4.620.1 E rev.: n 2004-12-16
Jib parking arrangement
Lifting block tightened to jib top with hoisting rope.
Jib support incl. jib locking arrangement
Fig. 7. Jib parking arrangement.

OPERATION 4.620.1 E rev.: n 2004-12-16
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. 8. Grab lowered to deck, fixed with suitable tightening equipment.
Example: Example:
Fix block
with wire
ropes
Deck Deck
Angle bar Angle bar
Fig. 9. Power swivel with lifting block secured to deck. Fig. 10. Power swivel secured to deck.

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 positioned, so that the hoisting ropes cannot deviate
are so placed that the hoisting wire can be more than 5°, at the most, from the crane house
maintained very nearly vertical during operation. centre line.
The crane jib should be set at an angle where it will
not require any subsequent shifting in order to N.B. The capacity of the wire pulling the hatch
achieve the required lifting height. cover 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 (1)
MAINTENANCE 5.005.58 E rev.: - 2005-01-14
Maintenance Chart
Lubricate crane according to LUBRICATING After 50 operating hours (running-in

CHART. period)
Daily or before taking crane into operation Oil tank, power swivel (optional)
- The first oil change see instruction, section 7.
Hydraulic oil tank
- Check oil level.
Every month
Slewing gear case
- Check oil level. See instruction, section 6.1. The
Escape device
oil quantity is marked on the name plate and in
- Visual inspections should be carried out with
instruction "Technical Data", section 2.
particular attention being paid to the condition of
the rope.
Winches, hoisting and luffing
- Check oil level. See instruction, section 6.1. The Automatic lubrication of slewing bearing, see
oil quantity is marked on the name plate and in instruction in section 5
instruction "Technical Data", section 2.
- Check grease pump, low level indicator, hoses
and couplings inside crane house.
Filter service indicator
- Check filter service indicator.
- If necessary, change filter cartridges, see
instructions "Filters" and "Filter, Extra Off-line
Filtration", section 5. Every 200 operating hours or every two
months
Limit switches; compare section 6.3 instruction
for stop position Pumps
- Testrun all functions and check that they are - Check for leakage.
working properly.
Multiple-disc brake, slewing gearset/winches
Slack wire switch - The drain plug shall be taken out every 200 hours
- Function test, see instruction, section 6.3. of operation, to drain off oil that may have been
collected.
Loose gear
- Check that block, beam, hook, swivel and shackle Slewing bearing screws, studs/nuts
are intact. Check according to instruction "Lifting - Inspect visually the slewing bearing screws or
block", section 6.2. studs/nuts from deck and inside pedestal. If any
screw or stud/nut shows any tendency to slacken,
tighten all screws or studs/nuts with a torque
wrench or a hydraulic tensioner according to
drawing "Slewing bearing, yard mounting" and
"Slewing bearing, mounting", section 9.3.

Wire rope sockets Every 500 operating hours or every six

- Check that wire rope thimbles are safely secured. months
- Check split pin for wear and damage.
- Change if necessary.
Oil cooler
Filter casette, ventilation fan, cabinet CT1 - Inspect oil cooler externally. Clean when required.
- Change filter casette.

Wire ropes, wire rope clamps
Note! It is important to change filter casette at - Inspect for wear. See instruction "Handling,
correct intervals to obtain as high cooling as Installation and Maintenance of Steel Wire Ropes"
possible. in section 6.2.
- Wire ropes are inspected according to stipulations
issued by classification associations and national
bodies.
After 200 operating hours - Check that wire rope clamps on wire drums are
safely secured.
Slewing gear case

Wire sheaves
- The first oil change. (Running-in period 200 hours.)
- Inspect for wear.
See instruction, section 6.1.
- Check that shafts are safely secured.
Winches, hoisting and luffing

Climb protection, jib top
- The first oil change (Running-in period 200 hours.)..
- Inspect climb protection for wear and damage.
See instruction, section 6.1.
- Check play between wire sheave and climb
protection. See instruction in section 6.2.
Multiple-dics brake, output side
- The first oil change (Running-in period 200 hours.).. Slack wire device
.
- Inspect rollers for wear or damage.
Electrical equipment including slip-ring unit

Every 3 months
- Inspect according to “Electrical Equipment,
Automatic lubrication of slewing bearing, see General Maintenance” in section 6.3.
instruction in section 5
Heating elements, cabinet CT2
- Fill grease in grease container on grease pump.
- Check grease pump, hoses and couplings inside - Check that the elements in cabinet CT2 is working
crane house i.e. get warm.
- Check function of time relay.
- Check hoses/pipes on outside of crane house. Crane house, foundation and jib welding joints
- Inspect for any sign of cracks.
See "Inspection of Stressed Components and
Structures", section 5.

Hydraulic system Winches

- Measure the pressures according to the hydraulic - Change oil. See instruction, section 6.1.
circuit diagram’s adjoining list, section 9.4.
- Reset as required.
Air breather, hydraulic oil tank
- Check and change air breather on top of the tank.
Oil analysis (oil tank)
- Sample oil and analyse every six months.
Hydraulic accumulators
- Check pressure, re-charge as required. See
Pump servo instruction “Hydraulic Accumulators”, section 6.1.
- Check plussing.
- If necessary adjust.
Cable winch (optional)
- V-belt, check tension.
Slewing gear, pinion - Slip-ring unit, check.
- Check backlash. - Brake discs, check.
- Brush holders, check.
Slewing bearing See instruction, section 7.
- Check seals.
Multiple-dics brake, motor side
Filter service indicator - Check for leakage.
- Check braking torque. Check according to
- Change filter cartridge. See instructions "Filters"
instruction "Winch", section 6.1.
and "Filter, Extra Off-line Filtration", section 5.
Multiple-dics brake, output side

Slip-ring unit
- Check for leakage.
- Check brush holders and wire brushes according
- Check braking torque. Check according to
to instruction in section 6.3.
instruction "Winch", section 6.1.
External access ways

Slewing bearing
Inspect for wear and damage.
- Grease sampling see instruction 625/1579 E.
Emergency escape ladder (optional)

- Inspect for wear or damage.
Every 2000 operating hours or every two
years
Every 1000 operating hours or at least

Hydraulic oil tank
every year
- Take out the drain plug.
- Drain oil and clean the reservoir. (See “Hydraulic
Slewing gear case oil tank”, section 5.).
- Verify that the oil level float switch is working
- Change oil. See instruction, section 6.1.
properly. This inspection is verified when changing
oil or cleaning of oil tank.

- Check air breather cap. Multiple-disc brake, output side

- Top up with fresh oil according to “Lubricants for - Change brake discs.
deck machinery”, section 5. - See instruction "Winches", section 6.1.
- Change all oil filter cartridges.
Hydraulic hoses inside crane house

Multiple-disc brake, slewing gearset - Check hydraulic hoses for damage. See
- Check for leakage. instruction section 6.1.
- Check braking torque.
- Check discs.
- Check according to instruction "Slewing gearset,
section 6.1.
Every ten years
Oil tank, cable winch (optional)
- Replace all hydraulic hoses. See instruction in
- Drain oil, turbo coupling.
section 6.1.
- Drain oil, spur gear.
See instruction, section 7.
Oil tank, power swivel (optional)

- Drain oil and clean the reservoir. See instruction,
section 7.
Every four years
Slewing bearing screws, studs/nuts

- Tighten all screws or studs/nuts with a hydraulic
screw tensioner or a torque wrench. Tightening
torque, see separate drawing, "Slewing bearing,
yard mounting" and "Slewing bearing, mounting",
section 9.3
- Consult MacGREGOR Cranes before replacing
studs or screws with any other specifications than
recommended.
Every five years or every 5000 operating

hours
Multiple-disc brake, motor side

- Change brake discs.
- See instruction "Winches", section 6.1.

MAINTENANCE 5.018 E rev.: b 2004-05-24
Inspection of Stressed Components and Structures
Introduction
Stressed parts of the crane structure subjected This inspection should be performed at intervals
to high loads require inspection for signs of cracks according to the Maintenance Chart.
and other damage at regular intervals.
Note!
Cracks detected at an early stage do not Rust on a painted surface does not necessarily
generally impair the handling safety of the crane mean that there is a crack in the underlying mate-
unless they are not repaired. rial.
For safety reasons, service routines should in-

Remedy
clude a regular inspection of the entire crane, with
When rust is found on top of or near a weld, grind
particular attention paid to stressed parts. Check
the topmost surface layer away to expose the crack
also the parking support for wear and cracks, see
clearly. When in doubt, use Magnaflux to identify
Fig. 2.
the crack.
Inspection Before repairing of a crack in a stressed part, al-

A thorough visual inspection is fairly easy to carry ways contact MacGREGOR Cranes, Service De-
out as cracks will generally show by cracking or partment for advice.
flaking of the paint followed by a brownish discol-
oration by rust.
(Inspect welds and surrounding material.)
Example:
Fig. 1. Crane structure. Fig. 2. Parking support.
1 (1)
Contamination Switch - Chip Detector
General
The crane hydraulic system is fitted with contamination The switches are used for early detection of wear in
switches/chip detectors in all main hydraulic circuits. the axial piston units as hydraulic pumps and motors
e.g. in the bearings of axial piston units.
The switches are connected to the housing of all main
pumps. Hoisting circuit pumps item 1243 and 1244,
luffing circuit pump item 2243 and slewing circuit pump
item 3243, see Fig. 1. See also hydraulic circuit
diagrams, Fig. 5-7.
3243
2243
1243
Connection T1 Connection T1
Connection T1
3111
2111
1111
1244
Connection T1
Slewing
Luffing 1112
Hoisting
Fig. 1. Pumps in crane.

Function
The contamination switch, see Fig. 2, has a perma-

nent magnet, which draws the ferromagnetic dirt
particles from the passing fluid. At increased
accumulation of dirt particles an electric connection
is provided from the magnet to the surrounding steel
sleeve. At a certain level of particles a warning sig-
nal is provided.
All switches are electrically connected to the control

panel in the operator's cabin, see Fig. 4 . The control
panel includes pilot light and alarm buzzer for con-
tamination warning. See also instruction "Controls and
Indicators" in section 4. Indicator relay
The pilot light "Contamination" illuminates and

indicates contamination, if any of the contamination
switches in the pumps are activated. The buzzer
sounds for 20 seconds after indication.
There are red LEDs marked V1, V2, etc. in the CT2
cabinet, see Fig. 3. When the contamination switch
on the pump is activated a LED lights up. It is then Permanent
Sleeve solenoid
possible to check on which pump the contamination
switch is activated. Ferromagnetic dirt particles
operating as switch
V1 - Hoisting, pump1
V2 - Hoisting, pump2 Fig. 2. Contamination switch.
V3 - Luffing pump
V4 - Slewing pump
See also Electrical system, circuit diagram, section

9.5.
LED
Fig. 3. CT2 cabinet.

Maintenance
When contamination is indicated on the control pa-

31
nel, see Fig. 4, the crane has to be stopped and the
contamination switch has to be identified, removed
1 2 3
from the pump and checked.
4 5 6
The ferromagnetic dirt particles have to be removed
7 8 9
from the switch, and the switch reassembled into the CONTAMINATION
(Pilot light)
pump. 10 11 12
13 14 15
Operate the crane for another 8-12 hours, and check
for contamination indication. 16 17 18
ALARM 19 20 21
If contamination is indicated in the same circuit during (Buzzer)
this operation period, the pump/pumps in the circuit 22 23 24
has/have to be checked. 25
Check the leakage condition of the pump.

Fig. 4. Control panel.

HOISTING CIRCUIT
1
2
3
4
5
1 = CONTROL PRESSURE
2 = FEED PRESSURE IN
3 = FEED PRESSURE OUT
4 = DRAIN
5 = FLUSHING PRESSURE
Fig. 5. Part of hydraulic diagram, hoisting circuit.

LUFFING CIRCUIT
1
2
3
4
5
1 = CONTROL PRESSURE
2 = FEED PRESSURE IN
3 = FEED PRESSURE OUT
4 = DRAIN
5 = FLUSHING PRESSURE
Fig. 6. Part of hydraulic diagram, luffing circuit.

SLEWING CIRCUIT
Fig. 7. Part of hydraulic diagram, slewing circuit.

MAINTENANCE 5.127.1 E rev.:- 2005-01-03
Automatic Lubricating System, Slewing Bearing
General
The slewing bearing is lubricated automatically by a A pilot light "LOW GREASE LEVEL" in the cabin
grease pump connected to the grease ports on the indicates that the grease container is empty and must
slewing bearing by hoses/pipes, two divider valves be refilled. Illuminates only when the crane is in
and couplings, see Fig. 1. The system has separate operation.
power supply from the ship and is activated by a See also instruction "Controls and Indicators" in
time relay. The system is designed to run section 4.
continuously even when the crane is not in use. An
hour meter (BC2) in the CT1 cabinet shows the When the pump is running grease is pressed out to
running time of the grease pump. the two divider valves by the pump elements, one
for each valve. The correct amount of grease is then
Function distributed by the divider valves to the grease ports
on the bearing.
The grease container in the pump is filled with grease
by using a separate grease refilling pump. For each stroke of the divider valve grease is supplied
The grease pump is controlled by a switch, to one grease port. There is a pin on the divider
"LUBRICATION SLEWING BEARING", in the cabin. valve that moves in and out at each stroke, see
When the switch is in position "MANUAL" the pump Fig. 3. If the hose from one of the connections on
is running continuously. In position "AUTO" the pump the divider valve is clogged the distribution of grease
is controlled by a time relay and the slewing bearing from this divider valve is stopped for all connections.
is lubricated at certain intervals. The grease pump Grease will then come out from the pressure relief
is running even if the crane is stopped or the main valve on the pump element on that side, see Fig. 2.
switch Q1 is in position OFF.
Divider valve
Grease pump (on

crane house wall)
Divider valve
Rail
Pipes/hoses to
grease points
Fig. 1. Automatic lubricating system.

There is a grease nipple on the divider valve that Check grease pump, low level indicator, hoses and
can be used for manual greasing of the bearing in connections inside crane house
case of grease pump failure, see Fig. 3. - Turn the switch "LUBRICATION SLEWING
BEARING" in the cabin to position MANUAL and
Pipes/hoses on the outside of the crane are protected check that the grease pump is running.
from damage by a rail. - Check that low level indicator on pump (H2) is
not on, see Fig. 2.
Maintenance - Check hoses inside crane house for damage.
- Check if there is grease coming out of the
For maintenance intervals see Maintenance Chart pressure relief valve on any of the pump elements
in Section 5. on the grease pump, see Fig. 2. If so, a hose to
the grease points on this side is clogged. Continue
Filling grease
with procedures for identifying which hose is
Grease is filled into the grease container by using a
clogged.
separate grease refilling pump. A yellow lamp under
- Turn the switch "LUBRICATION SLEWING
the crane bottom plate lights up when the grease
BEARING" in the cabin back to position AUTO
container is full. This lamp is functioning even if the
crane is stopped.
Identify which hose is clogged
- Turn the switch "LUBRICATION SLEWING
BEARING" in the cabin to position MANUAL.
(H3) Level too high = red
DC voltage OK = green - Check that the grease pump is running.
- Check that hose between pump element and
divider valve is not clogged.
(H2) Low level
indicator - Disconnect the upper hose from one side of the
divider valve.
(H1) Full level - Check if grease is still coming out of the pressure
relief valve.
- If so, connect the hose and disconnect the next
hose on the same side of the valve.
Hose from
pump element
Grease nipple (for
manual greasing)
Pressure
relief valve Grease
container
Pump
element Hose to slewing
bearing
Pressure
relief valve
Connection for
grease refilling
pump Pump
element
Pin
Fig. 2. Grease pump. Fig. 3. Divider valve.
2 (3)
- Check all hoses on the same side of the valve, - Reset the interval for the time relay to correct
one by one, and then the hoses on the opposite setting, see "Setting list" inside CT1-cabinet or
side. When no grease comes out of the in Electrical System drawing.
pressure relief valve the clogged hose is
identified. Note! In case of time relay failure the slewing bearing
- Clean the hoses/pipes and make sure that no can be greased by putting the switch
grease comes out of the pressure relief valve, "LUBRICATION SLEWING BEARING" in the cabin
ie. that the distribution of grease, all the way to to position MANUAL.
the bearing, is functioning.
- If cleaning of the hoses/pipes cannot be done Inspection of hoses and connections on outside
within a short period, leave the hose disconnected of crane house
and use a suitable container for taking care of - Check pipes/hoses on outside of crane house for
the grease from the pipe coupling. This will ensure damage.
lubrication of the rest of the grease nipples
connected to this divider valve. Note! Use life line when checking pipes/hoses on
- Clean connections on grease pump. outside of crane house.
- Turn switch "LUBRICATION SLEWING
BEARING" in the cabin to position "AUTO". Manual lubrication in case of grease pump failure
In case the automatic lubricating system does not
Check function of time relay (K84) function the slewing bearing must be lubricated
- Change interval on time-relay to 1 min on start and manually every 100 working hours.
stop, see Fig. 4. Lubricate the slewing bearing by pumping grease
- Turn the switch "LUBRICATION SLEWING into the grease nipples on top of each divider valve,
BEARING" in the cabin to position AUTO. see Fig. 3.
- Test function of time relay and greasing pump. For grease volume needed, see Lubricating Chart in
Section 5.
Lubrication should be performed under slewing

motion. If that is not possible to lubricate bearing
through grease fittings on divider valve, then turn
bearing approx. 200 mm and lubricate again. Repeat
Setting screw Start interval this procedure until overlap of greasing is achieved
and the whole bearing circumference is filled with new
grease at the gaps and seals. (Five movements/
greasings should be sufficient.)
Setting screw Stop interval
Fig. 4. Time relay.

LUBRICATING CHART PM51 1712-E00 rev.: - 2005-01-18
Item Part of crane (see page 2 for location) a b c d e f

1 Wire sheaves, Crane house top: 1 nipple/sheave (5-8 nipples) *
2 Wire sheaves, Jib stay: 1 nipple/sheave (1-2 nipples) (not on all cranes)
*
3 Wire sheaves, Jib top: 1 nipple/sheave (4-9 nipples) *
4 Wire sheaves, Lifting block: 1 nipple/sheave (1-2 nipples) *
5 Wire rope sockets: 2 pcs (in some cases on jib or block)
***
6 Swivel, Lifting block (Single) or Lifting beam (Twin): 1 nipple
7 All wire ropes
8 Electric motor: 2 nipples
9 Door hinges: 3 nipples
10 Jib bearings: 2 nipples
11 Oil tank
12 Air breather cap
13 Oil filters
14 Slewing gear case
15 Slewing bearing teeth
16 Slewing bearing - Automatic lubrication **
17 Hoisting + Luffing winches, bearing: 1 nipple/winch
18 Hoisting + Luffing winches, oil change
19 Parking cylinders: 4 nipples (optional)
Check what number of nipples that apply to your Key to symbols

* crane. It is of utmost importance that all nipples a Daily
are greased. b Every 100 working hours (or before taking
winch into operation, item 17)
c Every 200 working hours or every two months
Automatic lubrication. Volume of grease
** needed for manual lubrication = 7.5 kg. See
d Every 500 working hours or every six months
e Every 1000 working hours or every year
instruction in section 5. f Every 2000 working hours or every two years
Key to symbols
Before greasing proceed as follows:
*** Grease for ball and roller bearings
Crane jib parked on parking support: Grease for plain bearings
Park the crane and slack the luffing and hoisting Grease for wire ropes
wire.
Grease for open spur gears
Crane jib parked in wires: Grease for jib bearings
Hoisting wire - slacken the wire by lowering the Oil level, check
lifting block to deck. Oil filters, check
Luffing wire - run the block up against the jib Air breather cap, check
top to slacken the luffing wire.
Hydraulic oil, oil change
Gear case oil, oil change
The first oil change to be done after 200
working hours†(running-in period)
Gear case oil, oil change
The first oil change to be done after 200
working hours†(running-in period)
Slip-rings to be treated according to

separate instruction, see section 6.3.
Documents 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.

LUBRICATING CHART PM51 1712-E00 rev.: - 2005-01-18
Red lamp on right control panel in operatorís cabin Jib top with lifting block for single crane
CHECK 3. Wire sheaves
OIL FILTER
7. Wire ropes
4. Wire sheave(s)
6. Swivel
CAUTION!
Renew all filter cartridges
when this lamp is lit. The lifting block can have either 1 or 2 wire sheave(s).
Central greasing, see examples

Wire sheave(s) on jib stay for Lifting beam with hook for below:
cranes with special design twin cranes
Example: Wire sheaves jib top,
central greased.
3
6. Swivel
2. Wire sheave(s) 7
4
1. Wire sheaves
Filter service
indicator 6
5. Wire rope sockets
13
2
Filter 4135
Example: Wire sheave(s)
on jib stay central greased.
The sheave(s) to be lubricated
from the crane house top with
the crane jib positioned in min.
outreach.
13 Oil filling
8. Electric motor
Filter 4136-1 9. Door hinges
Example: Wire sheaves crane top, manual

and central greased.
Filter
service
indicator
13
Filter
4137
Manual greased
Grease central
12. Air breather cap

13. Oil filters
11. Oil tank
17, 18. Luffing winch
17, 18. Hoisting winch 14. Slewing gear case
19. Parking cylinders

16. Slewing bearing 10. Jib bearings
15. Slewing bearing teeth

MAINTENANCE 5.150.1 E rev.: b 1999-03-15
Lubricating and Maintenance

Cranes type GL
Contents
Door hinges ................................................................. 2

Electric motor .............................................................. 3
Slewing bearing ........................................................... 4
Jib bearing ................................................................... 5
Wire sheaves Jib ......................................................... 6
Wire sheaves Crane house .......................................... 7
Wire rope sockets ........................................................ 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
Parking cylinders (optional) ....................................... 16
Cable winch (optional) ............................................... 17
Power swivel (optional) .............................................. 18

Door hinges
Grease nipple;
Service door
Grease nipple;
Door in crane house top

Electric motor
Grease nipple;
Upper bearing
Grease nipple;
Lower bearing

Slewing bearing
Grease nipple; Grease;

Slewing bearing Slewing bearing teeth

Jib bearing
Grease nipple;
Inside cranehouse

Wire sheaves Jib
Grease nipples; Jib top Grease nipples; Jib top, Central lubricating
Grease nipple;
Jib stay

Wire sheaves Crane house
Grease nipple for one sheave
Grease central for several sheaves

Wire rope sockets
The wire rope sockets can also be located on jib top

or lifting block.
Grease

Slewing gear case
Oil change Air breather
Check oil level
Oil drain plug

Lifting equipment
Grease nipples, Lifting block
Grease nipple, Swivel

Oil tank
Check air breather

Check oil level (dipstick)
Drain oil tank

Oil filter
Filter unit, outlet Filter unit, inlet

Oil filling Electrical indicator

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 of sure not to lose
the filter unit the
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 not
26 mm) 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
6 the spanner.
cartridge.
Install the new
O-ring Mount the drain-plug and the O-ring on the
7 filter cap and tighten it using the spanner.
between the
filter cap and
the filter head.
Install the new
filter cartridge.

