MacGREGOR INSTRUCTION MANUAL te Page Dept. 250 2005-06-30 LO05001-1 1 (5) TABLE OF CONTENTS Manual No. Ses, CD-ROM (1 pc} Certificate for crane issued by Gt Certificate for foundation issued by: GL IMO No. 19300154 Name of ship Newbuilding No. Y2J 2003-663C Shipyard Yangzijiang Owners B. Rickmers Project No. L.005001-1 Mig. No. 62506560 - Crane 1 Type of crane GL 4526/4029-2 Collecting list Crane specification Order specification 490 4919-801 /A , El. Spec. 490 4949-801/B SAFETY DOCUMENTS Document names written with bold letters are documents with safety aspects. INSTRUCTIONNO. REV _ NAME OF INSTRUCTION GENERAL 1 1.00026 b SAFETY INSTRUCTIONS 4.005 € © PREFACE 1.908 € 2 GENERALINSTRUCTIONS, CLEANLINESS IN HYDRAULIC SYSTEMS 1102 © CONVERSION FACTORS 131830 2 HYDRAULIC AND ELECTRIC SYMBOLS TECHN.DESORIP, 2 LO95001-1 TECHNICAL DATA 2,007.61 E © TECHNICAL DESCAIPTION FUNCTION 2 ant0.70e b HYDRAULIC FUNCTION A9112E 2 STARTING AND STOPPING, ELECTRIC SAFETY FUNCTIONS, SINGLE CRANES 9142.22 ‘2 CRANE CONTROL SYSTEM GC2000 SINGLE CRANES WITH I/ORE THAN ONE 31553 E + THERMOSTATIC CONTROLLED VENTILATION FAN OPERATION 4 PMO 1945-€00 «CREW CHECKLIST, BEFORE TAKING CRANE INTO OPERATION M40 5500-£00 OPERATING INSTRUCTION Pao 6063-600 © ¢ +~—_OPERATING INSTRUCTION Pulao 6351-600 = ~—_CONTROLS AND INDICATORS Mai 0012-600. ~—=-EMERGENCY ESCAPE INSTRUCTIONS. 4520.1 E PARKING THE CRANE, SEA STOWING, GENERAL INSTRUCTION PMd6 2510-600 © @ PARKING OF CRANEIN WIRES 4690 € + HANDLING HATCHES BY DECK CRANE MAINTENANCE 58,005.50 © MAINTENANCE CHART 5018 b__ INSPECTION OF STRESSED COMPONENTS AND STRUCTURES MSI 1701-E00 ft -—_LUBRIGATING CHART. CRANE 5.1501 LUBRICATING AND MAINTENANCE 5301.8 FILTERS ‘The Original Manufacturer of HAGGLUNDS Cranes,MacGREGOR INSTRUCTION MANUAL Date Project No. Page Dept. 230 2005-06-30 LO05001-1 2(5) TABLE OF CONTENTS INSTRUGCTIONNO. REV _NAME OF INSTRUCTION MAINTENANCE 5 «5.302. 16E HYDRAULIC OL TANK 5315 ‘SAMPLING OF OIL. 70 VERIFY THE CLEANLINESS IN HYDRAULIC SYSTEM 5421.40 LUBRICANTS FOR DECK MACHINERY SERVICE 6 60 S000E HOW TO ORDER SPARE PARTS. 6,000.1 € STATEMENT REGARDING DELIVERY OF SPARE PARTS TO SWIVELS, LIFTING { 6.0002 RETURN FORM 6.9003. E 1 GLoBaL SERVICE 6.0041 € aV MacGREGOR GLOBAL SERVICES 6.0055 = INTRODUCTION 61 61006 MEASURES BEFORE STARTING, DURING AND AFTER COMPLETED SEAVICE:N 6.10836 2 TROUBLE-SHOOTING CHART. OVERHEATING 67 TROUBLE SHOOTING, PUMPS 6.12018 € —SLEWING GEARSET (PINION MODULE 14 AND 18), 6.12064 I HYDRAULIC MOTORS, HOISTING, LUFFING AND SLEWING CIRCUITS 6.120826 a WINCH 5.1213 2 TROUBLE-SHOOTING CHART. HYDRAULIC HIGH SPEED MOTORS. 6125.14 FEED PUMP UNIT 6127.40 HIGH PRESSURE PUMPS 6.1425€ @ RECOMMENDATION FOR INSPECTION AND REPLACEMENT OF HYDRAULIC HC 6.189 © HYDRAULIC PISTON ACCUMULATOR 388 0862-801, -802, -808 62 6200.14 8 INSPECTION OF CUMS PROTECTION, JIB AND CRANE HOUSE TOP 6214 h TIGHTENING TORQUES, STUDSISCREWS AND BOLTS 621521E = SERVICE DOOR (OPENING AND CLOSING) s21661€ © ROPE REEVING DIAGRAM CRANES TYPE GL-2 (vax version) 6.2201 € ‘2 HANDLING, INSTALLATION AND MAINTENANCE OF STEEL WIRE ROPES 6.208.126 b REPLACEMENT OF WIRES, ONE OR TWO FALL RIGGING 625/473 E 2 WEAR ON WIRE SHEAVES 25/1560 € > UFTIN@ BLOCK 62511579 © MEASURING PROCEDURE FOR WEAK IN SLEWING BEARINGS 85 690399 ELECTRONIC TROUBLESHOOTING FOR CRANE CONTROL SYSTEM CC2000, S| 414.6048 {SIGNAL OVERVIEW. CRANE CONTROL