Wire ropes
Relubricating of steel wire ropes, see instruction

6.222.1 E.
Grease

Winch with high speed motors
Grease nipple
Oil filler inlet

Oil dipstick
Grease nipple
Oil outlet

Parking cylinders (optional)

Grease nipples;
left cylinder
Grease nipple
Grease nipple
Grease nipples;
right cylinder

Cable winch (optional)
Oil change; Spur gear

Grease nipples; Electric motor
Oil drain plug;

Spur gear
Oil change; Turbo coupling

Power swivel (optional)
Check oil level (dipstick)
Grease nipples, ball bearing
Drain oil tank (seen from below)

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 approx. 45°C.
4135 and 4136. Upon reaching a certain degree of clogging, a red
indication can be seen on the top of the filter indicator.
Filter Indicators Replace both filter cartridges in the system when the
red indication shows.
The filter indicators function only when the crane is
started.
Replacing Filter Cartridges
Filter 4135 is equipped with two filter indicators. One Both cartridges (see Fig. 3) in the crane should be
indicator is electric and activates a warning lamp replaced at the same time. Flush all other parts of
placed on the control panel in the cab (see Fig. 4). the filters with white spirit when changing cartridges.
Use new seals. Reassemble the filters.
4101 Visual 4102

indicator
Electric
indicator
Filter Filter
4135 4136
Fig. 1. Filter inlet Fig. 2. Filter outlet
Filter cartridge
Fig. 3. Filter cartridge Fig. 4. Control panel

Filter
Extra Off-line Filtration
Introduction
To achieve extra filtration of the hydraulic system the The other indicator is visual (see Fig. 1) and should
crane is equipped with an extra filter, marked 4137. be read when the oil temperature is approx. 45°C.
Upon reaching a certain degree of clogging, a red
Filter indicators indication can be seen on the top of the filter indicator.
Replace filter cartridge in the system when the red
The filter indicators function only when the separate
indication shows.
pump, 4114, is started.
Filter 4137 is equipped with two filter indicators. One Replacing filter cartridge
indicator is electric and activates a warning lamp The filter cartridge (see Fig. 2) should be replaced at
placed on the control panel in the cabin (see Fig. 3). the same interval as the main filters. Flush all other
parts of the filter with white spirit when changing
cartridge. Use new seals. Reassemble the filter.
Electrical
indicator
Visual indicator
Filter cartridge
Filter
4137
Fig. 1. Filter. Fig. 2. Filter cartridge.
Fig. 3. Control panel

MAINTENANCE 5.302.16 E rev.: d 2002-05-27
Hydraulic Oil Tank
The hydraulic oil tank is placed on the crane house Filling oil
floor. The feed pump is located inside the oil tank. The Oil is filled at an ”aero-quip” type quick-release coupling,
main pump unit drive gearing is continually lubricated placed on the filter unit, see Fig. 2. When filling oil the
by oil from the hydraulic system, surplus oil being hydraulic system must be at rest and the electric power
returned to the tank by a drain line. switched off.
Checking oil level Fill oil to just under the MAX mark on the dipstick. Use
The oil tank has a dipstick to indicate the oil level. oil according to the ”Lubricating chart”.
Check that oil level is between min. and max on the
dipstick. NOTE! Oil must not be filled directly into the tank.
Oil level float switch Cleaning the oil tank
If the oil level drops below a certain minimum level an Before cleaning the oil tank, immobilise the crane jib in
oil level float switch installed in the oil tank, operates a suitable manner, push the stop button and switch off
alarm signals on the control panel in the operator's cab. the power. Drain off the oil into clean empty barrels or
drums.
Verify that the switch is working properly by starting the
crane, loosen the nut that holds the switch and lifting it
up slowly.
Oil filling
8
8
1.Radiator hose
2.Hydraulic hose
3.Vedge valve
2
4.Air filter with dipstick
5.Oil level and temperature guard
1 6.Feed pump
7.Quick coupling
8.Filter
9.Thermometer
Drwg. 188 1591
9
3 7
6
Fig. 1. Tank with feed pump unit

MAINTENANCE 5.302.16 E rev.: d 2002-05-27
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
Oil filling
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. Fig. 2. Oil filter
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”.

MAINTENANCE 5.315 E rev.: a 2003-04-04
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 service information describes sampling oil from - Special oil sampling bottles should be used and
a hydraulic 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
taken every six months and sent for analysis. This
the 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.
Procedure if Oil Sample is Showing Too High
Contamination
For maximum practical contamination in the sys-
tem, see Table 1. If the oil analysis shows too high contamination,
the oil and the filters should be changed. The crane
should be driven for approx. 1 hr and a new oil sam-
ple should be taken and sent for analysis.
Pump Hose
Gauge outlet 3.1

Bottle
Fig. 1. Sampling Hydraulic Oil.

MAINTENANCE 5.315 E rev.: a 2003-04-04
Cleanliness Level Correlation Table
Particles/millilitre
ISO ≥ 5 Micro- ≥ 15 Micro- ACFTD NAS Disavowed
Code meters meters Gravimetric 1638 "SAE" Level
Level, mg/L (1964) (1963)
26/23 640.000 80.000 1000
25/23 320.000 80.000
23/20 80.000 10.000 100
Not
21/18 20.000 2.500 12
OK
20/18 10.000 2.500
20/17 10.000 1.300 11
20/16 10.000 640 10
19/16 5.000 640 10
18/15 2.500 320 9 6
17/14 1.300 160 8 5
16/13 640 80 1 7 4
15/12 320 40 6 3
14/12 160 40
14/11 160 20 5 2
OK 13/10 80 10 0.1 4 1
12/9 40 5 3 0
11/8 20 2.5 2
10/8 10 2.5
10/7 10 1.3 1
10/6 10 .64 0.01
Table 1. Cleanliness Level Correlation Table.

MAINTENANCE 5.320.2 E rev.: a 2005-02-04
Extra Off-Line Filtration of Hydraulic System
General
The crane hydraulic system is fitted with a off-line filt- The hydraulic oil circulates from the oil tank through
ration circuit. For best performance of the filtration the vedge valve 4332, through a separate pump unit,
the off-line filtration is normally in constant operation 4114, through filter 4137, check valve 4171 and filter
regardless if the crane is in use or not. unit outlet 4102. The oil is then cooled by the oil cooler
4211. See Fig. 1.
Note! The vedge valve 4332 must be open during

operation.
4211
B6 B1 A1
4101
B2
4102
Oil tank
Open
4171
4137
Closed
Vedge
4114 valve 4332 (4332)
Fig. 1. Filtration of hydraulic system.

MAINTENANCE 5.320.2 E rev.: a 2005-02-04
Function
31
The circulation pump for the off-line filtration is
CHECK OIL FILTER
controlled from the control panel by switch S24, see
Fig. 2, in the operator's cabin. This switch should 1 2 3
normally be in position "ON".
4 5 6
The "OIL FILTRATION" switch has two positions, see 7 8 9

Fig. 3:
10 11 12
ON - starts the filtration
13 14 15
OFF - stops the filtration
16 17 18
Note! The filtration can be switched on/off indepen-
OIL FILTRATION
dent of main switch Q1 is switched on or off. 19 20 21
The filter is equipped with a visual service indicator 22 23 24

as well as an electrical indicator, which activates a 25
warning lamp, H3, in operator's cabin. See Fig. 2
and 4.
Fig. 2. Control panel.

Maintenance
- When performing maintenance work in the off-line OIL FILTRATION

filtration equipment the OIL FILTRATION switch
ON
should be in position "OFF".
OFF
- Vedge valve 4332 must be closed during the
maintenance work.
- Open the vedge valve 4332 and set the oil filtration
switch in position "ON" when maintenance work is
completed.
The filter has to be changed according to the

Fig. 3. Switch on control panel in cabin.
Maintenance Chart, 5.005.58 E in section 5.
Visual indicator
Electrical
indicator
Filter
4137
Fig. 4. Filter.

Lubricants for Deck Machinery

A. OILS
The oil shall be refined oil containing additives against Cable winch, turbo coupling (if applicable)
oxidation, rust and foaming, as well as wear inhibitor Viscosity 22 cSt/40°C (ISO VG 22).
and/or EP additives. Example: SHELL MORLINA.
Slewing gear unit Cable winch, spur gear (if applicable)

Synthetic oil (polyglycol type).
Synthetic oil brand.
Viscosity 220 cSt/40°C.
Example: MOBILE Glygoyle 30.
Viscosity index (VI) 210.
Solidification point -30°C or better.
The oils pass 12 stage in FZG, DIN 51 354. B. GREASES
CAUTION! The oil must not be mixed with mineral oil
or synthetic gear oil on PAO-basis. The oil can also
dissolve paints and some seals. Plain bearings and wire rope sockets
Example: Shell Tivela WB or similar. Lithium grease with molybdenum disulphide.
Base oil viscosity 150 cSt/40°C.
Hoisting and luffing winches Dropping point 180°C.
Example: MOBILGREASE Special 530303.
Synthetic oil (polyglycol type).
Viscosity 220 cSt/40°C.
Viscosity index (VI) 210. Crane jib bearing
Solidification point -30°C or better. Lithium/mineral oil-based grease.
The oils pass 12 stage in FZG, DIN 51 354. NOTE: MUST NOT contain molybdenum disulphide.
CAUTION! The oil must not be mixed with mineral oil Example:
or synthetic gear oil on PAO-basis. The oil can also SKF LGMT2 or SKF LGEP2. (-30°C to +110°C)
dissolve paints and some seals. TEXACO MULTIFAC EP2. (-30°C to +100°C)
Example: Shell Tivela WB or similar.
Roller/ball bearings
Crane hydraulic system Grease with EP additives.
For service in normal conditions: Must withstand wet conditions.
Viscosity 68 cSt/40o C approx. (ISO VG 68 HV). Example: SHELL Alvania EP (LF) 2 (-20 to +130°C).
Viscosity index (VI) min. 150. Arctic climate: SHELL Albida PPS2.
Solidification point -35o C or better.
Example: SHELL TELLUS T68. Ropes
Grease resistant to salt water and with antirust
For service in arctic climate: properties. (Very thin.)
Viscosity APPROX. 46 cSt/40o C (ISO VG 46 HV). Temperature range -30 to +100°C.
Viscosity index (VI) approx. 150. Viscosity 9.8 cSt/40°C.
Solidification point -45o C or better. Example: FUCHS Cedracon.
Example: SHELL TELLUS T46. Arctic climate: FUCHS Ceplattyn.
Load handling equipment, without oil heater

Viscosity 32 cSt/40oC approx. (ISO VG 32 HV). Open spur gear units
Viscosity index (VI) min. 150. Grease with good adhesion properties.
Solidification point -45oC or better. Example: SHELL MALLEUS GL95 (-15 to +150°C).
Example: SHELL Tellus T 32. SHELL MALLEUS GL65 (-30 to +150°C).
Slip-ring unit, signal slip-rings

Limit switch boxes Example: "Cramolin B"
Should not require further oil filling throughout its
service life under normal driving conditions.
Please contact MacGREGOR Cranes when choosing
Filled with synthetic oil.
lubricants for extreme temperatures.

How to order
spare parts 6.0
SERVICE
Hydraulic system 6.1
Mechanical
equipment 6.2
Address:
MacGREGOR Cranes AB
E 2003-01-31
S-891 85 ÖRNSKÖLDSVIK, Sweden

Telephone: 46 - 660 - 29 40 00 Electrical
Telefax: 46 - 660 - 139 77 (Spare Part & Service Dept.) 6.3
Telefax: 46 - 660 - 29 42 81 (Technical Info. Dept.) equipment
www.macgregor-group.com/cranes

SERVICE 6.000.1 E rev.: b 2004-08-10
Statement Regarding Delivery of Spare Parts to Swivels,

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

AND 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

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

SERVICE 6.000.2 E rev.: - 1997-10-02
RETURN FORM
How to return parts from deck crane manufacturing,
installation or guarantee exchange
Delivery address: MacGREGOR Cranes AB

Service Department 220
S-891 85 ÖRNSKÖLDSVIK
SWEDEN
Transport means, if necessary: Advised by us on request.

Tel. no 46-660-294049
Fax no 46-660-294288
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.

SERVICE 6.000.2 E rev.: - 1997-10-02
RETURN FORM
To be packed inside return box or parcel
Date
Sent by
Newbuilding no
Ship’s name
Lloyd 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 direction“.
(222/IN: 662 5000-706)

Global Service 6.003.1 E rev.: l 2004-02-25
MacGREGOR branches with

trained crane engineers
Central spare parts stock
Regional spare parts stock
Bergen Hamburg Oslo Singapore ÖRNSKÖLDSVIK

Bombay Newcastle Pusan Sydney MacGREGOR Cranes AB
S-891 85 ÖRNSKÖLDSVIK
Copenhagen New Orleans Rio de Janeiro Tokyo
Sweden
Dubai New York Rotterdam Valparaiso Tel +46 660 29 40 00
Gothenburg Norfolk Shanghai Vancouver Fax +46 660 139 77

SERVICE & PARTS 6.004.1 E rev.: av 2004-12-10
MacGREGOR Global Services
BELGIUM Shanghai, (S) (P) FRANCE

Antwerpen, (P) MacGREGOR (SHANGHAI) Marseille, (P)
MacGREGOR (NLD) B.V. Trading Co. Ltd. MacGREGOR (FRA) S.A.
Luithagen-Haven 2E Room 1701-1704, Pidemco Tower Porte 4, Cap Janet
B-2030 Antwerpen 318 Fuzhou Road 13314 MARSEILLE Cedex 15
Phone: (+32) 3-542 5112 SHANGHAI 200001 Phone: (+33) 491-09 52 52
Telefax: (+32) 3-542 4772 Phone: (+86) 21-6391 2798 Telefax: (+33) 491-09 52 40
Telefax (+86) 21-6391 2276
BRAZIL GERMANY
Rio de Janeiro, (S) CROATIA Hamburg, (S) (P) (LCE)
Offshore Reparos Navais Rijeka, (P) MacGREGOR (DEU) GmbH
Rua Delegado Waldir Guilherme 14 MacGREGOR (HRV) d.o.o. Normannenweg 24
Ilha da Conceicao Vrh Martinscice 93B D-20537 HAMBURG
CEP: 24.50-170 HR-51221 RIJEKA-KOSTRENA Phone: (+49) 40-25 44 40
Niteroi - RIO DE JANEIRO Phone: (+385) 51-289 717 / 718 Telefax: (+49) 40-25 44 44 44
Phone: (+55) 21-2717 2673 Telefax: (+385) 51-287 154
Telefax: (+55) 21-2620 0740 Hamburg LCE
CYPRUS MacGREGOR Logistic Centre
CANADA Limassol, (P) c/o Kühne & Nagel (AG & Co.) KG
Vancouver, (S) MacGREGOR (CYPRUS) Ltd. Altenwerder Hauptstraße 1
Nagesco Ltd. Titos Building, Office 201 D-21129 Hamburg
961A West 1st Street 58 Gladstone Street Phone: (+49) 40-239 39 0
NORTH VANCOUVER, B.C., CY 3041 LIMASSOL Telefax: (+49) 40-239 39 334
V7P 1A5 Phone: (+357) 5 763 670
Phone: (+1) 604-985 61 73 Telefax (+357) 5 763 671 GREECE
Telefax: (+1) 604-980 44 76 Piraeus, (P)
DENMARK MacGREGOR (GRC) Ltd.
CHILE Copenhagen, (S) (P) 4-6 Efplias Street
Santiago, (S) MacGREGOR (DNK) A/S GR-185 37 PIRAEUS
EXIMTEC Ltda. Phone: (+30) 210-42 83 838
Smedeholm 11,
Neveria 4444 - Piso 9 Telefax: (+30) 210-42 83 839
DK-2730 HERLEV
Las Condes Phone: (+45) 44-53 84 84
SANTIAGO Telefax: (+45) 44-53 84 10 INDIA
Phone: (+56) 2-207 65 90 Bombay, (S)
Telefax (+56) 2-207 65 91 FINLAND Renascent Enterprises
Turku, (P) Flat 8, Building D/6-9
CHINA MacGREGOR (FIN) OY Radha Nagar, Barave Road
Hong Kong, (P) KALYAN (WEST), Pin - 421 301
Hallimestarinkatu 6
MacGREGOR (HKG) Ltd. Phone: (+91) 251 232 30 65
FIN-20780 KAARINA
Unit 3119, 35/F, Tower 1, Telefax: (+91) 251 232 06 43
Phone: (+358) 2-412 11
Millennium City 1, Telefax: (+358) 2-4121 517
388 Kwun Tong Road
KOWLOON
Phone: (+852) 2394 1008
Telefax: (+852) 2787 7652
Telefax: (+852) 2787 9878 (cranes)
Codes for available services from branches

(S) = Branch with specially trained crane service engineers
(LCE) = Central spare parts stock
(LC) = Regional parts stock, servicing many countries in the same region
(P) = Branch with spare parts sales resources
(S) (P) MacGREGOR Cranes AB Address Telephone Telefax

SE-891 85 ÖRNSKÖLDSVIK (+46) 660-29 40 00 (+46) 660-139 77
www.macgregor-group.com/cranes Sweden

SERVICE & PARTS 6.004.1 E rev.: av 2004-12-10
ITALY Gdynia, (P) Dubai, (S) (P)

Genoa, (P) MacGREGOR (POL) Sp. z o.o. MacGREGOR (ARE) LLC.
MacGREGOR (ITA) S.p.A. Ul. Energetykow 5 P.O. Box 30029 Dubai
PL-81-184 GDYNIA Al Jadaf Shipyard area / GMMOS Yard
Via Al Molo Giano
Phone: (+48) 58-7855 110 DUBAI
16128 GENOA/PORTO
Telefax: (+48) 58-7855 111 Phone: (+971) 4-3241 335
Phone: (+39) 010-2770 412
Telefax: (+39) 010-24 61 194 Telefax: (+971) 4-3241 271
SINGAPORE 24h phone: (+971) 50-65 10 371
Singapore, (S) (P) (LC)
JAPAN UNITED KINGDOM
MacGREGOR (SGP) Pte. Ltd.
Tokyo, (S) (P)
No. 12 Benoi Crescent Newcastle, (P)
MacGREGOR-Kayaba Ltd. - 629975 SINGAPORE MacGREGOR (GBR) Ltd.
Head Office Phone: (+65) 6265 2322 1st Floor, Power House
9/F, Suzue Baydium Bldg. Telefax: (+65) 6264 1261 Silverlink Business Park
1-15-1, Kaigan Wallsend
Minato-Ku SPAIN NE28 9ND TYNE & WEAR
TOKYO 105 - 0022 Phone: (+44) 191-295 2180
Bilbao, (P)
Phone: (+81) 3-5403 1966 Telefax: (+44) 191-295 2188
Telefax: (+81) 3-5403 1953 MacGREGOR (ESP) S.A.
Edificio Inbisa
Amaya, 2 - 1o USA
KOREA
ES-48940 LEIOA - VIZCAYA New York, (S) (P)
Pusan, (S) (P) Phone: (+34) 94-480 7339 MacGREGOR (USA) Inc.
MacGREGOR (KOR) Ltd. Telefax: (+34) 94-431 6945 14 Ridgedale Avenue
Room No 1101, Dong Ju Building Suite 205
13-5 ka, Jungang-dong, Jung-ku Alicante, (S) Cedar Knolls
PUSAN Stanley van der Pers NJ 07927-1106
Phone: (+82) 51-441 0805 c/o Vanpershydro S.L. Phone: (+1) 973-285-7860
Telefax: (+82) 51-442 5777 Apartado de correos No. 7 Telefax: (+1) 973-285-7861
ES-03170 ROJALES - ALICANTE
NETHERLANDS Phone/telefax: (+34) 9667 13665 Norfolk, (S)
Rotterdam, (S) (P) Mobile: (+34) 620 953 722 MacGREGOR (USA) Inc.
MacGREGOR (NLD) B.V. 508 John Etheridge Road
Albert Plesmanweg 95-97 CHESAPEAKE, VA 23322
3088 GC ROTTERDAM SWEDEN Phone: (+1) 757-421-9406
Phone: (+31) 10-2832 121 Örnsköldsvik, (S) (P) Telefax: (+1) 757-421-2026
Telefax: (+31) 10-4293 219 MacGREGOR Cranes AB
Björnavägen 14 New Orleans, (S)
NORWAY SE-891 85 ÖRNSKÖLDSVIK MacGREGOR (USA) Inc.
Oslo, (P) Phone: (+46) 660-29 40 00 4757 River Road
MacGREGOR (NOR) A/S Telefax: (+46) 660-139 77 Jefferson
Malerhaugveien 25 www.macgregor-group.com/cranes LOUISIANA 70121
N-0602 OSLO Phone: (+1) 504-733-3321
Phone: (+47) 23-10 34 00 Gothenburg, (S) (P) Telefax: (+1) 504-733-3360
Telefax: (+47) 23-10 34 01 MacGREGOR (SWE) AB
Atlashuset, Banehagsliden 2
Bergen, (S) SE-414 51 GOTHENBURG
MacGREGOR (NOR) A/S Phone: (+46) 31 85 07 00
Bredalsmarken. 15-17 Telefax: (+46) 31 42 49 46
N-5006 BERGEN
Phone: (+47) 23-30 25 50 U. A. E.
Telefax: (+47) 23-30 25 51
POLAND
Codes for available services from branches
(S) = Branch with specially trained crane service engineers
(LCE) = Central spare parts stock
(LC) = Regional parts stock, servicing many countries in the same region
(P) = Branch with spare parts sales resources
(S) (P) MacGREGOR Cranes AB Address Telephone Telefax

SE-891 85 ÖRNSKÖLDSVIK (+46) 660-29 40 00 (+46) 660-139 77
www.macgregor-group.com/cranes Sweden

SERVICE 6.005.5 E rev.: - 2001-11-23
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.

SERVICE 6.005.5 E rev.: - 2001-11-23
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 to
shooting panel in the CT2 cabinet, according to error find, at an early stage, the defect producing the faulty
list and signal overview list, (see instruction under operation, thereby avoiding unnecessary waste of
section 6.3). time.
Also measure the feed pressure at gauge outlets 1 and

16. Check the control pressure at gauge outlet 2. All important pressure adjusting devices are sealed.
Pressure setting levels can be found in the pressure Breaking a seal voids the guarantee unless done with
setting list on the hydraulic circuit diagram. 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.

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.

SERVICE 6.106.3 E rev.: a 2004-02-12
Trouble-Shooting Chart, Overheating
Fault Probable cause Remedy
A. Overheating in hydraulic sys- 1. Oil cooler fan does not work Check direction of rotation,
tem. or rotates in wrong direction. connections and contactor.
Effect repair as required.
2. Oil cooler element loaded Clean cooling element.

with dirt.
3. Crane house ventilation fan Check direction of rotation,

does not work or rotates in connections, contactor.
wrong direction. Effect repair as required.
4. Oil by-passing cooler. Check by-pass check valve

4221.
5. Wrong oil type used. See instruction "Lubricants for

Deck Machinery" in section 5.
6. Too little oil flow through Contact MacGREGOR Cranes.

cooler caused by wrong
function of component.
B. Overheating caused by pump, 1. Internal leakage because of Contact MacGREGOR Cranes.

valving, or hydraulic motor. wear.
Note!
When the hydraulic system is overheated thermostat BT2 (+85oC)
opens.

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.

SERVICE 6.120.15 E rev.: c 2002-12-20
Slewing Gearset
(Pinion module 14 and 16)
Oil filling Air filter - Fill gear oil as required (see lubricating instructions
Expansion tank for appropriate type; the approximate quantity
Plug a
Expansion pipe
needed is given on the nameplate).
- Fill brake disc chamber with hydraulic oil; e.g. 0,1
litre ATF-oil, type A.
Disc brake
Brake surface sealed with Loctite type 573.
Oil level sight - Before assembling the drive motor, grease shaft
glass and gear teeth with a suitable grease for protection
against corrosion; we suggest OPTIMOLY PASTE
White T.
- Check function of slewing gearset with the drive
motor running, paying particular attention to the
Screws holding function of the brake and the correct control of
gearset to crane
house floor the motor.
Oil outlet
Maintenance
Lubrication
Fig. 1. Slewing gearset. The slewing gearset is splash lubricated. The output
shaft roller bearing is ”for-life” lubricated with ball
bearing grease.
Assembly of slewing gearset

Oil level check
- Install slewing gearset in crane without using force. Inspect oil level when the gear is at rest with the brake
- Use hand pump to release disc brake hydraulically. engaged.
Input drive sleeve must turn easily.
- Check slewing gear backlash (pinion-to-rim gear). Oil changes
See description under Checking and adjusting
Whenever practicable, let the oil drain off while still
slewing rim backlash.
hot; remove also the filler plug(s).
- The gear backlash may be adjusted by rotating the
gearset one or more screw hole divisions.
For oil change open both pipes. Remove air filter with
- Tighten the screws to torque recommended, secure
oil expansion tank at marked pos. a, see Fig 1.
with Loctite 242 (or a similar compound). Applying
a suitable sealing compound, such as Loctite 640,
At low ambient temperatures, flush out the gearcase
on the mating surfaces of the flanged connection,
with a quantity of fresh oil to remove abraded matter
is recommended.
and contamination products.
- Remove threaded plug from top of expansion pipe
(for transport sealing only).
- After installation of gear unit fit supplied air filter
with oil expansion tank, at marked position a
(optional to fit with a tube turn). See Fig. 1.

SERVICE 6.120.15 E rev.: c 2002-12-20
Gearcase and oil inspection
Sampling oil
Withdraw a sample of gearcase oil for inspection from If coarser abraded matter (above 25 µ) or flake off
the filling drained off at intervals as described in the material from the gear teeth is found, the gearset must
Maintenance Chart. To obtain a representative be dismantled, irrespective of the actual amount of
sample, drain the gearcase during operation and with foreign matter present, beginning at the input end of
the oil at operating temperature. the gearset.
Oil discoloration
Hydraulic-Release Multiple-Disc Brake
A darkish or black colour of the used oil suggests
that temperatures in excess of 100o C did occur in Technical description
operation, causing accelerated aging of the oil and The brake comprises the following major
impaired lubricating properties. In this case the oil components:
should be changed at shorter intervals. - Brake piston
- Brake cylinder
If the oil sample displays a cloudy aspect, it may be - Disc carrier
that water has managed to seep into the oil. The oil - Internal discs
must then be changed a t o n c e, and the gearcase - External discs
flushed out very thoroughly several times with fresh - Sealings
oil. - Thrust spring
The gearcase should preferably be dismantled for The brake housing is mounted on top of the gearcase,
inspection beginning at the input side, and the with long assembly screws through the motor adap-
components examined for signs of corrosion. ter housing and both parts of the brake housing.
Foreign solid matter The sleeve disc carrier, with the internal discs, is fixed
on the driven shaft with a shaft key or by splines.
- As a first simple test, drop some of the used oil
onto the filter fleece specified. Coarse foreign mat-
The disc assemblies are pressed together by a set
ter, if present, will then show up on inspection,
of thrust springs and the brake is disengaged by
preferablythrough a magnifying glass.
hydraulic power.
- A better test may be made by diluting an oil sample
with n-heptane, passing it through a diaphragm
filter, washing and drying it, and weighing it to Maintenance
determine the mass difference. The brake is self-adjusting.
Overall assessment Trouble-shooting

The maximum permissible amount of foreign matter a. Braking torque insufficient
carried by the oil is some 0.15 per cent of the total
mass of the oil in the gearcase. These impurities must Test of brake torque may be performed according to
be, exclusively, very fine abraded matter (max 25 following:
µ). If the contamination keeps within these limits, - Drive hydraulic motors against closed brakes.
continued operation of the gearset is permitted after Brakes shall be able to withstand motor torque
the oil has been changed. without slipping.
Note! Test procedure shall be performed only for a
short period, a few seconds.

SERVICE 6.120.15 E rev.: c 2002-12-20
Motor side
Thrust spring Brake piston Brake cylinder
Pressure oil
connection Sealing
Sealing
Total
thickness Leakage oil
of discs
Disc carrier
Internal discs
External discs
Gear side
Fig. 2. Disc brake.

Attention: Please select the requisite number of thrust springs from parts list "gear".
- Inspect brake discs and replace if excessively - Slew the crane 90 degrees and check.
worn. - Proceed to check the backlash at four 90-degree
- If discs are coloured dark yellow to blue, the discs position in the rim.
have been overheated. Replace discs and springs. - Put the dial gauge on the tooth of the pinion. By
- Inspect sealings for wear. If sealings are defect manual turning at the input, the pinion can be moved
replace brake cylinder and piston with sealings to in both directions up to contact with the teeth. Now,
new ones. the tooth flank clearance can be exactly measured
on the dial gauge.
b. Brake heats - Check the backlash at one spot
Check the hydraulic pressure to make sure that it is - Slew the crane 90°. Check again
sufficient in order to disengage the brake completely. - Proceed to check the backlash at four 90-degree
positions in the rim
- Compare the four backlash values.
Checking and setting slewing rim Backlash values:
backlash Module 14 and 16 0.45 ±0.20mm
An oversize backlash between the pinion and the The backlash shall be set at the position of the slewing
slewing rim will cause irregularities in the slewing rim with the lowest backlash value.
movement of the crane. Read this instruction carefully
prior to checking or resetting!
Setting backlash
The backlash may be set by turning the entire gearset
Checking backlash one or more screw hole divisions.
The backlash should be checked by a dial gauge or
a feeler. When slewing the crane, the backlash may Proceed as follows:
vary from one position to another due to some slight - Slew the crane into the position with the lowest
excentricity of the slewing rim. It is therefore backlash value.
recommended to check the backlash at four positions - Remove all screws holding the gearset to crane
of the slewing rim. house floor.
- Release the disc brake hydraulically by means of
Proceed as follows: a manual pump.
- Check the backlash at one spot.

SERVICE 6.120.15 E rev.: c 2002-12-20
- Turn the entire gearset one or more screw hole

Oil filling Air filter
to achieve the desired setting.
Expansion tank
To turn the gearset, remove the hydraulic motor Plug a
andturn the spline sleeve on top of the gear. Expansion pipe
Note! Disc brake

The turning of the entire gearset may be restricted by
the hoses connected or by space limitations. To over- Oil level sight Upper part
come this problem, release the upper part of the glass Screws
gearset by just removing the holding screws, see Fig.
3 ”Slewing gearset”.
Make sure that the upper part can be turned freely. Screws holding
Turn the entire gearset (except the upper part), until gearset to crane
house floor
the desired setting is achieved. Watch the hoses! Oil outlet
- Replace and tighten the screws holding the gearset

to the crane house floor using ”Loctite 242” or a
similar compound.
If the upper part has been removed

Fig. 3. Slewing gearset.
If the upper part has been removed, clean its contact
surfaces and apply Loctite 640 Sealant or a similar
compound. Make sure not to strain the hoses . Apply
Loctite 242 on the screws holding the upper part,
reinstall and tighten.

SERVICE 6.120.64 E rev.: i 2003-12-08
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.
The type of hydraulic oil must agree with the

"Lubricating Chart", Section 5.
Displacement: 106.7 cm3/rev.

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

Drain connection


Displacement Vg: 160.0 - 79.0 cm3/rev.

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

Drain connection



Oil filling
Drain connection

SERVICE 6.120.64 E rev.: i 2003-12-08

Drain connection



Oil filling
Drain connection

Drain connection



Oil filling
Drain connection

Drain connection


Oil filling
Drain connection

SERVICE 6.120.64 E rev.: i 2003-12-08
Hydraulic Motor 188 1774-801 Oil filling / Drain

connection


T1 alternatively T2 can be used as oil filling and drain

Oil filling / Drain
connections.
connection

Drain connection

Displacement Vg: 160 cm3/rev.

Oil filling
Drain connection

Drain connection


Displacement Vg: 160.4 cm3/rev.

Oil filling
Drain connection

SERVICE 6.120.64 E rev.: i 2003-12-08

Drain connection


Displacement: 200 cm3/rev.

Oil filling
Drain connection

Drain connection



Oil filling
Drain connection

Drain connection

Displacement Vg: 200 cm3/rev.

Oil filling
Drain connection

SERVICE 6.120.89 E rev.: a 2005-01-14
Winches, Hoisting/Luffing
Winch and gear case Journal Hoisting winch

bearing
General
The hoisting winch (lower) is/are driven by one or

two high speed hydraulic motor(s) with variable
displacement, via a planetary gear box.
The luffing winch (upper) is driven by one high
speed hydraulic motor with fixed displacement, via
a planetary gear box. Oil filler inlet Oil outlet
The planetary gear box has splash lubrication and Oil dipstick
is filled with gear oil.
A brake is integrated in each winch gear set. When
the winch is running, the brake is automatically Journal Luffing winch
released by hydraulic pressure. bearing
Assembly of winches
- Mount the winch together with winch support. The
clamping screws of the winch support must easily
be connectable.
- Tighten the screws according to torque Oil filler inlet
recommended. Secure with Loctite 242 or a Oil dipstick
similar compound.
- Connect brake line and release disc brake Oil filler inlet for wet Oil outlet
hydraulically. The drive sleeve in the drive unit running motor and shaft.
must turn easy.

- Remove plug off the drive sleeve of the drive unit. Fig. 1. Hoisting and luffing winches with oil filler inlet,
For protection against corrrosion the drive sleeve dipstick and outlet.
is provided with gear oil from the gear. The plug
prevents a filling with oil of the motor flange before - Oil type: See instruction "Lubricants for Deck
mountage of the motor. Machinery", section 5.
- Before test-running, fill the motor flange completely - Check rope winch with running motor as to function.
with oil. Check above all the control and function of the
- Center motor in the motor flange. Fix motor with holding brake and the drive motor.
screws. Motor shaft must be grease-free. - After test-running check oil level once more with
- Remove plug off the vent pipe and mount the air oil dipstick. During the test-running, the oil level in
filter. the gear and motor flange is adjusting itself and
- Check oil level with oil dipsstick. Refill oil if fills the space around the motor shaft slowly with
necessary. gear oil. Therefore the oil level may be reduced.
- The rope winch is normally filled with oil. If the - If necessary, refill oil.
winch is supplied without oil, this is indicated on a - The journal bearing is filled with grease. Before
corresponding label. taking into operation grease again until grease
- Oil volume: See name plate on winch or instruction emerges at the sealing profile.
"Technical Data", section 2. - Insert rope and fix it. Secure screws accordingly.

SERVICE 6.120.89 E rev.: a 2005-01-14
Oil changes Oil discoloration

Whenever practicable, let the oil drain off while still A darkish or black colour of the used oil suggests
hot. Remove the inlet plug (air filter). At low ambient that temperatures in excess of 100°C did occur in
temperature, flush out the gear case with a quantity operation, causing accelerated aging of the oil and
of fresh pre-heated oil to remove particles and impaired lubricating properties. In this case the oil
sediment. should be changed at shorter intervals.
If the oil sample displays a cloudy aspect, it may be
Maintenance that water has managed to seep into the oil. The oil
- Change gear case oil, see Fig 1. must then be changed at once, and the gear case
flushed out very thoroughly several times with fresh
- Grease journal bearing, see Fig 1.
oil.
- Check oil level, see Fig 1.
The gear case should preferably be dismantled for
Note! inspection beginning at the input side, and the
Oil level can only be inspected with non-running gear. components examined for signs of corrosion.
Maintenace interval and number of grease nipples:

Foreign solid matter
See "Lubricating chart", section 5.
As a first simple test, drop some of the used oil onto
Type of oil and grease:
the filter fleece specified. Coarse foreign matter, if
See "Lubricants for deck machinery", section 5.
present, will then show up on inspection, preferably
Oil volume:
through a magnifying glass.
See "Technical data", section 2.
A better test may be made by diluting an oil sample
with n-heptane, passing it through a diaphragm
Sampling oil filter, washing and drying it, and weighing it to
Withdraw a sample of gear case oil for inspection at determine the mass difference.
intervals as described in the "Maintenance Chart".
To obtain a representative sample, drain the gear Overall assessment
case during operation and with the oil at operating The maximum permissible amount of foreign matter
temperature. carried by the oil is some 0.15 per cent of the total
mass of the oil in the gear case. These impurities
Procedure for oil sampling: must be, exclusively, very fine abraded matter (max
- The oil temperature in the gearbox should be 25 µm). If the contamination keeps within these
above +40 0C. limits, continued operation of the gearset is permitted
- Special oil sampling bottles should be used that after the oil has been changed.
can be obtained from oil companies.
If coarser abraded matter (above 25 µm) or flake off
- The oil sample should be taken from the oil drain material from the gear teeth is found, the gearset
on the winch, see Fig. 1.
must be dismantled, irrespective of the actual amount
- Drain 1-2 litres of oil into a bucket. This oil should of foreign matter present, beginning at the input end
be disposed of. of the gearset.
- Fill the oil sample bottle.
- Send the oil sample to an oil company for analy-
sis.
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 MacGREGOR Cranes.

SERVICE 6.120.89 E rev.: a 2005-01-14
Hydraulic-Release Multiple-Disc Brake
Technical description Trouble-shooting

The brake comprises the following major Braking torque insufficient
components. See also Fig. 2.
Test of brakes may be performed as follows:
- Brake piston
- Drive winch hydraulic motors against closed
- Brake cylinder
brakes. The motors shall not be able to rotate.
- Disc carrier
Note! Test procedure shall be performed only for
- Inner discs
a short period; a few seconds.
- Outer discs
- Inspect brake discs and replace if excessively
- Hydr. part for disc brake
worn. If brake discs are coloured dark yellow to
- Pressure spring
blue, the discs have been overheated. Replace
The brake housing is mounted on top of the gear discs and springs.
case, with long assembly screws through the motor - Inspect brake for leakage. If leakage appears in
adapter housing and both parts of the brake housing. oil pressure unit, the complete unit must be
The disc assemblies are pressed together by a set replaced.
of thrust springs and the brake is disengaged by Note! Sealings are not available as spare parts.
hydraulic power.
Brake heats
Maintenance Check the hydraulic pressure to make sure that it is
The brake is self-adjusting. sufficient in order to disengage the brake completely.
Motor side
Hydr. part for
disc brake Pressure spring
Connect
pressure oil
Leakage oil
Arrangement of
Outer disc Inner discs Disc carrier
the brake discs
Gear side
Fig. 2. Disc brake

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.

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.

SERVICE 6.125.14 E rev.: - 1997-05-22
Feed Pump Unit
1
2
Introduction
The pump is a screw-type pump with fixed displacement 3
which supplies the feed and control circuits of the
crane. The pump is submerged in the hydraulic oil.
Thus, one pipe only connects the pump to the hydraulic
system.
The pump is separately driven by an electric motor

which is mounted in the oil tank. 5
4 7
To overhaul the pump or the electric motor, the entire
pump unit - motor and pump - should be taken out.
Caution!
Maintain cleanliness throughout! 6
Fig. 1. Tank with feed pump unit

1. Removing and dismantling pump unit
- Park crane jib, stop crane, switch off main switch 1. Air filter with oil dipstick
- Remove tank cover (2) 2. Tank cover
- Loosen the upper end of the hose (5) 3. Oil level and temperature guard
- Disconnect the electric connections to the electric 4. Chain
motor (6) 5. Hose
- Lift electric motor (6) with pump (7), using the chain 6. Electric motor
(4) 7. Pump
- Remove mounting screws holding electric motor (6)
Electric motor
onto the pump (7)
- Withdraw pump (7) from motor (6).
2. Reassembling pump
- Reassemble pump unit in reverse order to
dismantling.
- Replace pump unit. Reinstall and reconnect hydraulic
pipes and components. Reconnect electric motor
power cable.
Pump
- Jog start pump unit to check rotation.
Mounting screws
Fig. 2. Pump with electric motor

SERVICE 6.127.40 E rev.: b 2003-10-13
High Pressure Pumps
General
All pumps are the straight axial piston type with - Open CT2-cabinet and pull out the leftmost electronic
variable displacement controlled by a servo valve card (see Fig. 2).
mounted on the pump housing. - Turn the handle (main switch Q1) to position "I" on
electrical cabinet (i.e. the power supply is turned
The pumps are equipped with two adjustments, one on).
for “plussing“ and the other for pressure adjustment - Remove the two electrical connectors from the
(max. working pressure). “Plussing“ of the pumps is pump (see Fig. 1).
done to compensate for internal leakage in pumps - Start the crane.
and motors to prevent load drops (see Fig. 1). - Install a pressure gauge 0-400 bar at connection
3.1.
- Close valve 1663 (see Fig. 6).
Function checking/Adjusting of - Move control lever for the hoisting winch to the
“plussing“ brake open position (see Fig. 3).
- Check the pressure. See hydraulic circuit diagram.
- If the pressure is incorrect, an adjustment must be
Hoisting winch
made using the “zero setting“ screw (see Fig. 1).
- No load in hook.
If there is more than one hoisting pump, the lower
- Stop the crane.
pump should be adjusted.
- Turn the handle (main switch Q1) to position "O" on
- Stop the crane.
- Open valve 1663.
off).
Zero setting screw
Servo valve
Electrical connector Electrical connector
Pressure cut-off valve
Fig. 1. Pump A4VG.

SERVICE 6.127.40 E rev.: b 2003-10-13
Luffing winch
- No load in hook. - Move the control lever for the luffing winch for
- Park the crane or move the hook block close to the luffing-in (see Fig. 4).
jib top. - Check the pressure. See hydraulic circuit diagram.
- Stop the crane. - If the pressure is incorrect, an adjustment must be
- Turn the handle (main switch Q1) to position "O" on made using the “zero setting“ screw (see Fig. 1).
electrical cabinet (i.e. the power supply is turned - Stop the crane.
off). - Turn the handle (main switch Q1) to position "O" on
- Open CT2-cabinet and pull out the leftmost electronic electrical cabinet (i.e. the power supply is turned
card (see Fig. 2). off).
- Turn the handle (main switch Q1) to position "I" on - Reinstall the leftmost electronic card (see Fig. 2).
electrical cabinet (i.e. the power supply is turned - Close CT2-cabinet.
on). - Turn the handle (main switch Q1) to position "I" on
- Remove the two electrical connectors from the electrical cabinet (i.e. the power supply is turned
pump (see Fig. 1). on).
- Start the crane. - Reinstall the electrical connectors on the pump.
- Install a pressure gauge, 0-400 bar, in outlet 5.1, - Open valve 2661.
(see Fig. 7).
Pull out Pull out
CT2
CT1
Main switch
Fig. 2. CT2-cabinets.

SERVICE 6.127.40 E rev.: b 2003-10-13
Slewing machinery Adjustment of cut-off valves

- No load in hook.
- Stop the crane.
Hoisting pump
electrical cabinet (i.e. the power supply is turned - Valve 1111-10 has a setting of 100 - 420 bar. By
off). turning the adjustment screw 1 revolution the setting
- Open CT2-cabinet and pull out the leftmost is changed approx. 90 bar.
electronic card (see Fig. 2). - Back off the adjustment screw.
- Turn the handle (main switch Q1) to position "I" on - Install a pressure gauge 0-400 bar at connection
electrical cabinet (i.e. the power supply is turned 3.1.
on). - Close valve 1663 (see Fig. 6).
- Remove the electrical connectors from the pump - Drive in high speed mode and at max. 25 % speed.
(see Fig. 1). - Adjust the pressure cut-off valve1111-10 on pump
- Start the crane. 1111. See pressure setting list for hydraulic circuit
- Move the control lever for the slewing machinery diagram 1111-10.
for slewing left or right (see Fig. 5). - Open valve 1663.
- Ensure that the crane does not move in any
direction. With two hoisting pumps
- If the crane does move, an adjustment must be
- Turn valve1112-10 on pump 1112 to its maximum
made using the “zero setting“ screw (see Fig. 1).
setting.
- Stop the crane.
- Adjust valve 1111-10 on pump 1111 as described
in above paragraph "Hoisting pump".
- Adjust valve 1112-10 on pump 1112 by backing off
off).
the setting screw until a little lower pressure can be
- Reinstall the leftmost electronic card (see Fig. 2).
read.
- Close CT2-cabinet.
- Turn the screw 1/4 revolution.
- Turn the handle (main switch Q1) to position "I" on
on).
- Reinstall the electrical connectors on the pump.
Installation of a new servo or complete

pump
When a new servo unit or a complete pump is

installed, a function check of the "plussing" has to be
carried out. Proceed according to “Function checking/
Adjusting of “plussing”.
High speed
Fig. 3. Hoisting position. Fig. 4. Luffing position. Fig. 5. Slewing left or right.

SERVICE 6.127.40 E rev.: b 2003-10-13
Luffing pump
- Start the crane.
- Install a pressure gauge, 0-400 bar, in outlet 5.1,
(see Fig. 6).
- Back off adjustment screw on pressure cut-off valve
2111-10.
- Drive the crane with 25 % speed (see Fig. 4).
- Adjust pressure cut-off valve 2111-10. See hydrau-
lic circuit diagram for pressure setting.
- Stop the crane.
- Open valve 2661.
Slewing pump
- Start the crane.
- Install a pressure gauge, 0-400 bar, in outlet 6.1 or
6.2.
- Back off adjustment screw on valve 3111-10.
- Drive crane with 25 % speed (see Fig. 5).
- Adjust pressure cut-off valve 3111-10, see hydrau-
lic circuit diagram for pressure setting.
- Stop the crane.
- Open valve 3661.
Installation of a complete new pump

When a new pump is installed, the pressure cut-off
valve has to be adjusted (see “Adjustment of the
pressure cut-off valves”).
N.B. These valves are sealed and the seals must not
be broken.
Adjustment and replacement of these valves must be
done by qualified personnel only.
Contact the Service Department at MacGREGOR
Cranes for information about valve adjustment.

SERVICE 6.127.40 E rev.: b 2003-10-13
Valve
Outlet 3.1
Fig. 6. Part of hoisting circuit.

SERVICE 6.127.40 E rev.: b 2003-10-13
Valve
Outlet 5.1
Fig. 7. Part of luffing circuit.

SERVICE 6.127.40 E rev.: b 2003-10-13
Valve
Outlet 6.2
Outlet 6.1
Fig. 8. Part of slewing circuit.

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.

SERVICE 6.189 E rev.: e 2003-01-20
Hydraulic Piston Accumulator 388 0362-801, -802, -803
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.
N.B. - Do not bleed hydraulic accumulators! 2. New design, see Fig. 1. Connect the three-way
valve to the gas valve of the accumulator. The
Charging equipment bleed valve should be tightly closed.
To charge hydraulic accumulators, art. no. 388 0362, 2a. Old design, see Fig. 2. Connect the three-way
MacGREGOR Cranes supply a charging valve and valve to the gas valve of the accumulator. The
associated equipment, Fig. 2, comprising: filling screw of the three-way valve shall be
- a three-way valve backed out completely, and the bleed valve
- a 0-25 bar pressure gauge tightly closed.
- a 1-metre hose with a W24 connector for nitro- 3. Connect the charging valve, see Fig. 3 to the
gen cylinder reducing valve at the nitrogen cylinder.
- two reduction connectors, W24/32M and W24/14D. 4. Back out the adjusting screw of the reducing
valve on the nitrogen cylinder until the valve
Charging pressure for 388 0362-801: 15±1 bar at 20°C. spring is unloaded.
Charging pressure for 388 0362-802: 28±1 bar at 20°C. 5. Open the nitrogen cylinder valve.
Charging pressure for 388 0362-803: 20±1 bar at 20°C. 6. Adjust the reducing valve to the correct charg-
ing pressure.
New design
Valve guard
Protective cap
Gas valve
Protective cap Gas valve Open/close
Valve guard hexagonal nut
Open/close
hexagonal nut
Fig. 1. New design. Piston accumulators 388 0362-801, -802, -803.

SERVICE 6.189 E rev.: e 2003-01-20
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 N.B. - 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 N.B. 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 388 0362-801, -802, -803.

SERVICE 6.189 E rev.: e 2003-01-20
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.

SERVICE 6.214 E rev.: h 2003-01-09
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
ven. Apply Molycote 1000 Lubrication on the threads a lower surface notch indicating that the permitted
and under the bolt head. For stainless elements and tension 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 Molycote 1000 Untreated bolts greased with Molycote 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

SERVICE 6.214 E rev.: h 2003-01-09
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
SAE flange for high pressure hose couplings 8 7.8 17 22
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

SERVICE 6.214 E rev.: h 2003-01-09
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

SERVICE 6.214 E rev.: h 2003-01-09
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

SERVICE 6.216.64 E rev.: e 2000-10-06
Rope Reeving Diag

Reeving Diagrr am ffor
or Cr anes Type GL-2 (ne
Cranes w vversion)
(new ersion)
Luffing Hoisting
Jib top
Jib stay
Crane house
top
Crane house
top
Crane house top
Hoisting wire rope Luffing wire rope
Slack wire safety switch, hoisting and luffing. Slack wire condition

SERVICE 6.216.64 E rev.: e 2000-10-06
Securing the luffing wire socket to crane house top
Important!
It is of utmost importance to grease the wire socket
according to instructions "Lubricating Chart" and
"Lubricants for Deck Machinery".
Securing the hoisting wire socket to crane house top
Note! The wire rope socket should be safely secured.

SERVICE 6.222.1 E rev.: a 1998-04-17
Handling, Installation and Maintenance

of Steel Wire Ropes

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 manufac-
turer 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.

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 lubri-
cant might damage the wires when the rope trav-
els or sheaves.

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.

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 but because of the great length of rigid connection
reel 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.
thinner rope one must make sure that the connec- These 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.

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 instance between two boards. Structural changes
wrap a tape around the whole rope length to be would deform the rope beyond repair.
held by 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% up to the fix point. A pulling jack can be used to pull
of 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.