SYSTEM C2000 ana 7012 J ERROR MESSAGES, SINGLE AND TWIN CRANES, CRANE CONTROL SYSTEM C 6.08.1 € ELECTRICAL EQUIPMENT, GENERAL MAINTENANCE 6.07.11 E b —SUP-RINGUNIT 6att4E ~ _ OILLEVEL FLOAT SWITCH AND OVERHEATING PROTECTOR 6.320.299 & = LIMIT SWITCHES IN HOISTING AND LUFFING WINCH SYSTEMS 52113 2 SLACK WIRE SAFETY SWITCH HOISTING AND LUFFING WINIGHES 6,900.27 E EMERGENCY RELEASE OF PARKING LOCK IN CASE OF POWER FAILURE B 6.900.356 E 1 EMERGENCY LOWERING IN CASE OF COMPLETE POWER FAILURE, OPERA EXTRA EQUIPMENT 7 APPENDICES =a SPARE PARTS 9 SEE SEPARATE TABLE OF CONTENTS: ‘The Original Manufacturer of HAGGLUNDS Cranes,MacGREGOR PARTS MANUAL Date Project No. Page Dept. 230 7 2005-06-30, L005001-1 3 (5) TABLE OF CONTENTS GROUP DESCRIPTION PART NUMBER FG ° Ee2s-0014 80 HOWTO ORDER SPARE PARTS > e000€ 81 HOISTING WiNoH,C weoasiron 625-1440.089, HOISTING WINCH yes zoezer €25-1460.057 HYDRAULIC MOTOR seoamie8o: = N 25-2208.013 LUFFING WINCH, © yeoasieso; 625-1440 .068 LUFFING WINCH ye9.2ss0-801 wy 625-1460,0588 HYDRAULIC MOTOR yee izzte01 625.2208.009% WINCH MOUNTING SET zecioeser 625-2250.008, SLEWING GEAR MOUNTING s9025e7-001 25-0054.011 SLEWING GEAR zee 1sieeo1 625-0206.0198 HYDRAULIC MOTOR yee 120-801 AY 625-2205.010 82 PUNPUNIT te0.a7a0g01 AA 625-4996.191 ‘EAR BOX seoowseor 625-4040.0248 HYDRAULIC PUMP zosresseor 25-4845.025, HYDRAULIC PUMP zegieseeo1 BF €25-4045,0208 ‘TANDEM ASSEMBLY KIT saesie7a01 FF «25-4062 FEED PUVP UNIT 299655801 625-5181.008 co conten 2902405801 OY 625.5740.0114 OL COOLER ASSEMBLY 2909899801 OY 625.5740,0014 82 OIL TANK ASSEMBLY vesasoo1 cic 25-5065.038 (CRANE HOUSE MAIN COMPONENTS seoarmao, 525.6102.325 PARKING LOCKING MOUNTING zego7asso: Oy 625-6160.0088 COVER MOUNTING seoorereo: = 625-6169,000% JIB BEARING MOUNTING seo1s7eeo1 625-6170.0140 JIB SEARING HOUSING seg 1379801 |B 625-6170.0158 JIB TOP MOUNTING 292535001 25-6244.035 LUMIT SWITCHES BOX zeazareso) cl 625-6245.175, UMIT SWITCHES BOX. LUFFING 2002376801 OF 625-6245,191 UMIT SWITCHES BOX, MOUNT. seosmseor | N 625-6248.0014 SLACK WIRE DEVICE zecameer 625-6250.028, JIB MOUNTING sooeeeoeo: 25-€276.001 JIB MOUNTING 2e02sa7801 625-6408,075 CRANE TOP MOUNTING moose W 625-6459.025, INCUNOMETER, ¢ seeor7s801 8B 625.6509 (CAB MOUNTING zeoorsoe01 625-6540,000 ‘AB ASSEMBLY +89 2057-001 / 625-6545.040 EMERGENCY DOOR ASSY 904053801 625-6546.001 (CAB CUPOLA ASSEMBLY 2092051-801 625-65¢0.007 WINDSCREEN CLEANER se7ever802 FF 625-6561.0010 ROPE LADDER MOUNTING 07175801 625-6562.019 VENTILATION FAN, ASSEMBLY zeernee: 625-6625.0018 VENTILATION FAN seeowseen1 625-6605.015, LIFTING BLOCK zec142e00 625:7015.0498 JIB WELDING jes.200n-001 +109 2020 SLEWING BEARING zeeise2401 oF 20 1822 SLEWING BEARING MOUNTING 9 teseA01 9 1688 ‘The Original Manufacturer of HAGGLUNDS CranesMacGREGOR PARTS MANUAL Date Project No. Page Dept. 230 2005-06-30, L005001-1 4 (5) TABLE OF CONTENTS GROUP DESCRIPTION PART NUMBER FG © SLEWING BEARING YARD MOUNTING 2007057.01 Oy ave 7257 LOAD WIRE ROPE SEE TECHNICAL DATA seesroeecs LUFFING WIRE ROPE SEE TECHNICAL DATA seesresans uM swirct 5661 4118512 Mir swircH ‘5661 4125-001 84 VALVEUNTT zoszssran1 25-7207.007 VALVE UNIT zegiesaeo1 €25:7207.008 FLUSHING VALVE aegas7ono) FF exs-r287¢ UNLOADING UNIT seea57e001 BB e25-7291¢ FILTER UNIT, INLET yee onr7e01 oy 625:7914.0018 FILTER UNIT, OUTLET weoor1eeo: oF 625:7314.0008 DIRECTION VALVE 2002550001 25-7022.014 