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 "bro-
ken-in", so that the component
The rope is tightly wrapped for a distance of approx.
parts can settle and adjust them-
three rope diameters.
selves to the actual operating con-
ditions. It is most unfortunate that
in practice only too often the ex-
act opposite of this recommenda-
tion is performed: quite frequently
after installing the rope overload
tests are carried out with loads be- Both ends of the seizing wire are then pulled tight
yond the safe working load of the and twisted together for a length of one rope diam-
system. 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- The twisted connection is then hammered into a
quired for larger sizes. gusset between the strands. After preparing the
other side of the intended cut accordingly the rope
can now be cut.
The best method is to use a high speed disk cutter.
Unless the rope is being scrapped the use of flame
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- Instead of using one long seizing it is also possible
preformed as part of the manufacturing specifica- to apply at least three seizing the size of one rope
tion. 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- The maintenance of steel wire ropes
ing tape cannot prevent strand movement, so an-
nealed (iron) wire should always be used. Steel wire ropes must be serviced regularly, the kind
of maintenance depending on the lifting device, its
After marking the position of the cut the end of the use and the selected rope. Regular maintenance
seizing wire is laid along the rope axis leaving suf- may considerably increase the service life of a steel
ficient length to secure both ends by twisting when wire rope.
the seizing complete.

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 inter- This applies particularly to ropes operating in ex-
vals, depending on their use, particularly along the tremely abrasive conditions and to those that take
zones subjected to bending. If for operational rea- up chemicals.
sons relubrication cannot be carried out, shorter
service life of the rope is to be expected and the Effective cleaning without proper tools is quite a
inspection intervals have to be arranged accord- laborious job. For cleaning steel wire ropes the Ca-
ingly." nadian Rigging Manual recommends an appliance
with three rotating wire brushes and an air blast
When choosing the relubricant, it must be ensured drying system to follow. An American manufacturer
that it is in accordance with the recommendations offers a "rope porcupine", a sleeve equipped with
of the rope manufacturer. 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- Removing broken wires
ing or swabbing.
If during an inspection ends of broken wires are
Quite often the lubricant is applied at a sheave, detected which might cross adjacent wires and
sometimes a continuous drip method is used. If only destroy them when running over sheaves, these
a little lubricant is required, pressure spray noz- broken wire ends must be removed.
zles can be applied.
Under no circumstances should the broken wire
Maximum penetration of the lubricant into the gaps ends be pinched off with a pair of nippers. The best
of the rope, can only be quaranteed if high pres- method is to move the wire ends backwards and
sure lubrication is applied with the help of a pres- forwards until they break deep in the valley between
sure lubricator. two outer strands. With thicker wires a tool should
be moved backwards and forwards on the surface
With this method the two halfs of a sleeve, which of the rope, thus bending the wires until they break.
is equipped with rubber sealings, are clamped round
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.

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.

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.

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.

SERVICE 6.223.12 E rev.: b 2004-12-16
Replacement of Wires
One or Two Fall Rigging
General
This instruction covers almost all MacGREGOR cranes, - Run the winch by pulling in the new hoist wire, so
which are equipped with limit switch boxes containing that there are the same numbers of revolutions of
electric limit switches. The procedure is general and should wire on the wire drum as noted earlier and that the
be seen as a guidance only. winch corresponds to the position marked earlier .
- Attach the wire rope end to the wire drum with the
wire rope clamps and tighten the bolts.
Hoisting winch / wire
- Assemble the limit switch box in its proper place, the
For cranes with one or two fall rigging proceed as follows:
marking on the shaft/box must correspond.
- Place the jib in the jib rest.
- Run in the rest of the wire.
If applicable, park the crane, slewing position locked
Note! The wire rope socket should be safely secured,
with cylinders, and the jib at max. outreach with the
see Fig. 6.
hoisting block parked to the jib top.
- Remove the wooden piece holding the slack wire
See special instruction "Parking of crane in wires" in
roller.
section 4 .
- Test the winch and check all limits, which should
- Disengage the slack wire switch by blocking the
now function correctly, if the new wire is the same
spring tensioned roller, which can be done with a
length as the old one. If necessary, adjust the limits,
piece of wood, see Fig. 1.
see instruction under section 6.3.
- Loosen the wire rope socket attached to the crane
house top, see Fig. 6.
- Run the winch by paying out the hoist wire, and at Luffing winch / wire
the same time pulling on the loose wire end. - Place the jib in the jib rest.
- Stop the winch just before it enters into the empty - Disengage the slack wire switch by blocking the
drum limit. spring tensioned roller, which can be done with a
- Mark the position of the wire drum in relation to the piece of wood, see Fig. 1.
bracket, this to avoid setting of all hoisting limits again - Loosen the wire rope socket attached to the crane
after installing the new hoist wire. house top / jib, see Fig. 6 or 7.
- Remove the cover from the limit switch box. - Lower the luffing wire rope to the deck by means of a
Note! - Mark the position of the shaft in relation to the rope.
box. See Fig. 2. - Mark the position of the wire drum in relation to the
- Remove the limit switch box. bracket.
- Note how many revolutions of the wire there are - Remove cover from the limit switch box.
left on the drum at this position. Make a mark on Note! Mark the position of the shaft in relation to the
the drum. box. See Fig. 2.
- Secure the wire so the wire clamps that hold the - Note how many revolutions of the wire there are left
end of the wire can be removed safely. on the drum at this position. Make a mark on the
- Attach a long rope (longer than the wire rope) to drum.
the wire end, and place it 4 to 5 turns around the - Secure the wire so the wire clamps that hold the end
wire drum. of the wire can be removed safely.
- Run the winch by paying out the old (damaged) - Attach a long rope to the wire end (longer than the
wire until it is on the deck. wire rope) and place it 4 to 5 turns around the wire
- Attach the new hoist wire to the same rope by using drum.
tool 662 0754-000, see Fig. 5.

SERVICE 6.223.12 E rev.: b 2004-12-16
- Run the winch by paying out the old,damaged luffing Piece of wood
wire, and at the same time pulling on the loose wire ≈ 100 x 200
end until it is on the deck.
- Attach the new luffing wire to the rope, by using tool
662 0754-000.
- Run the winch by pulling in the wire, so that there
are the same numbers of revolutions of wire on
the wire drum as noted earlier and that the winch
corresponds to the position marked earlier as it
Piece of wood
was when the limit switch box was disconnected.
≈ 100 x 200
- Attach the wire rope end to the wire drum by the
wire rope clamps and tighten the bolts.
- Assemble the limit switch box in its proper place.
- Run in the rest of the wire.
- Attach the wire rope end to the crane house top or
jib, see Fig. 6 or 7.
Note! The wire rope socket should be safely se-
cured to the crane house top/jib, see Fig. 6 or 7.
- Remove the wooden piece holding the slack wire
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,
see instruction under section 6.3.
Tightening torque: In the first place look for

tightening torque on the winch spare part picture,
Fig. 1. Disengage of slack wire safety switch.
in the second place see instruction 6.214 E.
Fig. 2. Marking inside limit switch box.

SERVICE 6.223.12 E rev.: b 2004-12-16
Limit box Winch drum
Limit box
Winch drum
Fig. 3. Limit switch box, hoisting winch. Fig. 4. Limit switch box, luffing winch.
Fig. 5. Tool, wire rigging sock, 662 0754-000.

SERVICE 6.223.12 E rev.: b 2004-12-16
Securing of wire rope thimble
Check 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
New pin
Securing the hoisting wire socket to crane house top
Fig. 6. Securing wire sockets to crane house top.
New pin
Fig. 7. Securing the luffing wire socket to crane jib.

SERVICE INFORMATION
625/1473 E rev.: a 2002-12-20
Wear on Wire Sheaves
In the table below we have given recommended

maximum wear on wire sheaves.
The reasons for the given recommendations are:

- Increased wear on the wire.
- Decreased strength on wire sheave.
a
t max
16 4
12 3
10 2.5
8 2
6 1.5

S E RV I C E I N F O R M AT I O N
625/1532 E rev.: a 1999-08-19
Replacement of Wire Rope Types
MacGREGOR Cranes AB and the wire rope manu-

facturer Casar have agreed on using following wire
rope types for replacement and spare parts where
other types of wire ropes have been specified. Valid
for crane types GL, G, L1, LS and L2.
Hoisting wire rope

Casar Powerplast
Langslay, lefthand lay
1960 N/mm²
Luffing wire rope

Casar Turboplast
Langslay, righthand lay
1960 N/mm²
LC- and GP-cranes

Casar Eurolift
Langslay, righthand lay 1960 N/mm² can be used.
Note! When ordering wire ropes it is of most impor-

tance to use article numbers according to Table of
Contents for the particular crane.
Check that original minimum breaking load is

reached by the replacement rope.
Wire 2160 N/mm² is not recommended. The material

in wire 2160 N/mm² is more brittle than in wire 1960
N/mm² and the lifetime becomes much shorter.
GL (Germanischer Lloyd) and most of the

classification societies have restrictions against
2160 N/mm² wires, and will not accept this strength
limit for MacGREGOR cargo cranes.
If wire 2160 N/mm² is used and this is detected by

for instance GL, crane operation can be stopped
and they insist that the wire is to be changed.

SERVICE INFORMATION
625/1560 E rev.: b 2003-03-20
Lifting Block
Warning! Maintenance and Service

Where equipment has swivelling and moving parts
there are potential safety hazards.Care should be Inspection should be carried out, on every occa-
taken when working with or repairing such equip- sion before taking into operation.
ment. If used incorrectly breakage could occur in-
flicting injury or death. Particular attention should be paid to the following:
1. Wear in hook, centre pin, becket and threads in
General Safety hook and nut.
2. Play in sheave bushes or bearings.
When equipment is in use, do not put hands: 3. Spacer bolts, nuts and lynch pins.
4. Check for cracks in welds.
1. Between sheaves, sideplates and guards. 5. Condition of safety catch and grease nipples.
2. In area of becket, hook, hooknut and crosshead 6. Wear to holes in sideplates and becket.
Take great care to avoid clothing becoming trapped. If cracks or heavy gouges appear, the equipment
should not be used and qualified opinion should be
Repair and reeving should be carried out by trained sought. If grooved and the section reduced by more
personnel only. Power should be switched off be- than 5% the item should be replaced.
fore operations are carried out. Work should only
take place when equipment is supported on a firm
surface.

SERVICE INFORMATION
625/1560 E rev.: b 2003-03-20
Repairs should be effected by grinding. NO weld- Limitation of use

ing should be carried out unless prior authoritly is
obtained. 1. Safe working load should never be exceeded.
If the holes in the crosshead, sideplates, becket, 2. Crane blocks should be used in vertical lift only.
eyes or yaws are enlarged by more than 5%, the 3. Rigging blocks should be used only as in design
part should be replaced. specifications.
Blocks should not be used for towing, unless spe-
All repairs should be carried out by responsible cifically designed and marked for that purpose.
personnel, and great care should be taken in the 4. Swivels should be used in either the vertical or
re-assembly of the equipment and retaining parts, horizontal plane only.
i. e., grub screws, lynch pins, etc. Check and refit 5. Horizontal and vertical lead sheaves should only
only correct sizes and threads. be used as indicated in the description.
6. Shock or side loading should not be applied, un-
Important: less equipment is desigend for that purpose.
When replacing genuine parts an overload test of 7. Load should always be in seat of hook or eye.
the complete unit must be performed and new cer-
tificate must be issued.
Allowed wear on lifting eyes and links
Lubrication Wear and tear is allowed to take away maximum

5% of the diameter. Thereafter the component has
As a general rule sheaves, crossheads and bodies either to be replaced or repaired. The repair
should be oiled through nipples every 100 working recommended is a hardened cage, which shall be
hours, see also separate lubrication chart. shrinked according to the instruction from
MacGREGOR Cranes.
Fig. 1. Lifting eye.

SERVICE INFORMATION
625/1579 E rev.: c 2003-09-25
Measuring Procedure for Wear

in Slewing Bearings
General Procedure
First time a measurement is to be taken two reference
The slewing bearing is an essential part of the crane points on the crane's bottom plate are to be marked.
and must be well maintained. Over the years the These reference points shall then always be used at
slewing bearing will have some wear, and to be able any future measuring, see Fig. 3.
to know if there is a need for changing the slewing
bearing it is needed to keep a record of the wear. Measurements shall be taken on four positions of the
slewing bearing, if possible. With the jib pointing:
- Forward to the ship
Measuring - Starboard
- Aft
The measurements should be taken regularly, every - Port side
6 months. Measurements can be sent to It is important to use about the same position for all
MacGREGOR Cranes for evaluation. further measurements to be able to compare the
measurements.
When measurements are to be taken the ship shall
have as little list/trim as possible. With the jib at maximum outreach two measurements
are to be taken, see Fig. 1.
With the jib at minimum position one measurement

is to be taken, see Fig. 2.
Encl. table can be used to record the measurements.

Measurement B
(back of crane)
Jib direction
Empty hook
Jib at maximum outreach
Jib direction
Measurement A
(front of crane)
Fig. 1. Jib in outer position.

SERVICE INFORMATION
625/1579 E rev.: c 2003-09-25
Measurement C
(back of crane)
Jib direction
Min. outreach,
empty hook
Fig. 2. Jib at minimum outreach.

SERVICE INFORMATION
625/1579 E rev.: c 2003-09-25
Note! If there is a machined surface this shall be used

as reference point. In other cases a reference point
must be marked.
Reference point
Reference point
Fig. 3. Reference points.

SERVICE INFORMATION
625/1579 E rev.: c 2003-09-25
Fore
Vessel name:
Date: Ps Stb
Aft
Crane No.: 1
Measurement Play Jib direction
Jib at max. outreach Jib at min. outreach
A (front of crane) B (back of crane) C (back of crane) B-C
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

SERVICE INFORMATION
625/1579 E rev.: c 2003-09-25
Procedure of grease sampling
Following information is necessary in order to give a - Clean up the outer or inner seal close to the next
correct statement and allow further advice: grease nipple. When cleaning the area of the seal,
prevent the cleaner from contacting the seals or
1. Used grease (manufacturer and type). from entering the raceway's system.
2. Lubrication intervals. - Push new grease into the grease nipples / bearing
3. Running hours. without rotation and collect the first used grease
4. Information where the samples are taken. which will come out at the seal.
The correct procedure of grease sampling is very Attention: Do not take fresh grease for analyzing!
important. The required quantity of grease for analyzing is
approx. 2 cm3.
Procedure
The normal interval for grease sampling is 12 months.
Proceed as follows:
- The grease sample can be taken either at the inner
or outer seal of the bearing.
- One sample should be taken in the area under jib
and one sample 180° in opposite direction.

SERVICE 6.300.1 E rev.: - 1997-09-22
Emergency Operation Card CC2000

314 3615-801
Purpose
In case of MPC-card problems in the crane control When using the emergency operation card the lamp
system CC2000, cubicle MB, there are always a "Control system error in MB-box" is flashing because
possibility to replace the MPC-card with an emergency the MPC-card "Sc" gives an error message
operation card, see Fig. 1. "Communication error" for the movement that the
emergency operation card is controlling.
The emergency operation card is plugged in instead
of one (or more) of the movement control MPC-cards
for hoisting "Ho", luffing "Lu" and slewing "SL", see Use of emergency operation card
Fig. 2.
- Switch main switch OFF
The emergency operation card can not replace the - Remove the Micro Processor Card (MPC) for the
leftmost MPC-card "Sc", used for internal communi- faulty motion and plug in the emergency operation
cation and distribution of control system parameter card instead.
values. - Switch the main switch ON.
- Run the desired motion.
Low complexity - fixed speed
WARNING!
The emergency operation card is much less complex
The installation of an emergency operation card must
than the MPC-card. It is built up with relays that
be regarded only as a temporary measure to operate
activates the outputs for brake, displacement/
the crane in an emergency.
unloading and pumps from the control levers 24V
signals. The pump output is fixed, giving a constant
When the emergency operation card has been installed
speed of about 30% of maximum speed. Each motion
in the hoisting or luffing circuit, bear in mind that the
is controlled by overload, low pressure and limit
high hook switch is inoperative.
switches except the limit switch for high hook.
Fig. 1. Emergency operation card. Fig. 2. MPC-cards in cubicle MB.

SERVICE 6.303.33 E rev.: - 2003-10-30
Electronic Troubleshooting for Crane Control System CC2000

Single Cranes Type GL, GLB, and LC with More than One Outreach
Contents
1. Description of input and output signals ............................................................................................... 2
2. Control system input and output signal levels ...................................................................................... 5
3. Signals indicated on the MPC card front panels .................................................................................. 9
4. Troubleshooting the control system ................................................................................................... 12
5. Operating the crane with less than four MPC cards ............................................................................ 14
6. Spare parts ........................................................................................................................................ 15

SERVICE 6.303.33 E rev.: - 2003-10-30
1. Description of input and output

signals
1.1 General
The following description refers to the microcomputer
based crane control system CC2000 for MacGREGOR
Cranes hydraulic deck cranes, single crane versions.
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 CC2000 see section
"Function", Group 3. For detailed information about
the control system, a complete electric circuit
diagram relating specifically to your crane can 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 can be found in section "Spare Parts",
Group 9.4.
Fig. 1. CC2000 Power supply principle.
1.2 Power supply, control system 1.3 Power supply, control system anti-
operation condensation heating
The power supply transforms the input 380/400/440V The anti-condensation heating in CT2 cabinet (MB)
AC to 24V DC and 8V DC. See Fig. 1. is powered with 24V AC when the control system is
switched off or when the crane is not in operation. A
It consists mainly of a three phase transformer, separate transformer is used for all anti-
rectifier bridges and fuses. The output 24V DC is condensation heating in the crane. The transformer
used for the control system input and output signals. is fed by a separate power line.
The 8V DC is used by each MPC card to generate
5V DC for its microprocessor.
1.4 Control lever (joystick) potentio-
The output voltage has a ripple with 6 times the meters, outputs to and inputs from
frequency of the input power line. The ripple level is The control lever linear potentiometers are fed with
approx. 15%. 0V, +6V and +12V from their appropriate MPC card.
The potentiometer output is approx. +6V with the
The 0V level for 24V DC is grounded in the power lever in neutral. The output signal is controlled by the
supply unit and the 0V for the 8V supplyis grounded lever and depends on the direction of lever
via all four MPC cards in the CT2 cabinet (MB). movement. The output signal is increased to approx.

SERVICE 6.303.33 E rev.: - 2003-10-30
+10.5V for max. speed hoisting, luffing in and slewing 1.7 Pump solenoid outputs
left respectively. The output signal is decreased to
Each hydraulic pump has two solenoid valves, one for
approx. +1.5V for max. speed lowering, luffing out
each direction of the oil flow. The solenoids are controlled
and slewing right respectively.
by a 24V PWM (Pulse Width Modulated) signal with
current feed-back control. If the desired output current
1 . 5 Control levers (joysticks) direction is not reached (due to short-circuit, open-circuit or MPC
signal inputs card failure), the system gives an error message, see
ERROR MESSAGES sign.
The control lever for hoisting selects two out of four
24V direction signals, for selection of low speed/
Each MPC card is capable of controlling a maximum
high speed and hoisting/lowering. See Fig. 2. of three pumps with a total of six output drivers, one
for each solenoid valve. Each driver is capable of
The control lever for luffing/slewing gives two out of outputting a maximum current of 1A. To measure the
four 24V direction signals for selecting luffing in/ current without opening the circuit, a measuring point
luffing out and slewing left/slewing right. is available for each pump. Using a voltmeter, the
reading in mV equals the current in mA to within
1.6 Pressure/force sensor input approx. 5%.
If fitted, a sensor giving 4-20 mA is used to weigh the
load.
CT2 or MB
+ 24 V
Fig. 2. Control lever signals, hoisting movement.

SERVICE 6.303.33 E rev.: - 2003-10-30
1.8 Brake release/direction valve outputs 1.12 Lamp output "Error in control
Each MPC card has an output driver for the brake
system"
release signal (or direction valve for cranes All error LEDs (No. 28) on the MPC cards are wired
equipped with cylinder luffing). The system is together to a lamp in crane operator's cabin. When
capable of detecting short-circuited output and then an error first occurs the lamp flashes. When the error
giving an error-message, see ERROR MESSAGES is acknowledged by pushing the STEP push-button
sign. the appropriate MPC card, the lamp stays on if the
error remains or goes out if the error is not present
1.9 Displacement/unloading outputs at the moment. See ERROR MESSAGES sign for
detailed information about error messages.
Each MPC card has two separate outputs. They are
used for selecting low speed or high speed for the
hoisting movement and for the unloading function for
1.13 "Speed dependent overload"
the luffing movement. Each output gives a fixed 24V
function / pressure switch switching
output with a maximum current of 2 A. Some cranes have a system that switches from one
overload pressure switch to another depending on
1.10 Low feed pressure input the speed of the hoisting motor - due to differences
in efficiency between low and high speed. At speeds
The low feed pressure switch indicates that the above a programmed limit, the normal pressure
pump feed pressure is too low for safe operation. switch is used; but at low speed a pressure switch
Output signals to pumps, displacement/unloading with approx. 20% higher setting is used in the
valves and brake relief valves are immediately overload system. The control system uses a digital
switched off by a separate safety system on the speed encoder to sense the speed of the motor. At
MPC card. speeds lower than approx. 3 rpm, the output signal
plinth No. 229 activates a relay in the CT1 cabinet
If the low pressure signal comes back within approx (A-box) bypassing the pressure switch 1312. See
0.3 seconds, the crane operation continues with the parameter "Speed dependent overload" in cubicle
same output signal levels that existed before the CT2 cabinet (MB).
pressure drop. However, if short pressure drops are
repeated 4-5 times within a short period of time, the
crane operation is stopped and starts 4-5 seconds
after the feed pressure has a stable high level again.
1.11 Overload input

The overload pressure switch makes the MPC card
control program switch over from high speed to low
speed operation or, if already in low speed, stopping
the hoisting and luffing crane movement. The input
signal from the overload pressure switch is often
only seen as a short pulse.

SERVICE 6.303.33 E rev.: - 2003-10-30
2. Control system input and output signal levels
Control system interface signal Plinth No. MPC card Signal level
Power for control system input and 42 All +24V.

output signals 50 0V, connected to ground.
Anti-condensation heating 44 - 24V AC, powered when

46 crane stopped.
Power for microprocessors on MPC 58 (with fuse) All +8V, nominally 9V,
cards minimum 7V.
54 0V.
Cross-connection plinths, if mounted 60-99 - Cross-connections for external

261-278 limit switches, key switches,
361-378 overload switches etc.
461-470
Outputs to control lever potentiometer 201 Ho 12V from MPC "Ho".

hoisting 202 6V from MPC "Ho".
203 0V from MPC "Ho".
Control lever potentiometer input 204 Ho Analogue input signal 1.5 to

hoisting 10.5V with 6V in neutral posi-
tion
Control lever direction inputs hoisting 24V when control lever actuated
Hoisting 207 Ho Hoisting
Lowering 208 Ho Lowering
Low Speed 209 Ho Low speed
High speed 210 Ho High speed
Outputs to control lever potentiometer 301 Lu

Luffing 302 12V from MPC "Lu".
303 6V from MPC "Lu".
0V from MPC "Lu".
Control lever potentiometer input 304 Lu

signal luffing Analogue input signal 1.5 to
10.5V with 6V in neutral
position.

SERVICE 6.303.33 E rev.: - 2003-10-30
Control lever direction inputs slewing

Luffing in 307 Lu 24V when control lever actuated
Luffing out 308 Lu Luffing in
Luffing out
Outputs to control lever potentiometer 401 SL

slewing 402 12V from MPC "SL".
403 6V from MPC "SL".
0V from MPC "SL".
Control lever potentiometer input signal 404 SL

slewing Analogue input signal 1.5 to
10.5V with 6V in neutral
position.
Control lever direction inputs slewing

Slewing left 407 SL 24V when control lever actuated
Slewing right 408 SL Slewing left
Slewing right
Pressure/force sensor input 206 Ho

Current signal 4-20mA.
Brake relief valve - outputs

Hoisting 230 Ho
Luffing - (direction valve if cylinder 330 Lu 24V, max. 2A, open circuit gives
luffing) error message.
Slewing 430 SL
Hoisting displacement low speed output 231 Ho 24V, max. 2A, open and short-
circuit give error message.
Hoisting displacement output high 232 Ho

speed 24V, max. 2A, open and short
circuit gives error message.
Luffing unloading output 331 Lu

24V, max. 2A, open and short
circuit gives error message.
Pump PWM signals for Hoisting Pump1

Hoisting output 233 Ho
Lowering output 234 Ho 24V, 0 to approx. 600 mA,
Current return and current measured input 235 Ho Error message if desired
current not achieved.
1mA gives approx. 1mV.