DIRECTION VALVE zoo 1se7401 |W 25-7322.047 DIRECTION VALVE zag isoneo1 625-7322.048 DIRECTION VALVE 98 5114-801 625.7922.016 FLUSH AND UNLOADING UNIT seeasee01 cc 625-72498 HAND PUMP yeoouss-e01 25-7454 UNLOADING UNIT 2900570009 BB «25-76c2.008 HYDRAULIC CYLINDER, C 3665046001 625-4880 ACCUMULATOR seeonsee01 FY 75-7951 HYDRAULIC HOSES 6295-79706 FILTER ELEMENT segaroego: cr TUBING OL COOLER yeoomoer +89 0049 HYDRAULIC CIRCUIT DIAGRAM 169 4721 NA 99.4721 TUBING PARKING LOCK zogooioeo: = 2090640 25 POWER SUPPLY seaouogo) ae 625.6562.008 DRIVER'S DESK ‘e4ompe01 ae 625-£568.000 EL INST. CRANE JB LIGHT tesomareor 625-0567.017 EL INST. JB LIGHT ye40ess-001 25-6567.0198 CONTROLLER, HOISTING 3142005802 Oy c25-05916 CONTROLLER, LUFFINGSLEWING siazm06802 OF e2s-e5626 CONTROLLER PANEL auasraoa0) WA 25-8506 CONTROL PANEL z2aorn7e01 WW «25-0567.008 ELECTRICAL CABINET (CTH/CT2) 2240054801 NA 625-6500.041 ASSEMOLY GT-PLATE se4ose5e01 ie 625-6600.008, SUPAING UNIT s1sgoas001 25-6750.0058 WP GARD.W. SOFTWARE 3143803815 GY INST POWER/CABLE CONNECTION sani 1 weaiv70 ELECTRICAL SYSTEM sate / 2a 1184 ©7 —_PUNPSET FOR OIL REPLACEMENT 490 asoz000 NA 4904592 FIRE EXTINGUISHER, MOUNT asoaoree01 WN xa-2524 RESCUE EQUIPMENT see 9561-801 BF 24-25008 EL INST. WARNING LIGHT, J18 yesoaugor ay 1240008 EL INST, WARNING LIGHT, JIB sesoms-e01 wy 124.0005 EL INST. GRANE FORCE LiMWT 240057901 24.0087 EL INT. PARKING LOCK CRANE te4oasaeo1 OY 24 0269 EL INST. PARKING LOCK, CAB ‘e4ozete0; a ‘2ec2es ‘The Original Manufacturer of HAGGLUNDS CranesMacGREGOR PARTS MANUAL Date Project No. Page Dept. 230 >” 2005-06-30 — LO05001-1 5 (5) TABLE OF CONTENTS GROUP DESCRIPTION PART NUMBER FG. 8.7 EL INST. WARNING LIGHT, GRAN 124 0288-801 : 1240086 EL. INST. WARNING LIGHT, CRANE 124 0289-801 + 124 0288 ELINST.EXTRA GABLE (CTW/OT2) ‘124 0526-801 “ 124 0824 EL. INST. AUTO-PLUSSING CRANE 124. 0291-801 oO 1240291 EL. INST. IMPULSE RELAY CT! 2240116-801, y 2240116 EL INST. PMS ELECTRIC CABINET 224 0119-801 ny 224 0119 EL INST. PARK, LOCK (CT!) 22400124-601, Ny 224 0124 EL. INST. PMS CABIN 924 0449-801, a 924 0449, ELINST. CABIN DECK LIGHT 824 1016-801, 2 324 1016 ELINST WARNING LIGHT CRANE TOP (CABIN) ‘324 1182-801 s 324 1182 ELINST. FORCE LINIT(CABIN) 324 1183-801 1 324 1183 EL. INST. WARNING LIGHT CABIN '924.0507-801 4 924.0507, ELINGT. EXTRA CABLE (CABIN) ‘924 1296-801 4 924 1206 ‘The Original Manufacturer of HAGGLUNDS Cranes,MacGREGOR GENERAL 1,000.2 E rev. b 2004-02-10 Safety Instructions Cargo Handling Equipment The MacGREGOR crane is a cargo handling de- Vice. Itis designed and manufactured to meet inter- national cargo handling standards for quality, safety and performance within capacity specifications and outreach as per certificate, ‘The erane is designed for operation in harbour or shel tered water environments where there is no signif ‘cant movement of the ship due to wave action. Testing and examination ‘The crane shall be tested and thoroughly examined and certified by @ competent person after any substantial repair The responsible officer on board shall ensure that the crane is operated under safe conditions, by per- sonnel familar with its functons and operating instruc- tions, All safety and precautionary issues contained in this manual must be observed. Proper instructions, and precautions are prerequisites for proper use. Preparation for Use and Operation