SERVICE 6.303.33 E rev.: - 2003-10-30
Pump PWM signals for hoisting pump2

(if fitted)
Hoisting output 236 Ho 24V, 0 to approx. 600 mA,
Lowering output 237 Ho Error message if desired
Current return and current measured input 238 Ho current not achieved.
Pump PWM signals for luffing pump1

Luffing in output 333 Lu 24V, 0 to approx. 600 mA,
Luffing out output 334 Lu Error message if desired
Current return and current measured input 335 Lu current not achieved.
Pump PWM signals for luffing pump2

(if fitted)
Luffing in output 336 Lu 24V, 0 to approx. 600 mA,
Luffing out output 337 Lu Error message if desired
Current return and current measured input 338 Lu current not achieved.
Pump PWM signals for slewing pump1

Slewing left output 433 SL 24V, 0 to approx. 600 mA,
Slewing right output 434 SL Error message if desired
Current return and current measured input 435 SL current not achieved.
Pump PWM signals for slewing pump2

(if fitted)
Slewing left output 436 SL 24V, 0 to approx. 600 mA,
Slewing right output 437 SL Error message if desired
Current return and current measure input 438 SL current not achieved.
Limit switch inputs hoisting

Hoisting 214 Ho
Lowering, slack wire 215 Ho 24V at normal operation, 0V
High hook 216 Ho at limit. At limit, movement is
stopped and brake applied.
Speed-reduce limit inputs hoisting

Hoisting 211 Ho
Lowering 212 Ho 24V at normal operation, 0V
High hook 213 Ho at limit.
Limit switch inputs luffing

Luffing in 314 Lu
Luffing out, slack wire 315 Lu 24V at normal operation, 0V
High hook 316 Lu at limit. At limit, movement is

SERVICE 6.303.33 E rev.: - 2003-10-30
Speed-reduce limit inputs luffing

Luffing in 311 Lu
Luffing out 312 Lu 24V at normal operation,
High hook 313 Lu 0V at limit.
Limit switch inputs slewing

Slewing left 414 SL 24V at normal operation,
Slewing right 415 SL 0V at limit. At limit movement is
Speed-reduce limit inputs slewing
Slewing left 411 SL
Slewing right 412 SL 24V at normal operation,
0V at limit.
Pressure switch input for low feed 219 Ho
pressure 319 Lu 24V at normal operation,
419 SL 0V at low feed pressure.
Pressure switches for overload 220 Ho

320 Lu 24V at normal operation,
0V at overload.
Output "Error in control system" 128 All
228 24V outputs wired together to
328 error lamp in crane operator's
428 cabin.
Digital speed encoder hoisting 221 Ho

(if fitted) 222 Digital speed encoder giving
223 four digital 24V pulse inputs.
224
Output for "Speed dependent" 229 Ho

overload function (if fitted). 24V when the hoisting speed is
less than approx. 3 rpm.
Output for "Hoisting Overload" 242 Ho
indication lamp (if fitted) 24V when the hoisting pressure
- valid from software MGX 02.00. exceeds adjusted value.
Speed reduction, input signal ext. 1 217 Ho 24V input from cabin switch,
(bit 0) to reduce normal operation 317 Lu such as grab operation, parking
speed (utilization). 417 SL lock slewing, power limiter, twin
operation, etc.
Speed reduction, input signal ext. 2 218 Ho 24V input from cabin switch,
(bit 1) to reduce normal operation 318 Lu same as above.
speed (utilization). Same as above, 418 SL
but could be used with different
utilization.

SERVICE 6.303.33 E rev.: - 2003-10-30
3. Signals indicated on the MPC

card front panels
3.1 Coloured LEDs 3.2 LEDs show the microprocessor

information
24V signals to and from each MPC card are indicated
by green, yellow and red LEDs (Light-Emitting Signals are indicated at the logic 5V level, close to
Diodes) on the front panel of each MPC card . the microprocessor chip.
Green is used for normal inputs and outputs. Yellow When an input LED is on, that signal has passed the
indicates that the crane motion concerned is driven optoisolated 24V to 5V conversion and reached the
at slower speed. Red indicates that the motion has microprocessor.
been stopped.
When an output LED is on, the microprocessor
Normal operation green signals are shown with outputs the signal at 5V level, but it has not yet
inputs to the left and the corresponding outputs to passed the 5V to 24V output driver stages. Check
the right of the input. They are on when the signal is the signal output level on the corresponding plinth if
active, 24V. missing output is suspected.
Speed reducing limit switches are shown with yellow 3.3 Identifying the plinth number
LEDs when the 24V signal is absent. Speed reduction corresponding to an LED
inputs from key switches are shown with yellow LEDs
when the input is active, 24V. The plinth number is identified by a three-digit
number. The first digit of each number signifies the
Stop limit switches, low feed pressure and overload MPC card to which the signal is connected:
are indicated with red LEDs when the 24V signal is 1.. Supervisory MPC card, "Sc".
absent. 2.. Hoisting MPC card, "Ho".
3.. Luffing MPC card, "Lu".
All signals indicated by LEDs are listed on the 4.. Slewing MPC card, "SL".
SIGNAL OVERVIEW sign inside CT2 cabinet (MB),
see section "Service", Group 6.3. The last two digits signify the LED number on each
MPC card front panel, showing the status of the 24V
input and output signals for the card. The same two-
digit number is used on the cables from the plinth to
each MPC card.

SERVICE 6.303.33 E rev.: - 2003-10-30
3.4 MPC card normal readouts at idling

During idling, two LEDs are expected on each MPC
card. The green LED no. 42 (+24V) is on and the
green LED Tx is flashing/glowing. See Fig. 3 and
Table 1.
(Tx indicates internal communication between the
MPC cards. Tx on the MPC "Sc" is glowing stronger
than the others because it sends data three times
more often than the others.)
MPC card displays must show "Sc", "Ho", "Lu" and

"SL" respectively.
Software Software Software Software

MGXxxxx MGXxxxx MGXxxxx MGXxxxx
Rev Rev Rev Rev
Fig. 3. MPC card displays and LEDs for idling crane.
MPC "Sc" MPC "Ho" MPC "Lu" MPC "SL"

Input Output Input Output Input Output Input Output
42 42 42 42
(+24V) (+24V) (+24V) (+24V)
Tx Tx Tx Tx
Table 1. MPC card readouts for idling crane.

SERVICE 6.303.33 E rev.: - 2003-10-30
3.5 MPC card normal readouts when

hoisting, luffing and slewing
When hoisting at low speed, luffing in and slewing
left, the following LEDs are on for each MPC card
(crane with one pump per movement and unloading
on luffing). See Fig. 4 and Table 2.
Software Software Software Software

MGXxxxx MGXxxxx MGXxxxx MGXxxxx
Rev Rev XX Rev Rev
Fig. 4. MPC card displays and LEDs when

hoisting at low speed and luffing in and
slewing left.
MPC "Sc" MPC "Ho" MPC "Lu" MPC "SL"

Input Output Input Output Input Output Input Output
07 33 07 33 07 33
(hoisting) (hoisting (luffing in) (luffing in (slewing left) (slewing left
pump1) pump1) pump1)
09 31 31
(low speed) (low speed) (unloading)
30 30 30
(brake) (brake) (brake)
42 42 42 42
(+24V) (+24V) (+24V) (+24V)
Tx Tx Tx Tx
Table 2. MPC card readouts when hoisting at low speed and luffing in and slewing left.

SERVICE 6.303.33 E rev.: - 2003-10-30
4. Troubleshooting the control

system
4.1 General
This section provides information for identifying and
correcting malfunctions which may develop while
operating the cargo crane. Before performing
troubleshooting, read and follow all safety
instructions found in section "General", Group 1, of
this manual. This chapter cannot list all malfunctions
that may occur, nor all inspections and corrective
actions. If a malfunction is not listed, or is not
corrected by the listed corrective actions, notify
your supervisor.
When troubleshooting a malfunction: locate the

symptom or symptoms that best describe the
malfunction. If the appropriate symptom is not listed,
notify your supervisor.
Perform each step in the order listed until the

malfunction is corrected.
Note!
Read this section in conjunction with the
electrical and hydraulic diagrams provided
in Group 9.5 and 9.4.

SERVICE 6.303.33 E rev.: - 2003-10-30
4.2 Hoisting, luffing or slewing movement does not function
(a) Power supply 24V and 8V to CT2 cabinet (MB).

(1) Check overcurrent relay Q3 (HC3) in CT1 cabinet (HC).
(2) Check fuse in plinth 58 in CT2 cabinet (MB), only 8V.
(3) Check fuses, 1 to 6 inclusive, in T1 in CT1 cabinet (CE).
(4) Check rectifier unit wall-mounted in CT1 cabinet (in CE cubicle).
(5) Check relay K34 in CT1 cabinet (A90 in A cubicle) (see crane circuit diagram).
(b) Control system, CT2 cabinet (MB).

(1) Check control system signals in CT2 cabinet (MB).
(a) No LEDs on and no display readout - indicates loss of 8V.
(b) Check for red LEDs - indicating stop limits.
(1) If LED 28 on or flashing, see sign ERROR MESSAGES.
(c) Check for yellow LEDs - indicating speed reduces.
(d) Check for loss of green input signal LEDs - from joystick.
(e) Check analogue input signal from joystick potentiometer.
(f) Check for loss of green output signal LEDs.
(1) Replace the MPC card by other movement MPC card.
(2) Replace faulty MPC card with a new one.
(2) Check control lever (joystick).

Check electric cable connections.
(3) Check limit switches.

Adjust limit switches.
(4) Check valves 1221, 1226, 2221, 2226 and 3221.

Replace electric coil.
Replace valve.
(5) Check pump servo valves 1111-9, (1112-9), 2111-9, (2112-9) and 3111-9.

SERVICE 6.303.33 E rev.: - 2003-10-30
5. Operating the crane with fewer

than four MPC cards
5.1 General
With one or more faulty MPC cards, the crane can be
operated temporarily with MPC card "Sc" together
with remaining card(s).
- To be able to use luffing movement, functional MPC

cards have to be in "Sc" position, "Ho" position and
"Lu" position.
- To be able to use hoisting movement, functioning
MPC cards have to be in "Sc" position and "Ho"
position.
- To be able to use slewing movement, functioning
MPC cards have to be in "Sc" position and "SL'
position.
5.2 Actions taken to replace MPC cards

- Switch off the power to the CT2 (MB) cabinet by
stopping the crane.
- Remove the MPC card to use for replacement
and leave this position empty.
- Replace the faulty MPC card.
- Start the crane. It can now be operated with chosen
movement.
The error lamp "control system error" is now flashing

as the system now has no communication with the
card that has been removed. (Error 40-49 on the
"Sc"-card.)

SERVICE 6.303.33 E rev.: - 2003-10-30
6. Spare parts
6.1 MPC card, 314 3603-8xx
The ready-to-use MPC card, no. 314 3603-8xx, (where Memory Card 314 3605-801
-8xx means any one of -801, -802, -803 etc.) consists consists of
of a hardware electronic card loaded with software.
Hardware: 314 3605-901
For correct article no., see spare parts list, section Software: 6250xxxx
9.5.
When ordering an MPC card without knowing the 6 . 3 Return report

article no. (-8xx), specify the software version needed
It is essential that the service department gets infor-
and proceed as follows.
mation about when and why the card was removed
from the crane system. Fill out the return form, see
Look for:
Group 6.0, and send it back with the replaced card.
- the software version specified on the replaced
card.
- the software version specified on the parameter 6.4 Conductive transit boxes
list in the CT2/MB cabinet.
To protect all types of electronic cards from dama-
ges from ESD (electrostatic discharge) it is important
or:
to use pink anti-static plastic bags and conductive
- refer to the crane's mfg. no., which can be found
transit boxes of the same type as used for delivered
stamped in crane operator's cabin.
original spare parts.
Customers who purchase a replacement card will

receive a credit note of 15% of the sales price when
the damaged card is returned to MacGREGOR
Cranes in Örnsköldsvik.
6.2 Parameter Memory Card, 314 3605-

801
The parameter memory card, order no. 314 3605-
801, is not a general spare part. Each parameter
memory card needs to be programmed with the
crane's unique parameter values (see parameter
list in CT2/MB cabinet). When ordering a parameter
memory card always specify the manufacturing
number (mfg. no.), which can be found in the CT2/MB
cabinet or in the crane operator's cabin.
The programmed memory card delivered by us will

be labelled with the crane mfg. no.

6HLWH 'DWXP
6,*1$/29(59,(:
6LQJOHDQG7ZLQ&UDQHV 1U 5HYLVLRQ
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/('V
24V Input and Output signals are indicated with coloured LEDs.
&RORXU ,QGLFDWLQJ /('VRQZKHQ
Green Normal inputs and outputs +24V
Yellow, Speed reduce limits
11,12,13 0V
Yellow Speed reduction switches +24V
17,18
Red Limits switches, low pressure 0V
and overload
/(' connected to plinth number 42 and indicates power +24V
DC to the card.
/('7[ indicates that the card is transmitting serial data to other
cards on an internal data bus.

3OLQWKQXPEHU
Combine card no with LED no 3 1 9
Sc, Supervisory card card no 1 1 LED number

Ho, Hoisting card card no 2 2
Lu, Luffing card card no 3 3
SL, Slewing card card no 4 4
6FVXSHUYLVRU\ +RKRLVWLQJ /XOXIILQJ 6/VOHZLQJ

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QR QR QR QR
1 Twin control on, input 2 Hoisting, input 3 Luffing in, input 4 Left, input
1 Twin reset, input 2 Lowering, input 3 Luffing out, input 4 Right, input
1 Twin, encoder calibration 2 Low speed, input
1 Not used 2 High speed, input
1 Connected to +24V 2 Speed reduce hoisting 3 Speed reduce luffing in 4 Speed reduce left
1 Connected to +24V 2 Speed reduce lowering 3 Speed reduce luffing out 4 Speed reduce right
1 Connected to +24V 2 Speed reduce high-hook 3 Speed reduce high-hook
2 Limit switch hoisting 3 Limit switch luffing in 4 Limit switch left
2 Limit switch lowering 3 Limit switch luffing out 4 Limit switch right
2 Limit switch high-hook 3 Limit switch high-hook
1 Not used 2 Speed reduction, ext1 3 Speed reduction, ext1 4 Speed reduction, ext1
1 Not used 2 Speed reduction, ext2 3 Speed reduction, ext2 4 Speed reduction, ext2
2 Low pressure switch 3 Low pressure switch 4 Low pressure switch
2 Overload switch input 3 Overload switch input
1 Alarm (error in 2 Alarm (error in CT2(MB)) 3 Alarm (error in CT2(MB)) 4 Alarm (error in
CT2(MB)) CT2(MB))
1 Not used 2 Hoisting brake, output 3 Luffing brake, output 4 Slewing brake, output
1 Not used 2 Low speed, output 3 Unloading, output
1 Not used 2 High speed, output
1 Not used 2 Pump1 hoisting, output 3 Pump1 luff in, output 4 Pump1 left, output
1 Not used 2 Pump1 lowering, output 3 Pump1 luff out, output 4 Pump1 right, output
2 Pump2 hoisting, output 3 Pump2 luff in, output 4 Pump2 left, output
2 Pump2 lowering, output 3 Pump2 luff out, output 4 Pump2 right, output
2 Pump3 hoisting, output
2 Pump3 lowering, output
+24V +24V +24V +24V
Contamination Switch - Function
The contamination switch has a permanent magnet, The pilot light "Contamination" illuminates and
which draws the ferromagnetic dirt particles from indicates contamination, if any of the contamination
the passing fluid. At increased accumulation of dirt switches in the pumps are activated. The buzzer
particles an electric connection is provided from the sounds for 20 seconds after indication.
magnet to the surrounding steel sleeve. At a certain
level of particles a warning signal is provided. There are red LEDs marked V1, V2, V3 and V4 in
the CT2 cabinet, see figure below. When the
All switches are electrically connected to the control contamination switch on the pump is activated a
panel in the operator's cabin. The control panel LED lights up. It is then possible to check on which
includes pilot light and alarm buzzer for pump the contamination switch is activated
contamination warning.
See also "Contamination Switch - Chip Detector, 5.025.2" in the Instruction Manual.
V1 - Hoisting pump1
V2 - Hoisting pump2
V3 - Luffing pump
V4 - Slewing pump
This document remains our property. It must not be reproduced or made accessible to our competitors or others who could make undue use of it, without our written permission.
-
Rev ind Revision Appd Year Week
Description (English) Drawn by Year Week
Contamination LEDs C Lundquist
Deescription (own language) Drawing No Rev ind Sheet
Contamination LEDs 4240606 - 1 (1)
SERVICE 6.305.1 E rev.: b 1994-01-27
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 are placed in section 9, SPARE PARTS.
Start the crane and try out all combinations of

movements that are practicable. This will show if the
electric functions are satisfactory.
Inspect all electrical equipment cabinets, and

components. Any defective component must be repai-
red or replaced without delay. A detailed inspection
and overhaul at two-year intervals is recommended.
Check that all screws and nuts are securely tighte-
ned in the contactor cabinets, that all switches and
pushbuttons operate correctly, and that cable
connections are perfectly tight and all insulating parts
intact. Make sure that inspection door gaskets seal
perfectly.
Danger!
Electrical equipment can be alive unless the main
switch and the separate supply is disconnected.
Fig.1. Electrical equipment cabinet

Earth connection, hull
Verify that the protective earth connection of the crane
is made to the ship’s hull.
Clean contact surfaces, when required.
- Clean contacts, insulating parts, cams, contact

Earth connection, crane rolls, and rotary potentiometers.
Check crane system earth connections, and clean - Make sure that all cable connnections are clean
contact surfaces as required. and securely tightened.
- Clean the control levers, and grease their sliding
Portable control boxes surfaces.
- Check on the return springs and grease lightly so
Control panels and remote control boxes may be
that no grease transfers to the contacts.
subjected to abuse an abnormal wear, and should be
inspected after every use. The control boxes must be
stored in a compartment that is well protected against Jib floodlight
moisture. Remove moisture that may have collected Make sure that connections in the junction box are
in the boxes, and find out how it entered. clean and well tightened.

SERVICE 6.305.1 E rev.: b 1994-01-27
- Remove moisture and dirt.

- When necessary, clean contact surfaces of termi-
nal strips and of lamp holder.
- Make sure that lamp holder gasket seals correctly.
- Make sure that the work light can be rotated.
Slip-ring unit
Danger!
Before opening the slip-ring unit, make sure that
power supplied by separate transformers is switched
off in the ship's engine room. Also check by means
of a voltmeter that the slip-ring unit is not alive.
- 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
assemblies 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 thermostat
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 cooler inlet line.

SERVICE 6.307.11 E rev.: b 2003-01-08
Slip-Ring Unit
Danger! Use only insulated tools and original spare parts.

Before opening the slip-ring unit, make sure that
power supplied by separate transformers is No responsibility will be assumed for damage to
switched off in the ship's engine room. Also check property or injury to persons caused by improper
by means of a voltmeter that the slip-ring unit is not use of the slip-ring assembly.
alive. Make sure that the current can not be switched
on again during the maintenance operation. Removal
Work on a slip-ring assembly may only be carried 1. Park the jib in a suitable manner.
out by a qualified electrician or by persons under 2. Disconnect the ship's power supply at all points
the supervision of a qualified electrician and only of feed.
according to accepted electrical safety procedures. 3. Disconnect all the cables connection from crane-
and ship supply.
The function of the slip-ring assembly may not be 4. Remove the driver connecting the slip-ring unit
changed in any way. Especially safety devices must and the foundation. Note the cables mounting
not be made ineffective. Other than during mainte- sequence.
nance and inspection work the housing must always 5. Remove mounting screw holding the slip-ring unit
remain closed. on cranehouse bottom. See Fig. 1.
6. Remove the slip-ring unit.
Mounting screws
Connection crane
Slip-ring unit
Connection ship Connection box

power
Guide pins
Driver
Rubber protection
Note! Must be
tightened.
Fig. 1. Slip-ring unit.

SERVICE 6.307.11 E rev.: b 2003-01-08
Any extra equipment such as extra limit switches Carbon brushes

fitted on top of the slip-ring unit are removed prior - The carbon brushes must never wear down so
to 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 into contact with the brushes or the slip-rings.
and cranehouse bottom. Tighten all screws prop-
erly. See instruction "Tightening torque".
Wire brushes
- Assemble the slip-ring unit under crane bottom - Check wire brushes.
- Assemble the driver to the bottom of the founda- Debris caused by wear is to be removed with dry,
tion oil free, compressed air or with a vacuum cleaner.
- Remove the cover around the slip-ring unit Afterwards the slip-ring ways and wire brushes
- Fit the slip-ring unit guide pins to the driver's slot- should be lightly sprayed with "Cramolin B" or
ted holes by pulling apart the driver and lock it equivalent contact spray.
with help of the through bolt
- Install the cables against the driving bar Others
- Connect the crane cables from the crane on 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
insulating parts in the collector.
After installation
- 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 ensure that no mechanical side
forces are transferred to the unit.
- Tighten the rubber protection , see Fig. 1.
Maintenance
Always cut current before accessing the collector

for inspection or maintenance. Make sure that the
current can not be switched on again during the
maintenance operation.
At regular intervals
- Check collector for damaged parts
- Check contact pressure of brushes
- Check brush holders

SERVICE 6.311.4 E rev.: - 2001-11-16
Oil Level Float Switch and Overheating Protector
Introduction
To prevent operation of the crane with too little oil in
LOW OIL LEVEL CHECK OIL FILTER
the hydraulic oil tank, an oil level float switch is installed
in the oil tank. The level float switch operates alarm
signals on the control panel in the crane operator’s
cab and a siren. Warning lamps and a selector switch
are placed on the right-hand control panel in the cab FLOATS WIT
C H
FLOAT SWITCH
(see Fig. 1). In normal operation, the switch should BELL OFF
F BY-PASS
be in the position shown in the illustration.
TEST T
Fig. 1. Right-Hand Control Panel.
Fig. 2 shows the design of the oil level float switch.

Normally, the float is at its topmost position (i.e. when
the level in the hydraulic tank is sufficient).
The float controls switches which in turn, control the

warning lamps and the bell.
Oil Cooling
The oil cooler starts when the oil temperature exceeds
100C.
Fig. 2. Oil Level Float Switch.

SERVICE 6.311.4 E rev.: - 2001-11-16
Normal Oil Level

Normal oil level is between marks MIN and MAX and
3.01 3.02 3.03
LOW OIL LEVEL warning lamp is extinguished. Se- MAX
lector FLOAT SWITCH (see Fig. 3.03) must be in LOW OIL LEVEL FLOAT SWITCH
position shown. BELL OFF BY-PASS
MIN TEST
Oil Level Float Switch Function

A low oil level should be remedied as soon as possible
operating conditions permit. If this is not practicable,
certain emergency measures may be undertaken as
described below.
3.04 3.05 3.06
MAX
FLOAT SWITCH
Oil Level MIN LOW OIL LEVEL
BELL OFF BY-PASS

If the oil level drops to MIN, the float activates the
MIN
upper switch and lamp LOW OIL LEVEL goes on. At TEST
the same time, the alarm bell sounds.
Oil Level MIN, Continued Operation

In an emergency, the operation of the crane may be
continued for a short time provided that there is no
MAX 3.07 3.08 3.09
important leakage of oil. In this case, turn selector
LOW OIL LEVEL FLOAT SWITCH
FLOAT SWITCH to position BELL OFF; the bell will
BELL OFF BY-PASS
then be silent and lamp LOW OIL LEVEL goes out.

MIN TEST
Oil Level Below MIN

When the oil level has dropped a certain distance
below MIN level, the float activates the lower switch
and stops the crane. LOW OIL LEVEL lamp goes on.
3.10 3.11 3.12
MAX
Oil Level Below MIN, Emergency Operation LOW OIL LEVEL FLOAT SWITCH
BELL OFF BY-PASS

In an extreme emergency (e.g. if the crane has
stopped with a load suspended on the hook) the crane MIN TEST
can be started anew and operated if selector FLOAT

SWITCH is turned to position BY-PASS. The lamp
LOW OIL LEVEL goes on and the alarm bell sounds.
This is permissible if no important leakage is present,
but is entirely at the risk and responsibility of the 3.14 3.15
3.13
crane operator or the officer who gives the order. MAX
LOW OIL LEVEL FLOAT SWITCH
BELL OFF BY-PASS
MIN TEST
Fig. 3. Sub-Level Operation.

SERVICE 6.311.4 E rev.: - 2001-11-16
Testing Warning Lamps

With selector FLOAT SWITCH in TEST position (see
DO NOT OPERATE LOW OIL LEVEL CHECK OIL FILTER
Fig. 4) DO NOT OPERATE and LOW OIL LEVEL
lamps illuminate and the alarm bell sounds. The
function and continuity of these lamps is checked in
this manner.
Testing Oil Level Float Switch

The float of the level float switch is fitted with a built-
SIREN/BELL
FLOAT SWITCH
in magnet which, makes a control circuit when the oil
BELL OFF BY-PASS
level drops below certain levels. The function of the
float is preferably tested when performing oil changes TEST
or tank cleaning. For the purpose of this test, the main

switch will have to be temporarily switched on.
Overheating Protector Fig. 4. Selector FLOAT SWITCH, Position TEST.

The crane stops automatically when the oil tempera-
ture exceeds 85oC. The overheating protector is fitted
on the inlet line of the oil cooler (see Fig. 6). DO NOT OPERATE LOW OIL LEVEL CHECK OIL FILTER
SIREN/BELL FLOAT SWITCH
BELL OFF BY-PASS
TEST
Fig. 5. Part of Right-Hand Control Panel.
BT2
85°C
Fig. 6. Overheating Protector.

SERVICE 6.320.288 E rev.: - 2005-01-14
Limit Switches in Hoisting and Luffing Winch Systems
General
The limit switches of the hoisting and luffing winches

are contained in 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 location of the switch boxes is shown in the figure.
The limit switch system performs the following func-

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

at chosen safety limits.
2. Speed reduction - the speed of a hook or jib move-

ment is reduced to 25-30% at a predetermined Limit switch box,
point before the stop position is reached. luffing winch
3. Position control function - the jib working radius Limit switch box,
hoisting winch
and the level of the crane hook are controlled in
relation to each other.
Fig. 1. Limit switch boxes in crane house.
The limit switch boxes of the hoisting and luffing
winches are similar except for the demultiplication Together with an angle encoder on the luffing winch the
ratios of their driving gearboxes. system senses the jib outreach as well as the load in
the hook. The system gives automatically the correct
The cams in the luffing winch limit box are marked hoisting speed and jib outreach corresponding to the
BL1, BL2, BL3 etc.; those of the hoisting winch box, load.
BH1, BH2, BH3 etc.
The pilot light "LOADSTEP LIMIT" in the cabin
CAUTION! indicates when permitted jib outreach for actual load
is reached.
Store Keys Safely - Flashing light for jib in speed reduce area.
When the crane is rigged ready for operation, all keys - Fixed light when jib has stopped.
for all lockable switches must be stored in a safe place The pilot light "OVERLOAD" in the cabin lights at
by the responsible officer on board. overload.
Automatic loadstep Anti-collision sensor

The cranes are equipped with pressure transmitters The crane is prepared for receiving a signal from an
which measure the hydraulic pressure proportional anti-collision sensor, connected to an anti-collision
to the load. equipment which is not supplied by MacGREGOR.

SERVICE 6.320.288 E rev.: - 2005-01-14
The anti-collision equipment protects against collision with Measure references

obstacles such as containers. When the sensor is The following measures are stated in the document
activated the speed of the luffing and slewing movements TECHNICAL DATA under the section 2 TECHNI-
are reduced and stopped after 2 seconds. CAL DESCRIPTION.
Setting limit switches Jib Radius, Max (m)

Jib Radius, Min (m)
Back off the lockscrews of the switch cams in the
Lifting Height, H (m)
limit switch boxes, using a 10 mm articulated wrench;
Lifting Height, K (m)
the cams are then easily rotated to their proper
settings.
Other measures are stated in the figures.
After setting the cams correctly, retighten the

Please note that the Jib radius measures refer to the
lockscrews and operate all crane movements, begin-
crane house slewing centre (Not to the jib bearing
ning at reduced speed and finishing at maximum speed
centre!). The measures H and K refer to the jib bearing
to check cam settings.
centre.
Adjustment Adjustment
screws screws
For spanner
size 10 mm
Fig. 2. Cam.
H
Jib radius
Jib radius K
Fig. 3. Jib radius lifting height.

SERVICE 6.320.288 E rev.: - 2005-01-14
Limit switch angles Luffing winch limit switches
Limit switches Degrees Remarks The included limit switches are shown in the below
luffing winch figs. Note that switches BL2 and BL4 actuate speed
BL1 30∞ reduction of the crane jib.
BL2 90∞
BL3 60∞ Note! When adjusting the luffing limits it is important
BL4 30∞ to start with BL1 and to continue with BL2, BL3, BL4
BL5 30∞ and so on.
BL6 120∞
BL7 150∞ When changing wires it is important that the proce-
BL8 170∞ dure in instruction 6.223.4 E is followed, thus to avoid
BL9 190∞ readjustments of limits.
Table 1. Limit switches, luffing winch.
BL1
Limit switches Degrees Remarks BL2

hoisting winch BL3
BH1 30∞
BL4
BH2 40∞
BH3 40∞ BL5
BH4 30∞ BL6
BL7
Table 2. Limit switches, hoisting winch.
BL8
BL9
Fig. 4. Limit switch box on the luffing winch.

SERVICE 6.320.288 E rev.: - 2005-01-14
BL5 Stop
BL4 Speed reduce, luffing in
BL2 Speed reduce, luffing out
BL3 Stop
BL1 Jib parking position

(At least three locking turns)
3.0 m*
Approx. 3.0 m
Approx. 1.5 m
30.0 m
Fig. 5. Luffing winch basic limit switches, 36 Ton / 3.0-30.0 m.
Stop BL5
BL4 Speed reduce, luffing in
Speed reduce, luffing out
Stop BL6 Activates the 36 ton pressure switch.
3.0 m*
Approx. 3.0 m
Note! The speed reduce and stop limit for 27 m
Approx. 1.5 m
outreach are controlled by an angle encoder and the
27.0 m CC2000 Software.
Fig. 6. Limit switch positions, 40 Ton / 3.0-27.0 m.

* MIn. jib radius.
= Speed reduce
= Stop. By-pass.
= Stop.

SERVICE 6.320.288 E rev.: - 2005-01-14
Speed reduce, luffing in
3.0 m*
Approx. 3.0 m

Approx. 1.5 m
outreach are controlled by an angle encoder and
24.0 m the CC2000 Software.
3.0 m*
Approx. 3.0 m

Approx. 1.5 m
outreach are controlled by an angle encoder and
22.0 m the CC2000 Software.
* MIn. jib radius.
= Speed reduce
= Stop. By-pass.
= Stop.

SERVICE 6.320.288 E rev.: - 2005-01-14
3.0 m*
Approx. 3.0 m
Approx. 1.5 m
outreach are controlled by an angle encoder and the
19.0 m CC2000 Software.
* MIn. jib radius.
= Speed reduce
= Stop. By-pass.
= Stop.

SERVICE 6.320.288 E rev.: - 2005-01-14
Hoisting winch limit switches

BH1
Raise the jib into the MIN Jib radius position, which
is the correct jib position for setting the limit switches BH2
according to the below figs. Note that the switches BH3
BH2 and BH3 actuate speed reduction of the crane
BH4
hook.
Fig. 10. Limit switch box on the hoisting winch.
BH4 Full drum limit, stop position

Approx. 2.5 m
BH3
H = 10.0 m
K = 20.0 m
BH2
Approx. 2.5 m
Empty drum limit, stop position
BH1 (Three locking turns or tank top)
Reduced speed
Fig. 11 . Hoisting winch basic limit switches.

SERVICE 6.320.288 E rev.: - 2005-01-14
Jib top and hook block functions at big

outreaches
In a certain area there is a possibility that hook block The cranes are designed, calculated and manufac-
and jib top will meet. See Figs. 12 and 13. This will tured in accordance with and approved by classifica-
not cause any problem as the cranes safety system tion societies.
takes care of it.
A slacking luffing or hoisting wire rope should stop
It is only possible for the hook block to reach jib top the luffing out and hoisting movements by use of the
at big outreaches. slack wire switch BWL1.
The hook block and the crane jib is designed and Hook block hoisting the jib:
calculated to take care of the forces which occur when - This actuates the slack wire switch BWL1 and the
the hook block is hoisting the jib top or the jib top hoisting movement stops.
lands on the hook block.
Jib landed on the hook block:
At small outreaches the full drum limit, BH4, on the - Luffing wire slackens and the slack wire switch
drum will be in operation. BWL1 actuates. The luffing out movement stops.
Area for big outreaches where hook block

and jib top will possibly meet.
Fig. 12. Big outreaches.

SERVICE 6.320.288 E rev.: - 2005-01-14
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

radius radius
Fig. 13. Hook way.
Hook stop
Hook stop
Fig. 14. Jib top.

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.

SERVICE 6.990.49 E rev.: - 2005-02-09
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 the 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)
Valve 1C
Plug, to be used
when emergency
slewing
T-coupling to MA on pump,
hoisting or luffing
Port 3A-B Port 3A-F
Valve 3B Valve 3A
Connection to tank By-pass line Bushing Screw
Fig. 1. Hand pump (optional).

SERVICE 6.990.49 E rev.: - 2005-02-09
CAUTION!
- This work has to be done with great care by skilled
personnel.
- Only one function to be activated at the time.
- Verify that nobody is within the working area of the
crane.
- Valves 1663, 2661 and 3661 must not be actu-
ated except in emergency brake release operation.
Hoisting pump
1111 or 1112 MA (guage
connection 3.2)
MB (guage
connection 3.1)
CAUTION!
Hose must be connected to MA-port (guage
connection 3.2) on hoisting pump to avoid
uncontrolled lowering.
By-pass line
3B
3A
1221
Valve 1663
1128-1
Pilot hoses
Pilot hose (disconnected)
P
Open
Oil tank
Disconnect (4332)
and plug
Vedge
valve 4332
Quick
coupling1664
1226
Hand pump
Fig. 2. Connection of hand pump, hoisting winch.

SERVICE 6.990.49 E rev.: - 2005-02-09
Hoisting circuit, see Fig. 4 and 5 Caution!

It is of most importance that the hoses to MA and
MB are not switched, because the load could be
dropped.
- Connect the hoses from the hand pump as shown in
Fig. 1, Fig. 2 and in the hydraulic diagram Fig. 4.
- Disconnect the pilot hose from connection “P”,
valve 1128-1. Plug the disconnected hose. See
Fig. 2, 3, and 4.
- Remove check-restriction valve 1241 from valve
1128, see Fig. 3.
Function - Attach the bushing and screw into coupling in
The emergency lowering system works in such a way connection “P”, valve 1128-1. Screw in the,
that the motor hydraulically controls the load. If the threaded up to the neck, screw to actuate the pis-
motor tends to overspeed, by the force from the load, ton to blocked position. See Fig. 3.
the brake will close. - Close valve 1663. See Fig. 2 and 4.
Hand pump 1A builds up pressue on the low pressure Operation

side of the motor and on the brake. The brake opens
Release the brake by pumping oil from the hand
at approx. 1,2 MPa, to be read on pressure guage 1D
pump. The load must be lowered slowly and carefully
and adjusted at valve 1C. Oil from the high pressure
controlled. Speed can be reduced by closing valve
side (pump B-port) goes through the needle valve 3B
3B, partially or completely.
and flow control valve 3A to the low pressure side
The load must be lowered slowly by pumping in a
(pump A-port). Valve 3A is fixed and load independent.
slow and even pace.
With a load in the cargo hook, valve 3B can be
compleatly or partially closed in order to reduce the
speed. Twin operation
The twin beam must be as horizontal as possible
during emergency lowering.
Connection, see Fig. 2 and 4.
- Install the hand pump to the base plate using the
provided screws. After operation
- Disconnect pilot hoses at MA- and MB-port on the After the lowering operation is completed, reset the
pump. crane to “NOT EMERGENCY COUPLED“. Open
- Connect the by-pass line. See Fig. 2 and 4. valve 1663. See Fig. 5.
Note! Vedge valve 4332 must be open due to the

off-line filtration.
Check-restriction
Coupling
valve 1241
1128-1
Bushing P
Screw
Piston
Fig. 3. Valve 1128.

SERVICE 6.990.49 E rev.: - 2005-02-09
Fig. 4. Hydraulic circuit, hoisting. Emergency coupled.

SERVICE 6.990.49 E rev.: - 2005-02-09
Fig. 5. Hydraulic circuit, hoisting. Not emergency coupled.

SERVICE 6.990.49 E rev.: - 2005-02-09
Luffing circuit, see Fig. 8 and 9
MB (gauge connection 5.1)

CAUTION! MA (gauge connection 5.2)
Hose must be connected to MA-port (guage
Luffing pump 2111
connection 3.2) on hoisting pump to avoid
uncontrolled lowering.
Gauge
connections
removed 3B 3A
By-pass line
2127
T-connection, included in
emergency equipment
Pilot hose
Open
P
2221
Disconnect Oil tank
and plug (4332)
2661
Vedge
valve 4332
Quick
coupling 2664
2226 Hand pump
Fig. 6. Connection of hand pump, luffing winch.

SERVICE 6.990.49 E rev.: - 2005-02-09
Function - Remove check-restriction valve 2241 from valve

The emergency lowering system works in such a way 2127, see Fig. 7.
that the motor hydraulically controls the load. If the - Attach bushing and screw into coupling in connec-
motor tends to overspeed, by the force fom the load, tion P, valve 2127. Screw in the threaded up to
the brake will close. the neck screw to actuate the piston to blocked
position. See Fig. 6 and 7.
Hand pump 1A builds up pressue on the low pressure - Close valve 2661. See Fig. 6 and 8.
side of the motor and on the brake. The brake opens
at approx. 1,2 MPa, to be read on pressure guage 1D Operation
and adjusted at valve 1C. Oil from the high pressure
Release the brake by pumping oil from the hand
side (pump B-port) goes through the needle valve 3B
pump.The jib must be lowered slowly and carefully
and flow control valve 3A to the low pressure side
controlled. Speed can be reduced by closing valve
(pump A-port). Valve 3A is fixed and load
3B, partially or completely.
independent. Valve 3B can be compleatly or partially
The load must be lowered slowly by pumping in a
closed in order to reduce the speed.
slow and even pace.
Connection, see Fig. 1, 6 and 8

Twin operation
- Install the hand pump on the base plate with screws
The jibs must be as parallel as possible to each
provided.
other during the lowering.
- Before connecting the by-pass line, remove the
gauge connections from MA- and MB-port.
If only the luffing circuit is out of operation, try to lower
the load onto deck or quay with the hoisting winch.
Caution!
Remove the twin beam and lower the jib one by one.
It is of the utmost importance that the hoses to MA-
and MB-port are not switched, because the load
could be dropped. After operation
After the lowering operation has been completed, re-
- Connect the by-pass line. See Fig. 6 and 8. set the crane to “NOT EMERGENCY COUPLED“.
- Connect hoses from the hand pump as shown in Valve 2661 must be open. See Fig. 9.
Fig. 6 and hydraulic diagram Fig. 8.
- Disconnect the pilot hose from connection P, valve Note! Vedge valve 4332 must be open due to the off-
2127. Plug the disconnected hose. See Fig. 1, Fig. line filtration.
6 and Fig. 7.
Check-restriction Coupling
valve 2241
P 2127
Screw Bushing Piston
Fig. 7. Valve 2127.

SERVICE 6.990.49 E rev.: - 2005-02-09
NOTE: VALVE MEC. EFFECTED
Fig. 8. Hydraulic circuit, luffing. Emergency coupled.

SERVICE 6.990.49 E rev.: - 2005-02-09
Fig. 9. Hydraulic circuit, luffing. Not emergency coupled.

SERVICE 6.990.49 E rev.: - 2005-02-09
Slewing circuit, see Fig. 11 and 12
Connection Note!
- Install the hand pump onto the base plate with the The brake opens at approximately 1.3 MPa.
screws provided. See Fig. 10.
- Connect the hoses from the hand pump as shown Warning!
in Fig. 10 and hydraulic diagram Fig. 12.
If the crane is tilted, the brake must be released with
- Close valve 3661. See Fig. 10.
great caution. If the speed increases too much, the
brake can be activated by ceasing to pump or opening
Operation valve 3661.
- Release the brake by pumping oil from the hand
pump.
After operation
- The crane may now be slewed to a set position
After the slewing operation has been completed, reset
with the help of another crane. Use caution.
the crane to NOT EMERGENCY COUPLED. Valve
3661 must be opened. See Fig. 10.
Note! Vedge valve 4332 must be open due to the off-

line filtration.
Quick-coupling
Valve
3661
Vedge
valve 4332
Open
Plug*)
1A (4332)
T-coupling To be plugged at
emergency operation
*) Included in pump set.
Fig. 10. Hand pump connected to slewing machinery.

SERVICE 6.990.49 E rev.: - 2005-02-09
Fig. 11. Hydraulic circuit, slewing. Emergency coupled.

SERVICE 6.990.49 E rev.: - 2005-02-09
Fig. 12. Hydraulic circuit, slewing. Not emergency coupled.

E 625-0014
9.0 How to order

spare parts
9.1 Machinery
Parts Manual
9.2 Pump unit

Oil cooler
9.3 Mechanical
equipment
9.4 Hydraulic
components
9.5 Electric
components
9.6
Address:
MacGREGOR Cranes AB
9.7 Extra equipment
S-891 85 ÖRNSKÖLDSVIK, Sweden
E 1999-06-14
Telephone: 46 - 660 - 29 40 00
Telex: 6050 haegg s
Telefax: 46 - 660 - 29 42 88 (Service Dept.)
Telefax: 46 - 660 -139 77 (Spare Part Dept.)
Telefax: 46 - 660 - 29 42 91 (Technical Info. Dept.)

PARTS MANUAL Date Group Fig. Page
2005-01-05 9.1 625-1440.070 1 (2)
HOISTING WINCH
2005-01-05 9.1 625-1440.070 2 (2)
HOISTING WINCH
Item Qty Article no Description Supplementary data
000 1 189 4211-801 HOISTING WINCH
001 2 188 1222-801 . HYDRAULIC MOTOR A6VM 160. SEE FIG 625-2205.008
002 1 189 2663-801 . WINCH HOISTING. SEE FIG. 625-1450.052
004 1 289 3269-801 . VALVE UNIT SEE FIG. 625-7207.009
007 1 388 3580-801 . FLUSH AND UNLOADING UNIT SEE FIG. 625-7449
021 8 2121 2032-630 . SCREW M6S 16 x 50 -8.8 FZB

2003-11-19 9.1 625-1450.052A 1 (2)
HOISTING WINCH
2003-11-19 9.1 625-1450.052A 2 (2)
HOISTING WINCH
000 1 189 2663-801 HOISTING WINCH
001 1 875 13004-058 . DRIVE IN, COMPLETE SEE FIG. 625-1451.016
002 1 875 13019-066 . GEAR, COMPLETE SEE FIG. 625-1451.017
003 1 875 13021-021 . FLANGE, COMPLETE SEE FIG. 625-1451.015
205 1 875 13017-001 . CABLE FIXING
220 24 2121 2532-719 . SCREW MC6S 24 x 55 -8.8 FZB; DIN 912
223 5 875 13018-011 . SCREW M20 x 45
402 6 2121 2032-720 . SCREW M6S 24 x 60 -8.8 FZB; DIN 933
404 24 2121 2030-767 . SCREW M6S 30 x 80 -10.9; DIN 933
405 24 875 13014-005 . WASHER
411 2 875 13016-001 . SPACER
600 1 875 13009-049 . OIL PIPE, COMPLETE

2003-11-19 9.1 625-1451.016 1 (2)
DRIVE IN, COMPLETE

2003-11-19 9.1 625-1451.016 2 (2)
DRIVE IN, COMPLETE

000 1 875 13004-058 DRIVE IN, COMPLETE
004 2 875 13013-002 . DRIVING SLEEVE
007 2 875 13027-002 . MOTOR FLANGE
022 24 2121 2532-561 . SCREW MC6S 12 x 160 -8.8 FZB;DIN 912
030 2 875 13011-007 . BEARING
036 8 2121 2532-558 . SCREW MC6S 12 x 130 -8.8 FZB;DIN 912
039 4 875 13011-008 . BEARING
040 1 875 13012-016 . CIRCLIP
041 2 875 13012-028 . CIRCLIP
043 2 875 13012-011 . CIRCLIP
046 1 875 13012-011 . CIRCLIP
050 2 875 13007-012 . SHAFT SEALING
053 2 875 13007-006 . SHAFT SEALING
058 1 875 13015-004 . O-RING 410 x 3
059 2 875 13015-003 . O-RING 180 x 3
060 6 875 13006-003 . PLUG M10
061 6 875 13007-007 . SEALING
064 6 875 13006-004 . PLUG M18
065 6 875 13007-008 . SEALING
069 2 875 13008-011 . VENTILATION FILTER M10
075 28 875 13002-003 . SPRING Change all 56 springs at the same time.
076 28 875 13002-004 . SPRING Change all 56 springs at the same time.
089 4 875 13014-009 . SHIM
090 2 875 13014-031 . WASHER
094 2 875 13014-014 . WASHER
095 2 875 13003-008 . PRESSURE UNIT
096 2 875 13028-001 . DISC CARRIER
097 16 875 13001-003 . MULTIPLE DISC, OUTER Change all 30 discs at the same time.
098 14 875 13001-004 . MULTIPLE DISC, INNER Change all 30 discs at the same time.
2003-11-19 9.1 625-1451.017 1 (2)
GEAR, COMPLETE
2003-11-19 9.1 625-1451.017 2 (2)
GEAR, COMPLETE
000 1 875 13019-066 GEAR, COMPLETE
021 24 2121 2532-785 . SCREW MC6S 30x240 -8.8 FZB; DIN 912
031 1 875 13007-035 . SHAFT SEALING
041 x 875 13020-004 . SEALING BAND Length depending on gear.
054 1 875 13029-007 . BAND ROLLER BEARING, COMPLETE
444 1 875 13012-006 . CIRCLIP
473 18 875 13014-008 . SHIM
491 1 875 13014-007 . WASHER

2003-11-19 9.1 625-1451.015 1 (2)
FLANGE, COMPLETE
2003-11-19 9.1 625-1451.015 2 (2)
FLANGE, COMPLETE
000 1 875 13021-021 FLANGE, COMPLETE
001 1 875 13026-011 . FLANGE
003 1 875 13014-029 . WASHER
004 1 875 13012-027 . CIRCLIP
005 x 875 13022-001 . FELT STRIP L = 400 mm
006 1 875 13011-019 . BEARING
008 1 875 13023-010 . COVER
009 1 875 13024-001 . DRIVER
012 2 875 13025-001 . PIN 4 x 16
014 1 2121 2515-360 . SCREW M 6 x 6; DIN 913
401 1 875 13032-002 . GREASE NIPPLE M10 x 1; DIN 71412

1998-10-09 9.1 625-2205.008 1 (2)
HYDRAULIC MOTOR
1998-10-09 9.1 625-2205.008 2 (2)
HYDRAULIC MOTOR
001 1 188 1222-801 HYDRAULIC MOTOR HOISTING
002 1 489 6115-801 . GASKET SET

2004-10-12 9.1 625-1440.064 1 (2)
LUFFING WINCH
2004-10-12 9.1 625-1440.064 2 (2)
LUFFING WINCH
000 1 189 3516-801 LUFFING WINCH
001 1 188 1221-801 . HYDRAULIC MOTOR SEE FIG. 625-2205.009
002 1 189 2669-801 . LUFFING WINCH SEE FIG. 625-1450.058
003 1 289 1639-801 . VALVE UNIT SEE FIG. 625-7207.006
004 1 388 3576-803 . UNLOADING UNIT SEE FIG. 625-7802.004
005 10 487 0545-001 . WASHER
015 2 2121 2032-469 . SCREW M6S 8 x 90 -8.8 FZB
016 4 2121 2032-473 . SCREW M6S 8 x 110-8.8 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
020 4 2151 2022-185 . WASHER BRB 17 x 30 FZB; DIN 125A

2003-03-17 9.1 625-1450.058A 1 (6)
LUFFING WINCH
2003-03-17 9.1 625-1450.058A 2 (6)
LUFFING WINCH
000 1 189 2669-801 LUFFING WINCH
001 22 2121 2030-720 . SCREW M6S 24 x 60 -10.9; DIN 933
002 22 875 13014-002 . WASHER
003 6 2121 2032-673 . SCREW M6S 20 x 45 -8.8 FZB; DIN 933
004 1 875 13009-002 . OIL PIPE, COMPLETE
005 2 875 13016-001 . SPACER
011 18 2121 2032-719 . SCREW M6S 24 x 55 -8.8 FZB; DIN 933
012 24 2121 2032-674 . SCREW M6S 20 x 50 -8.8 FZB; DIN 933
013 1 875 13017-001 . CABLE FIXING
014 4 875 13018-002 . SCREW M 20 x 50; DIN 912
021 1 875 13019-062 . GEAR, COMPLETE Includes item 22 - 26.
022 1 875 13020-001 .. SEALING BAND L = 1382 mm
023 1 875 13020-002 .. LOCKING BAND L = 1500 mm
024 1 875 13020-003 .. SOCKET
025 1 875 13007-009 .. SHAFT SEALING
026 1 875 13014-003 .. WASHER
031 1 875 13021-027 . FLANGE, COMPLETE Includes item 32 - 42.
032 1 875 13026-001 .. FLANGE
033 1 .. FLANGE PLATE Not sold separately. See item 31
034 1 875 13014-004 .. WASHER
035 1 875 13012-010 .. CIRCLIP
036 1 875 13022-001 .. FELT STRIP L = 400 mm
037 1 875 13011-005 .. BEARING

2003-03-17 9.1 625-1450.058A 3 (6)
LUFFING WINCH
2003-03-17 9.1 625-1450.058A 4 (6)
LUFFING WINCH
038 1 875 13023-001 .. 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
042 1 875 13032-002 .. GREASE NIPPLE M10 x 1; DIN 71412
051 1 875 13004-072 . 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
054 14 875 13002-003 .. SPRING Change all 28 springs at the same time
055 14 875 13002-004 .. SPRING Change all 28 springs at the same time
056 1 875 13003-009 .. 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 13013-018 .. DRIVING SLEEVE Includes item 61 - 62.
061 1 875 13012-007 ... CIRCLIP
062 10 875 13014-001 ... SHIM Clearance of 1 - 2 mm to sunwheel.
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 13015-002 .. O-RING

2003-03-17 9.1 625-1450.058A 5 (6)
LUFFING WINCH
2003-03-17 9.1 625-1450.058A 6 (6)
LUFFING WINCH
070 12 2121 2532-559 .. SCREW MC6S 12 x 140-8.8 FZB; DIN 912
071 8 2121 2532-540 .. SCREW MC6S 12 x 40 - 8.8 FZB; DIN 912
072 1 875 13008-011 .. VENTILATION FILTER M 10
073 2 875 13006-003 .. PLUG M 10
074 2 875 13007-007 .. SEALING
075 1 875 13006-004 .. 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

2004-07-01 9.1 625-2250.001C 1 (2)
WINCH MOUNTING SET

2004-07-01 9.1 625-2250.001C 2 (2)
WINCH MOUNTING SET

000 1 288 2710-801 WINCH MOUNTING SET
003 10 489 5009-010 . WASHER
004 10 488 7386-002 . WASHER
005 22 488 7386-001 . WASHER
006 22 488 7386-006 . WASHER t = 45 mm
007 2 489 6415-801 . LIMIT SWITCHES BOX, MOUNT.
008 1 1263 2078-001 . MODISULPHIDE
009 32 2121 2037-737 . SCREW M6S 24 x 160 -10.9 SPEC
010 10 2126 2039-126 . NUT M6M 24 -10 SPEC.

2003-01-16 9.1 625-3254.011 1 (2)
SLEWING GEAR MOUNTING

2003-01-16 9.1 625-3254.011 2 (2)
SLEWING GEAR MOUNTING

000 1 390 2587-801 SLEWING GEAR MOUNTING
001 1 289 1546-801 . SLEWING GEAR MODULE 16
002 1 188 1223-801 . HYDRAULIC MOTOR
003 24 487 2826-009 . WASHER
004 4 487 2826-004 . WASHER
005 24 2121 2030-678 . SCREW M6S 20 x 70 -10.9; DIN 933
006 4 2121 2541-540 . SCREW MC6S 12 x 40 -12.9
007 1 487 7218-002 . NIPPLE
008 1 2152 2151-178 . SEALING INCLUDED IN GASKET SET.
009 1 2522 4506-248 . PROTECTIVE PLUG

2003-10-22 9.1 625-3255.013A 1 (2)
SLEWING GEAR
2003-10-22 9.1 625-3255.013A 2 (2)
SLEWING GEAR
000 1 289 1546-801 SLEWING GEAR MODULE 16
001 1 875 13004-075 . DRIVE IN, COMPLETE Includes item 2-24. Also order springs.
002 9 875 13001-001 .. MULTIPLE DISC, OUTER Change all 16 discs at the same time
003 7 875 13001-002 .. MULTIPLE DISC, INNER Change all 16 discs at the same time
006 1 875 13003-001 .. PRESSURE UNIT
009 1 875 13007-002 .. SHAFT SEALING
010 1 875 13011-001 .. BEARING
011 1 875 13012-001 .. CIRCLIP
012 1 875 13012-002 .. CIRCLIP
021 1 875 13027-006 .. MOTOR FLANGE
022 1 875 13028-002 .. DISC CARRIER
023 1 .. BRAKE FLANGE Not sold separately. See item 1.
024 1 .. DRIVING SLEEVE Not sold separately. See item 1.
025 16 875 13002-001 . SPRING Change all 32 springs at the same time
026 16 875 13002-002 . SPRING Change all 32 springs at the same time
031 1 . SUN WHEEL Not sold as spare part.
041 1 875 13006-001 . PLUG, MAGNETIC M22
042 6 875 13006-002 . PLUG M22
043 8 875 13007-001 . SEALING
044 2 875 13005-001 . OIL SIGHT GLASS M22
047 2 875 13009-051 . PIPE

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

2005-01-12 9.2 625-4935.137 1 (2)
PUMP UNIT
2005-01-12 9.2 625-4935.137 2 (2)
PUMP UNIT
000 1 189 4212-801 PUMP UNIT
006 3 289 1833-801 . HYDRAULIC PUMP A4VG 125. SEE FIG. 625-4945.025
007 1 289 1834-801 . HYDRAULIC PUMP A4VG 125. SEE FIG. 625-4945.026
013 1 390 5128-801 . ELECTRIC MOTOR
014 1 388 3580-801 . FLUSH AND UNLOADING UNIT
015 1 390 3433-801 . GEAR BOX SEE FIG. 625-4940.024
017 1 388 5167-801 . TANDEM ASSEMBLY KIT
018 4 390 0757-801 . CONTAMINATION SWITCH
055 23 2121 2032-674 . SCREW M6S 20 x 50 -8.8 FZB; DIN 933
081 8 2151 2052-192 . WASHER TBRB 21 x 36 FZB
109 4 2197 2525-055 . RUBBER BUSHING

2005-01-05 9.2 625-4935.138 1 (2)
PUMP UNIT
2005-01-05 9.2 625-4935.138 2 (2)
PUMP UNIT
000 1 289 3458-801 PUMP UNIT
010 1 875 18001-004 . ELECTRIC MOTOR 1.5 kW
011 1 2166 1903-120 .. CABLE GLAND M20; Ø7-16 mm
020 1 875 18007-002 . SHAFT COUPLING
030 1 875 18007-001 . INTERMEDIATE FLANGE
050 1 390 6830-801 . PUMP
091 4 2121 2032-499 . SCREW M6S 10 x 40 -8.8 FZB; DIN 933
092 4 2121 2032-497 . SCREW M6S 10 x 35 -8.8 FZB; DIN 933
093 8 2151 2022-173 . WASHER BRB 10.5 x 22 FZB; DIN 125A

2005-01-27 9.2 625-4940.024B 1 (2)
GEAR BOX
2005-01-27 9.2 625-4940.024B 2 (2)
GEAR BOX
000 1 390 3433-801 GEAR BOX Ratio 0.692
020 3 875 21401-001 . GEAR WHEEL Z = 36
030 1 875 21401-002 . GEAR WHEEL Z = 52
040 3 875 21402-001 . HUB
050 1 875 21407-001 . SPACER
060 1 875 21406-001 . WASHER
070 6 875 21404-001 . BEARING
075 3 2152 2115-837 . O-RING 150.0 x 3.0 - NBR - 70 IRHD
080 3 875 21403-001 . CIRCLIP DIN 471
090 3 875 21403-002 . CIRCLIP DIN 471
100 3 875 21403-003 . CIRCLIP DIN 472
110 6 875 21406-002 . WASHER
120 3 875 21408-001 . KEY
130 1 2121 2032-674 . SCREW M6S 20 x 50 -8.8 FZB; DIN 933
140 1 875 21405-001 . PIN 6 x 30
150 2 875 21411-001 . PLUG M42
160 1 875 21409-001 . OIL SIGHT GLASS R 3/4
170 1 875 21410-001 . SEALING
180 2 875 21410-002 . SEALING

2001-04-18 9.2 625-4945.025 1 (2)
HYDRAULIC PUMP
2001-04-18 9.2 625-4945.025 2 (2)
HYDRAULIC PUMP
000 1 289 1833-801 HYDRAULIC PUMP A4VG 125
001 1 390 2841-801 . SERVO VALVE SEE FIG. 625-4948.002
002 1 875 19204-002 . SHAFT SEALING
003 2 875 19205-002 . RETAINING RING
011 1 875 19202-003 . PRESSURE RELIEF VALVE SEE NOTE IN ILLUSTRATION!
012 1 875 19209-006 .. GASKET SET, VALVE SEE NOTE IN ILLUSTRATION!
021 1 875 19202-004 . PRESSURE RELIEF VALVE
022 1 875 19209-004 .. GASKET SET, VALVE
031 1 875 19203-002 . PRESSURE CUT-OFF VALVE SEE NOTE IN ILLUSTRATION!

2004-06-02 9.2 625-4945.026A 1 (2)
HYDRAULIC PUMP
2004-06-02 9.2 625-4945.026A 2 (2)
HYDRAULIC PUMP
000 1 289 1834-801 HYDRAULIC PUMP A4VG 125
001 1 390 2841-801 . SERVO VALVE SEE FIG. 625-4948.002
002 1 875 19204-002 . SHAFT SEALING
003 2 875 19205-002 . RETAINING RING
021 2 875 19202-007 . PRESSURE RELIEF VALVE Fixed setting 370 bar.
022 2 875 19209-004 .. GASKET SET, VALVE
031 1 875 19203-002 . PRESSURE CUT-OFF VALVE SEE NOTE IN ILLUSTRATION!

1996-04-09 9.2 625-4963A 1 (2)
TANDEM ASSEMBLY KIT

1996-04-09 9.2 625-4963A 2 (2)
TANDEM ASSEMBLY KIT

000 1 388 5167-801 TANDEM ASSEMBLY KIT
001 1 388 5167-006 . LOCKING RING
002 1 388 5167-003 . SPLINES CAGE
003 2 388 5167-008 . O-RING
004 1 388 5167-004 . SEALING RING
005 1 388 5167-007 . O-RING
006 1 388 5167-001 . PUMP FLANGE
007 1 388 5167-009 . O-RING
008 4 388 5167-005 . SCREW MC6S 12 x 35 -10.9
009 1 388 5167-002 . PUMP RING
010 1 388 5167-010 . O-RING

2002-10-21 9.2 625-5176C 1 (2)
FEED PUMP UNIT

2002-10-21 9.2 625-5176C 2 (2)
FEED PUMP UNIT

000 1 388 0364-801 FEED PUMP UNIT
001 1 388 1669-801 . PUMP
002 1 388 0369-801 . ELECTRIC MOTOR
003 4 2151 2052-165 . WASHER TBRB 8.4 x 16 FZB
005 4 2126 2636-122 . NUT M6M 12 -8 FZB
006 4 2121 2032-538 . SCREW M6S 12 x 35 -8.8 FZB; DIN 933
007 4 2151 2058-179 . WASHER TBRSB 13.5 x 36 FZB

2004-01-13 9.2 625-5738G 1 (2)
OIL COOLER
2004-01-13 9.2 625-5738G 2 (2)
OIL COOLER
000 1 287 8763-801 OIL COOLER
001 1 287 8764-801 . COOLER ELEMENT
002 1 875 18002-001 . ELEMENT COVER
003 1 875 18004-001 . MOTOR COVER
004 1 875 18005-001 . FAN WHEEL
005 1 875 18003-001 . FAN WHEEL COVER
006 1 875 18001-001 . ELECTRIC MOTOR
007 1 489 3780-801 . MOUNTING SET Incl. screws, nuts and washers
2002-05-22 9.2 625-5740.002A 1 (2)
OIL COOLER ASSEMBLY

2002-05-22 9.2 625-5740.002A 2 (2)
OIL COOLER ASSEMBLY

000 1 389 2804-801 OIL COOLER ASSEMBLY
001 1 287 8763-801 . OIL COOLER
002 2 2528 2512-635 . COUPLING
010 1 2166 2051-821 . FITTING
011 1 2166 2051-822 . CABLE FITTING

2003-06-25 9.3 625-5865.014E 1 (2)
OIL TANK ASSEMBLY

2003-06-25 9.3 625-5865.014E 2 (2)
OIL TANK ASSEMBLY

000 1 188 1591-801 OIL TANK ASSEMBLY
001 1 . FILTER UNIT, OUTLET SEE COMP. LIST HYDR. CIRC. DIAGRAM
002 1 . FILTER UNIT, INLET SEE COMP. LIST HYDR. CIRC. DIAGRAM
005 1 . AIR FILTER WITH DIPSTICK SEE COMP. LIST HYDR. CIRC. DIAGRAM
006 1 5692 4700-803 . LEVEL AND TEMPERATURE GUARD
007 2 2152 2151-228 . SEAL RING
009 1 2515 6148-090 . HYDRAULIC HOSE
010 1 314 3672-801 . CONNECTION BOX
011 1 288 2553-801 . DIRECTION VALVE
012 1 388 0364-801 . FEED PUMP UNIT SEE FIG. 625-5176
013 1 2541 2506-117 . VEDGE VALVE 1 1/4"
014 1 2521 2310-220 . NIPPLE R 1 1/4" x 1"
015 1 5695 1000-063 . THERMOMETER

2005-01-04 9.3 625-6102.305 1 (2)
CRANE HOUSE ASSY.

2005-01-04 9.3 625-6102.305 2 (2)
CRANE HOUSE ASSY.

000 1 189 4232-801 CRANE HOUSE ASSY.
001 1 289 1347-801 . VENTILATION FAN, MOUNT
002 1 289 1348-801 .. VENTILATION FAN, ASSEMBLY SEE FIG. 625-6625.016
003 1 288 2710-801 . WINCH MOUNTING SET SEE FIG. 625-2250.001
004 1 189 4211-801 . HOISTING WINCH SEE FIG. 625-1440.070
005 1 189 2663-801 .. WINCH SEE FIG. 625-1450.052
006 1 189 3516-801 . LUFFING WINCH, C SEE FIG. 625-1440.064
007 1 189 2669-801 .. LUFFING WINCH SEE FIG. 625-1450.058
008 1 289 3490-801 . CRANE TOP MOUNTING SEE FIG. 625-6459.037
009 1 289 2249-801 . CAB MOUNTING SEE FIG. 625-6540.009
010 1 189 2357-801 .. CAB ASSEMBLY SEE FIG. 625-6545.048
011 1 289 2251-801 ... CAB CUPOLA ASSEMBLY SEE FIG. 625-6560.007
012 1 289 2377-801 . LIMIT SWITCHES BOX, LUFFING SEE FIG. 625-6245.223
013 1 289 2375-801 . LIMIT SWITCHES BOX, HOISTING SEE FIG. 625-6245.166
014 1 289 3393-801 . SLACK WIRE DEVICE, MOUNT.
015 1 289 3396-801 .. SLACK WIRE DEVICE SEE FIG. 625-6250.023
016 1 288 2016-801 . OIL COOLER MOUNTING
017 1 389 2804-801 .. OIL COOLER ASSEMBLY SEE FIG. 625-5740.002
018 1 287 8763-801 ... OIL COOLER SEE FIG. 625-5738
019 1 189 4212-801 . PUMP UNIT SEE FIG. 625-4935.137
020 2 389 1452-801 . JIB BEARING MOUNTING SEE FIG. 625-6170.020
021 3 390 2587-801 . SLEWING GEAR MOUNTING SEE FIG. 625-3254.011
022 1 289 1546-801 .. SLEWING GEAR MODULE 16. SEE FIG. 625-3255.013
023 1 188 1591-801 . OIL TANK ASSEMBLY SEE FIG. 625-5865.014
024 1 390 0191-801 . COVER MOUNTING SEE FIG. 625-6169.003
025 1 390 6900-801 . SLEWING BEARING MOUNTING
026 1 289 3491-801 .. SLEWING BEARING

2001-12-13 9.3 625-6169.003A 1 (2)
COVER MOUNTING
2001-12-13 9.3 625-6169.003A 2 (2)
COVER MOUNTING
000 1 390 0191-801 COVER MOUNTING
001 1 390 0192-801 . COVER ASSEMBLY
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 . NUT M6M 8 -A4-80
005 x 390 0198-801 . GAS SPRING ASSEMBLY
008 4 2151 2054-165 . WASHER TBRSUB 8.4 x 26 - FZV
009 x 1236 2825-001 . SEALING COMPOUND

2004-04-19 9.3 625-6170.020A 1 (2)
JIB BEARING MOUNTING

2004-04-19 9.3 625-6170.020A 2 (2)
JIB BEARING MOUNTING

000 1 389 1452-801 JIB BEARING MOUNTING
001 1 389 1453-801 . JIB BEARING HOUSING
002 1 389 1487-001 . SHAFT
003 12 487 2826-002 . WASHER
004 1 489 3644-001 . COVER
005 1 489 4247-001 . SPACER RING
006 2 2152 2115-537 . O-RING
007 12 2121 2030-630 . SCREW M6S 16 x 50 -10.9
008 1 2545 2110-003 . GREASE NIPPLE A-M 10 x 1 -A2-50

1997-10-07 9.3 625-6170.021 1 (2)
JIB BEARING HOUSING

1997-10-07 9.3 625-6170.021 2 (2)
JIB BEARING HOUSING

000 1 389 1453-801 JIB BEARING HOUSING
001 1 287 9856-001 . BEARING HOUSE
002 2 388 5790-001 . RING
003 2 388 5791-001 . WASHER
004 30 487 2826-002 . WASHER
005 6 489 3362-001 . CLIP
006 1 489 3646-801 . BEARING
007 2 2152 2115-549 . O-RING
008 2 2186 2187-220 . SEAL RING
009 15 2121 2037-651 . SCREW M6S 16 x 180 -10.9
010 15 2126 2038-124 . NUT M6M 16 -10

2005-01-11 9.3 625-6244.044 1 (2)
JIB TOP MOUNTING

2005-01-11 9.3 625-6244.044 2 (2)
JIB TOP MOUNTING

000 1 289 3495-801 JIB TOP MOUNTING
001 2 389 4520-001 . WASHER 10.5 BR = RF
004 2 490 3906-801 . WIRE SHEAVE
006 2 389 1557-001 . SHAFT
010 8 489 5334-002 . LOCK WASHER 17 SSt
011 4 489 5666-001 . SPACER
016 8 2121 2034-628 . SCREW M6S 16 x 40 -A4-80
020 6 2545 2110-003 . GREASE NIPPLE A-M 10 x 1 -A2-50; DIN 71412
022 4 490 4300-801 . WIRE SHEAVE

2004-12-20 9.3 625-6245.166 1 (2)
LIMIT SWITCHES BOX, HOISTING

2004-12-20 9.3 625-6245.166 2 (2)
LIMIT SWITCHES BOX, HOISTING

000 1 289 2375-801 LIMIT SWITCHES BOX, HOISTING
003 1 875 15006-008 . SHAFT COUPLING, COMPLETE
010 1 875 15012-005 . WORM GEAR, COMPLETE Incl. screws. Ratio 50:1.
019 1 875 15008-002 . KEY 4 x 4 x 20
020 2 875 15002-002 . CABLE GLAND WITH NUT
051 6 875 15001-001 . MICRO SWITCH 1A
052 2 875 15001-002 . THREADED STUD WITH NUTS M3. Cut to right length.
061 1 875 15017-008 . CAM DISC WITH ARM, COMPLETE 30° - 55°
110 1 875 15003-019 . COVER, COMPLETE Incl. screws and sealing.
111 1 875 15003-002 .. SEALING L = 1500 mm
112 4 2121 2034-457 .. SCREW M6S 8 x 35 -A4-80
113 4 2126 2034-118 .. NUT M6M 8 -A4 -80
114 4 2151 2027-164 .. WASHER BRB 8.4 x 16 -A4
115 4 2126 2432-118 .. CAP NUT MHM 8 -6 FZB
901 ANGLE INDICATOR Ordered separately.

2004-12-20 9.3 625-6245.223 1 (2)
LIMIT SWITCHES BOX, LUFFING

2004-12-20 9.3 625-6245.223 2 (2)
LIMIT SWITCHES BOX, LUFFING

000 1 289 2377-801 LIMIT SWITCHES BOX, LUFFING
003 1 875 15006-008 . SHAFT COUPLING, COMPLETE
010 1 875 15012-005 . WORM GEAR, COMPLETE Incl. screws. Ratio 50:1.
019 1 875 15008-002 . KEY 4 x 4 x 20
026 2 875 15002-002 . CABLE GLAND WITH NUT
051 10 875 15001-001 . MICRO SWITCH 1A
052 4 875 15001-002 . THREADED STUD WITH NUTS M3. Cut to right length.
210 1 875 15003-017 . COVER, COMPLETE Incl. screws and sealing.
211 1 875 15003-002 .. SEALING L = 1500 mm
212 4 2121 2034-457 .. SCREW M6S 8 x 35 -A4-80
213 4 2126 2034-118 .. NUT M6M 8 -A4 -80
214 4 2151 2027-164 .. WASHER BRB 8.4 x 16 -A4
215 4 2126 2432-118 .. CAP NUT MHM 8 -6 FZB

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

2001-11-20 9.3 625-6275.004B 1 (2)
CRANE JIB, YARD MOUNTING

2001-11-20 9.3 625-6275.004B 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 8 488 8518-006 . WASHER

2005-01-10 9.3 625-6408.085 1 (2)
CRANE JIB MOUNTING

2005-01-10 9.3 625-6408.085 2 (2)
CRANE JIB MOUNTING

000 1 289 3494-801 CRANE JIB MOUNTING
002 1 289 3495-801 . JIB TOP MOUNTING SEE FIG. 625-6244.044
003 1 289 2906-801 . JIB STAY MOUNTING SEE FIG. 625-6409.001

2005-01-13 9.3 625-6459.037 1 (2)
CRANE TOP MOUNTING

2005-01-13 9.3 625-6459.037 2 (2)
CRANE TOP MOUNTING

000 1 289 3490-801 CRANE TOP MOUNTING
001 3 490 3906-801 . WIRE SHEAVE
002 3 490 4300-801 . WIRE SHEAVE
003 1 288 1644-801 . SHAFT
004 2 389 1575-001 . SHAFT
005 1 389 1913-001 . SPACER
006 1 389 1913-003 . SPACER
007 2 389 1914-001 . SPACER
008 2 389 1914-002 . SPACER
009 1 489 5336-001 . COVER
010 3 489 5691-001 . COVER
011 12 489 5334-001 . LOCK WASHER
012 8 489 5334-002 . LOCK WASHER
013 20 2121 2034-495 . SCREW M6S 10 x 30 -A4-80
014 8 2121 2034-628 . SCREW M6S 16 x 40 -A4-80

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

2002-08-09 9.3 625-6540.009 1 (2)
CAB MOUNTING
2002-08-09 9.3 625-6540.009 2 (2)
CAB MOUNTING
000 1 289 2249-801 CAB MOUNTING
001 1 189 2357-801 . CAB ASSEMBLY SEE FIG. 625-6545.048
002 3 489 5395-801 . BRACKET
003 3 489 5154-003 . SHAFT
004 1 488 9225-001 . WASHER
005 1 489 2045-001 . RUBBER MOULDING L = 8.35 m
007 3 2151 2027-192 . WASHER RB 21 x 37 -A4
008 6 2114 2014-201 . SPLIT PIN SP 4 x 40 A4
010 x 1234 2413-050 . LOCKING FLUID 243

2002-08-20 9.3 625-6545.048 1 (2)
CAB ASSEMBLY
2002-08-20 9.3 625-6545.048 2 (2)
CAB ASSEMBLY
000 1 189 2357-801 CAB ASSEMBLY
004 1 289 2251-801 . CAB CUPOLA ASSEMBLY SEE FIG. 625-6560.007
005 1 390 2914-801 . CAB DOOR ASSEMBLY SEE FIG. 625-6546.002
013 1 390 4053-801 . EMERGENCY DOOR ASSY SEE FIG. 625-6546.001
016 2 488 3152-801 . VENTILATOR, C
020 2 490 3825-001 . PLATE
021 12 489 3492-001 . SHIM
024 1 1856 2141-006 . RUBBER MOULDING L=3020 mm
035 39 2121 2034-495 . SCREW M6S 10 x 30 -A4-80
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 . NUT M6M 5 -A4 -80
048 17 2126 2634-116 . NUT M6M 6 -A4 -80
050 39 2126 2634-120 . NUT NYLOC-M6M 10-A4-80
056 18 2151 2027-146 . WASHER BRB 5.3 x 10 -A4
057 8 2151 2027-156 . WASHER RB 6.7 x 14 -A4
059 39 2151 2027-173 . SPRING WASHER RB 10.5 x 20 -A4

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

2002-08-09 9.3 625-6560.007 1 (2)
CAB CUPOLA ASSEMBLY

2002-08-09 9.3 625-6560.007 2 (2)
CAB CUPOLA ASSEMBLY

000 1 289 2251-801 . CAB CUPOLA ASSEMBLY
001 1 189 2327-001 . CAB CUPOLA
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 1 487 2152-001 . RUBBER MOULDING
008 1 487 2153-001 . LOCKING LIST
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

2004-06-30 9.3 625-6561.001B 1 (2)
WINDSCREEN CLEANER
2004-06-30 9.3 625-6561.001B 2 (2)
WINDSCREEN CLEANER
000 1 387 6227-802 WINDSCREEN CLEANER
001 1 6179 2151-280 . WIPER MOTOR
003 1 6179 2153-700 . WIPER BLADE L = 700 mm
009 1 6179 2152-600 . ARM L = 600 mm

2000-12-13 9.3 625-6625.014 1 (2)
VENTILATION FAN
2000-12-13 9.3 625-6625.014 2 (2)
VENTILATION FAN
000 1 390 2115-801 VENTILATION FAN
001 1 . FAN
002 1 . MOTOR
2000-12-14 9.3 625-6625.016 1 (2)
VENTILATION FAN, ASSEMBLY

2000-12-14 9.3 625-6625.016 2 (2)
VENTILATION FAN, ASSEMBLY

000 1 289 1348-801 VENTILATION FAN, ASSEMBLY
001 1 288 0945-801 . TUB FOR FAN
002 1 390 2115-801 . VENTILATION FAN
003 x 1236 2296-020 . SEALING COMPOUND
004 8 2121 2032-459 . SCREW M6S 8 x 40 -8.8 FZB
005 8 2126 2636-118 . NUT NYLOC -M6M 8 -8 FZB
006 8 2151 2058-165 . WASHER TBRSB 8.4 x 26 FZB
007 x 1684 2136-124 . CABLE RU 4 x 1.5
008 4 2166 4127-114 . TUBE CLIP D = 11 (RSGU 1100 11/20)

2004-12-22 9.3 625-7013.080 1 (2)
LIFTING BLOCK
2004-12-22 9.3 625-7013.080 2 (2)
LIFTING BLOCK
000 1 288 1423-803 LIFTING BLOCK SWL 60 tonnes
001 1 875 12411-004 . SWIVEL WITH HOOK, COMPLETE Incl. safety latch kit.
002 1 875 12064-002 .. SAFETY LATCH KIT Incl. spring, screw, nut.
004 2 875 12401-003 . SHEAVE, COMPLETE Incl. bearing and lock rings.
005 2 875 12054-004 .. BEARING
006 4 875 12062-003 .. LOCK RING
007 2 875 12402-003 . SHAFT, COMPLETE Incl. nut, split pin, nipple.
008 2 2114 2014-258 .. SPLIT PIN 8 x 120; DIN 94
010 1 875 12403-003 . BOLT, COMPLETE Incl. nut, split pin.
011 1 2114 2014-258 .. SPLIT PIN 8 x 120; DIN 94
012 4 875 12406-002 . SPACER, COMPLETE Incl. spacer tube, screw, nut.
013 3 2183 2022-126 . EYE BOLT M20; DIN 580

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

2004-11-24 9.4 625-7207.009 1 (2)
VALVE UNIT
2004-11-24 9.4 625-7207.009 2 (2)
VALVE UNIT
000 1 289 3269-801 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 2612-615 . 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
023 1 2528 3634-210 . COUPLING
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

2002-05-08 9.4 625-7314.001A 1 (2)
FILTER UNIT, INLET

2002-05-08 9.4 625-7314.001A 2 (2)
FILTER UNIT, INLET

000 1 188 0117-801 FILTER UNIT, INLET
001 1 489 3731-801 . VALVE UNIT
002 1 .. O-RING INCLUDED IN GASKET SET
003 8 .. SCREW UC6S 1/2 x 114
004 1 489 3732-801 . FILTER UNIT
005 1 .. FILTER HEAD
006 1 .. EL. INDICATOR
008 1 .. SEALING INCLUDED IN GASKET SET
009 1 489 3104-001 .. FILTER ELEMENT
010 1 .. FILTER CAP
012 1 .. DRAIN PLUG INCLUDED IN GASKET SET
013 1 389 1479-801 . BLOCK
015 4 .. SCREW UC6S 1/2 x 89
016 1 489 5647-801 . GASKET SET
017 1 489 5647-802 . GASKET SET

2002-05-08 9.4 625-7314.002A 1 (2)
FILTER UNIT, OUTLET

2002-05-08 9.4 625-7314.002A 2 (2)
FILTER UNIT, OUTLET

000 1 188 0118-801 FILTER UNIT, OUTLET
001 1 489 3734-801 . VALVE UNIT
003 8 .. SCREW UC6S 1/2 x 114
004 1 489 3735-801 . FILTER UNIT
005 1 .. FILTER HEAD
006 1 .. SEALING INCLUDED IN GASKET SET
007 1 489 3104-001 .. FILTER ELEMENT
008 1 .. FILTER CAP
010 1 .. DRAIN PLUG INCLUDED IN GASKET SET
011 1 389 1479-801 . BLOCK
013 4 .. SCREW UC6S 1/2 x 89
014 1 489 5647-801 . GASKET SET
015 1 489 5647-802 . GASKET SET

2005-01-10 9.4 625-7314.010 1 (2)
FILTER UNIT
2005-01-10 9.4 625-7314.010 2 (2)
FILTER UNIT
000 1 289 3459-801 FILTER UNIT
002 1 289 3459-002 . INDICATOR Visual & Electric; 2.5 bar
003 1 490 4632-801 . FILTER CARTRIDGE
004 2 2152 2115-980 .. O-RING 91.67 x 3.53
005 1 875 22002-001 . SEAL KIT

1999-03-23 9.4 625-7322.014 1 (2)
DIRECTION VALVE
1999-03-23 9.4 625-7322.014 2 (2)
DIRECTION VALVE
000 1 288 2553-801 DIRECTION VALVE
001 1 489 6335-801 . COIL
002 1 489 6334-801 . GASKET SET

2003-02-11 9.4 625-7322.047 1 (2)
DIRECTION VALVE
2003-02-11 9.4 625-7322.047 2 (2)
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
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

2005-03-08 9.4 625-7454E 1 (2)
HAND PUMP
2005-03-08 9.4 625-7454E 2 (2)
HAND PUMP
000 1 188 0366-801 HAND PUMP
001 1 5693 4121-060 . MANOMETER
002 1 389 3862-801 . RELIEF VALVE
003 1 389 3864-801 . NEEDLE VALVE
004 1 489 3126-801 . FLOW CONTROL VALVE
005 1 2515 6244-050 . HYDRAULIC HOSE L = 3000 mm
007 1 2522 4560-165 . PROTECTING COVER
008 1 2529 2458-111 . QUICK COUPLING G 3/8"
009 1 2529 2458-116 . QUICK COUPLING G 1"
010 1 489 5663-001 . BUSHING
011 1 389 1507-801 . SINGLE ACTING PUMP
013 1 489 5901-801 . COUPLING
015 1 2528 2773-100 . NUT
016 1 2528 2763-100 . PLUG
017 1 2121 2033-463 . SCREW M6S 8 x 60 H -8.8 FZB

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

2002-10-24 9.4 625-7951E 1 (2)
ACCUMULATOR
2002-10-24 9.4 625-7951E 2 (2)
ACCUMULATOR
001 1 388 0362-801 ACCUMULATOR Feed press. circ; Charg. press. 1.5 MPa
004 X 488 7888 GASKET SET Valid for item 1-3.
008 X 490 3956 GASKET SET Valid for item 5-7.
009 1 488 4033-801 ACCUMULATOR Stab. circuit; Charg. press. 5.0 MPa
010 1 489 2520-801 ACCUMULATOR Stab. circuit; Charg. press. 5.0 MPa
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.

2001-12-19 9.5 625-8562.008 1 (2)
POWER SUPPLY
2001-12-19 9.5 625-8562.008 2 (2)
POWER SUPPLY
000 1 324 0440-801 POWER SUPPLY
002 1 324 0500-801 . PLINTH
003 3 5672 4257-015 .. FUSE 15 A
004 3 5672 4214-120 .. FUSE 2A
005 1 324 0499-801 . TRANSFORMER
006 1 314 3440-801 . RECTIFIER PLATE
007 3 414 5842-001 . CONDENSATOR
008 1 414 5468-020 . CONDENSATOR
009 2 2121 2550-368 . SCREW MC6S 6 x 16 -A4 -80
010 2 2126 2634-116 . NUT M6M 6 -A4 -80

2001-07-05 9.5 625-8563.009 1 (2)
DRIVER’S DESK
2001-07-05 9.5 625-8563.009 2 (2)
DRIVER’S DESK
000 1 124 0239-801 DRIVER’S DESK
002 1 488 6922-001 . DRIVER’S SEAT
003 1 224 0117-801 . CONTROL PANEL SEE FIG. 625-8597.008
004 1 414 6792-801 . CONTROLLER PANEL
006 1 314 3980-801 . SIREN
007 1 5915 4262-002 . ARMATURE
008 1 5911 4145-060 . LAMP BULB
009 1 387 6227-802 . WINDSCREEN CLEANER
010 3 5217 4837-240 . SCREW CONNECTION
011 3 5217 4838-240 . BULKHEAD HOUSING
013 1 314 4244-801 . CABIN HEATER

2002-08-12 9.5 625-8567.017A 1 (2)
EL. INST. CRANE JIB LIGHT

2002-08-12 9.5 625-8567.017A 2 (2)
EL. INST. CRANE JIB LIGHT

000 1 124 0231-801 EL. INST. CRANE JIB LIGHT
005 1 5388 4121-002 . CONNECTION BOX
006 1 1684 2146-301 . CABLE Ru 3 x 1,5 L=4m
007 2 2121 2550-370 . SCREW MC6S 6 x 20 -A4 -80
008 2 2151 2027-156 . WASHER RB 6.7 x 14 -A4
009 2 2126 2634-116 . NUT M6M 6 -A4 -80
011 1 2166 2051-823 . CABLE FITTING PR 22,5

2004-03-03 9.5 625-8567.019B 1 (2)
EL. INST. JIB LIGHT

2004-03-03 9.5 625-8567.019B 2 (2)
EL. INST. JIB LIGHT

000 1 124 0255-801 EL. INST. JIB LIGHT
003 1 5921 2141-101 . HEAD LIGHT
004 1 5911 4529-410 . HALOGEN LAMP 12013R 1000 R7s-15
005 1 388 3252-801 . BRACKET
006 2 490 3843-001 . SCREW
007 2 2151 2027-185 . WASHER BRB 17 x 30 -A4
008 2 2126 2034-122 . NUT M6M 12 -A4 -80
009 1 1686 2136-134 . CABLE L = 40 m
010 1 2686 4426-204 . NIPPLE
011 2 2166 2051-823 . CABLE GLAND PR 22,5
018 12 2166 4127-154 . CLAMP
019 12 2126 2034-118 . NUT M6M 8 -A4 -80
020 12 2151 2027-164 . WASHER BRB 8.4 x 16 -A4

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

2001-08-22 9.5 625-8597.008 1 (4)
CONTROL PANEL
2001-08-22 9.5 625-8597.008 2 (4)
CONTROL PANEL
000 1 224 0117-801 CONTROL PANEL
001 1 314 3624-001 . COVER
002 1 5372 2038-003 . PUSH BUTTON
003 1 414 4621-801 . SWITCH
004 1 414 4622-801 . SWITCH
005 1 414 4625-801 . SWITCH
006 1 414 4626-801 . SWITCH
007 1 414 4628-801 . SWITCH
008 1 414 6954-057 . SIGN WITH FRAME
009 1 414 6954-002 . SIGN WITH FRAME
010 1 414 6954-007 . SIGN WITH FRAME
011 1 414 6954-013 . SIGN WITH FRAME
012 1 414 6954-063 . SIGN WITH FRAME
013 1 414 1500-051 . SIGN
014 4 5298 2057-001 . INDICATOR HEAD
015 4 5372 2017-001 . LAMP HOLDER
016 1 5372 2040-001 . PUSH BUTTON
017 1 5372 2039-003 . PUSH BUTTON
018 2 5372 2016-005 . CONTACT BLOCK
019 1 5372 2016-006 . CONTACT BLOCK
020 10 2152 2069-225 . COVER PLATE
021 1 2152 2067-018 . COVER PLATE
022 1 5372 1960-101 . EMERGENCY STOP
023 4 5911 4509-002 . BULB

2001-08-22 9.5 625-8597.008 3 (4)
CONTROL PANEL
2001-08-22 9.5 625-8597.008 4 (4)
CONTROL PANEL
024 1 5672 4245-002 . CIRCUIT BREAKER
025 1 314 2005-802 . CONTROLLER SEE FIG. 625-8591
026 1 2121 2550-331 . SCREW MC6S 5 x 20 A4-80
027 2 2126 2634-114 . NUT M6M 5 -A4 -80
028 1 2151 2027-146 . WASHER RB 5.3 x 10 -A4
030 1 414 6924-053 . SIGN WITH FRAME

2005-01-18 9.5 625-8598.038 1 (4)
CABINET
2005-01-18 9.5 625-8598.038 2 (4)
CABINET
000 1 224 0166-801 CABINET
001 1 224 0104-801 . CABINET BASIC
004 1 324 0439-801 . TRANSFORMER 1-PHASE
006 1 324 0212-801 . ASSY PLATE, CABINET CT2 (MB)
010 1 414 1941-801 . THERMISTOR
011 1 414 4627-801 . SWITCH
012 1 5639 4161-402 . IMPULSE RELAY
013 2 2638 3100-160 . COPPER BAR
014 2 2638 3100-224 . COPPER BAR
015 2 2638 3100-288 . COPPER BAR
019 8 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 6 2151 2027-146 . WASHER RB 5.3 x 10 -A4
036 1 2663 4660-003 . CONNECTION PLINTH
040 2 2669 4160-015 . END HOLDER
046 2 5354 4130-220 . CONTACTOR RELAY
050 1 5237 4190-035 . FLANGE
054 1 5340 2010-102 . CIRCUIT BREAKER
058 3 5349 2001-105 . CONNECTOR
062 1 5349 2010-105 . COVER
066 2 5354 4130-400 . CONTACTOR RELAY
070 9 5354 4137-501 . AUXILIARY CONTACT BLOCK

2005-01-18 9.5 625-8598.038 3 (4)
CABINET
2005-01-18 9.5 625-8598.038 4 (4)
CABINET
071 5 5354 4137-510 . AUXILIARY CONTACT BLOCK
074 1 5354 4273-009 . CONTACTOR
075 3 5354 4273-052 . CONTACTOR
080 1 5372 1960-101 . EMERGENCY STOP
082 1 5381 4280-001 . ELECTRICAL SOCKET
083 1 5572 4105-250 . MOTOR SWITCH
085 1 5572 4100-400 . MOTOR SWITCH 2.5 - 4.0 A
086 2 5218 3109-230 . REMOTE UNIT
087 1 5572 4103-140 . MOTOR SWITCH
090 1 5591 2153-200 . STAR DELTA START
092 2 5632 4209-002 . TIME RELAY
093 1 5632 4209-004 . TIME RELAY
095 1 5672 4248-006 . CIRCUIT BREAKER
099 1 7635 4113-200 . THERMOSTAT
101 1 5349 2020-101 . KNOB
103 1 5692 4740-024 . HOUR METER
105 3 2689 4121-009 . SLEEVE
106 1 424 0523-001 . STEERING
107 4 2124 2126-287 . SCREW RXS 3.5 x 25 FZB
110 1 6480 2160-101 . FAN
111 2 2641 4227-001 . RECEPTACLE

2005-02-14 9.5 625-8600.002B 1 (2)
ASSY PLATE, CABINET CT2 (MB)

2005-02-14 9.5 625-8600.002B 2 (2)
ASSY PLATE, CABINET CT2 (MB)

000 1 324 0212-801 ASSY PLATE, CABINET CT2 (MB)
005 4 . MPC-CARD SEE TABLE OF CONTENTS SECTION 9.5
006 1 314 3605-X . MEMORY CARD X = CRANE MFG NO

2000-02-23 9.5 625-8750.005B 1 (2)
SLIPRING UNIT
2000-02-23 9.5 625-8750.005B 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

2003-03-12 9.7 624-2195.002 1 (2)
EL INST ANGLE ENCODER (HOISTING WINCH)

2003-03-12 9.7 624-2195.002 2 (2)
EL INST ANGLE ENCODER (HOISTING WINCH)

000 1 124 0375-801 EL INST ANGLE ENCODER (HOISTING WINCH)
001 1 414 7320-801 . ABSOLUTE ENCODER
002 1 414 7325-801 . SHAFT COUPLING
003 3 414 4809-001 . MOUNTING CLAMPS
004 3 2121 2550-226 . ALLEN SCREW MC6S 3 x 12 A4-80
005 18 2166 4127-084 . CLIP RSGU 8/22
006 36 2126 2032-118 . NUT M6M 8.8 -FZB

2005-01-17 9.7 624-2195.003 1 (2)
EL INST ANGLE ENCODER (LUFFI.)

2005-01-17 9.7 624-2195.003 2 (2)
EL INST ANGLE ENCODER (LUFFI.)

000 1 124 0460-801 EL INST ANGLE ENCODER (LUFFI.)
001 1 414 7320-801 . ABSOLUTE ENCODER
002 1 414 7325-801 . SHAFT COUPLING
003 3 414 4809-001 . MOUNTING CLAMPS
005 15 2166 4127-084 . CLIP RSGU 8/22
006 30 2126 2032-118 . NUT M6M 8 -8 FZB

2005-01-19 9.7 624-2195.004 1 (2)
EL. INST. AUTO-PLUSSING CRANE

2005-01-19 9.7 624-2195.004 2 (2)
EL. INST. AUTO-PLUSSING CRANE

000 1 124 0291-801 EL. INST. AUTO-PLUSSING CRANE
001 1 414 7283-801 . INCREMENTAL ENCODER ATD
002 1 414 7325-801 . SHAFT COUPLING
003 3 414 4809-001 . MOUNTING CLAMPS
005 18 2166 4127-084 . CLIP RSGU 8/22
006 36 2126 2032-118 . NUT M6M 8 -8 FZB

2005-01-25 9.7 624-2484.001 1 (2)
LUBRICATION SYSTEM
2005-01-25 9.7 624-2484.001 2 (2)
LUBRICATION SYSTEM
000 1 189 4356-801 LUBRICATION SYSTEM
001 1 289 3592-801 . GREASE PUMP SEE FIG. 624-2484.002
002 2 390 7096-801 . DIVIDER VALVE
006 20 189 4356-006 . PIPE COUPLING

2005-01-26 9.7 624-2484.002 1 (2)
GREASE PUMP
2005-01-26 9.7 624-2484.002 2 (2)
GREASE PUMP
000 1 289 3592-801 GREASE PUMP
010 2 875 29021-001 . PRESSURE RELIEF VALVE 350 bar
020 1 875 29021-002 . ELECTRIC MOTOR 230VAC 50Hz; 0.18 kW
021 4 2121 2032-329 . SCREW M6S 5 x 16 - 8.8 fzb; DIN 933
030 2 875 29021-003 . PUMP ELEMENT WITH PISTON
040 1 875 29021-004 . LEVEL SENSOR, ULTRA-SONIC 24VDC
090 1 875 29021-005 . SEAL KIT Includes item 91-95.
091 1 .. SHAFT SEALING Not sold separately. See item 90.
092 4 .. SEALING RING Not sold separately. See item 90.
093 1 .. SEALING Not sold separately. See item 90.
094 1 .. O-RING Not sold separately. See item 90.
095 1 .. SEALING Not sold separately. See item 90.

1 (2)
2005-01-25 9.7 624-2484.003
GREASE REFILLING PUMP

2005-01-25 9.7 624-2484.003 2 (2)
GREASE REFILLING PUMP

000 1 390 7036-801 GREASE REFILLING PUMP
001 1 . LID WITH HOSE HOLDER Not sold separately.
002 1 . FOLLOWER PLATE WITH SEAL Not sold separately.
003 1 . PUMP Not sold separately.
004 2 . QUICK COUPLING Not sold separately.
005 1 . HYDRAULIC HOSE L = 2000 mm. Not sold separately.

2003-02-04 9.7 624-2524 1 (2)
FIRE EXTINGUISHER, MOUNT

2003-02-04 9.7 624-2524 2 (2)
FIRE EXTINGUISHER, MOUNT

000 1 490 4074-801 FIRE EXTINGUISHER, MOUNT
001 1 6956 2020-061 . HOLDER
002 2 2121 2034-447 . SCREW MC6S 8 x 12 - A4-80
003 1 6956 2020-060 . FIRE EXTINGUISHER POWDER

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INSTRUCTION MANUAL Date Project No.

GENERAL 1 1.000.2 E b SAFETY INSTRUCTIONS

TECHN. DESCRIP. 2 LO04062 TECHNICAL DATA

FUNCTION 3 3.110.102 E - HYDRAULIC FUNCTION

OPERATION 4 PM40 1857-E00 - CREW CHECKLIST

MAINTENANCE 5 5.005.58 E - MAINTENANCE CHART

The Original Manufacturer of HÄGGLUNDS Cranes

MAINTENANCE 5 5.150.1 E b LUBRICATING AND MAINTENANCE

6.0 6.000 E b HOW TO ORDER SPARE PARTS

6.2 6.214 E h TIGHTENING TORQUES, STUDS/SCREWS AND BOLTS

6.3 6.300.1 E - EMERGENCY OPERATION CARD CC2000

The Original Manufacturer of HÄGGLUNDS Cranes

SPARE PARTS 9 SEE SEPARATE TABLE OF CONTENTS

The Original Manufacturer of HÄGGLUNDS Cranes

9.0 HOW TO ORDER SPARE PARTS b 6.000 E

9.1 HOISTING WINCH, C 189 4211-801 -/ 625-1440.070

9.2 PUMP UNIT 189 4212-801 C/C 625-4935.137

9.3 OIL TANK ASSEMBLY 188 1591-801 G/G 625-5865.014E

The Original Manufacturer of HÄGGLUNDS Cranes

9.3 SLEWING BEARING YARD MOUNT. 390 0405-801 A/ 390 0405

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

9.5 POWER SUPPLY 324 0440-801 B/B 625-8562.008

9.7 LIFE LINE 388 0962-801 -/ -

The Original Manufacturer of HÄGGLUNDS Cranes

9.7 FIRE EXTINGUISHER, MOUNT 490 4074-801 A/ 624-2524

The Original Manufacturer of HÄGGLUNDS Cranes

Supervision, Instructions, Signs and Warnings

Preparation for Use and Operation According to Improper Use

MacGREGOR are available for full service of this

The Original Manufacturer of HÄGGLUNDS Cranes 1 (16)

Functions, Installations and Equipment Safety Functions and Equipment

Specific safety equipment is installed and delivered

2 (16) The Original Manufacturer of HÄGGLUNDS Cranes

The Original Manufacturer of HÄGGLUNDS Cranes 3 (16)

b. Covers and houses: c. Firefighting equipment:

4 (16) The Original Manufacturer of HÄGGLUNDS Cranes

Danger, Warning, Caution and Notice

Principles of Risk Classification

Safety installations, covers or houses prevent ex-

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

The Original Manufacturer of HÄGGLUNDS Cranes 5 (16)

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

6 (16) The Original Manufacturer of HÄGGLUNDS Cranes

Attached at brake cylinders, narrow spaces near them, at work platforms

Attached at brake cylinders.

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

The Original Manufacturer of HÄGGLUNDS Cranes 7 (16)

PM40 7114-E00DANGEROUS OIL PRESSURE - BE CAREFUL!

Attached to surfaces close to pipes inside the cranehouse.

This sign is attached generally to the walls of work platforms.

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