According to Manual The crane operator, authorized by the responsible officer on board, must be familiar with all safety sues contained in this Chapter and with preparation for use and operating instructions before work is started Maintenance and Service 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 only for its own professional services. Our product guarantee is not valid unless MacGREGOR authorized service Is used, The use of proper Spares and Exchange details MacGREGOR shall be contacted for ordering of ex- change equipment and spares for this crane. Articles supplied by MacGREGOR are designed and quality tested for this application and are supplied with our warranty for correct function and safe working of the crane. Mac@REGOR accepts no liability for the functioning of the crane systems, nor for the safe use of the crane, Unless original spare parts are used ‘Supervision, Instructions, Signs and Warnings Proper use of this crane and its equipment is possi- ble as long as the owners, users and operators main- tain the crane to mest full operational standards, This includes the replacement of signs, instructions and warnings as per delivery. MacGREGOA does not ac- cept responsibility for any parly who fails to ensure that this manual, signs, instructions, and warnings are legible and easily accessible to porsonnal Improper Use 1. Elevation of persons. 2. Exposing persons to the risks of falling cargo. 3. Overloading, 4, Unlocking the crane or crane jib or operating the equipment at sea without full acceptance and con- trol of personnel and equipment safety 5. Unprofessional, intended or unintended, adjustment of safely locks, hydraulic or electric settings. 6. Disregard of occupational and safety standards of work, The Original Manufacturer of HAGGLUNDS Cranes 1 (16)MacGREGOR GENERAL 1,000.2 € rev.:b 2004-02-10 Functions, Installations and Equipment General ‘The MacGREGOR crane has built-in safety functions and installations to allow for sate normal use, opera- tion, care and control. This is applicable to instructed personnel without specific professional education or certification, but working according to this manuel. Specific service and repair of the electrical, hydrau- lie and the mechanical functions, controls and sattings require professional service personnel knowledgeable of risks involved. Regular Care and Contro! (Maintenance) This manual contains checklists for regular care and control of crane equipment, wire ropes and hydraulic filters. These checklists routine contain inspections and maintenance regularly prescribed for safe func- tion, e.g Chapter 4 contains: Safety Precautions Checklist for Single and Twin Cranes. Chapter 5 contains, it applicable: Inspection of Stressed Components and Structures. Lubrication chart; Crane. Lubrication chart; Twin Platform, Lubrication chant; Cable Winch and Stabilizing Equip- ment Lubrication chart: Power Swivel Filters, Handling and Checking Steel Wire Ropes. Checking brake settings. (Valid for winches equipped with low speed motors.) Before maintenance and service work is started, cer- tain measures and procedures must be followed. Chapter 6 contains: Measures before Starting Service/Maintenance Work Electrical Equipment, General Maintenance. Safety Functions and Equipment Specific safety equipment is installed and delivered with this crane and must be available for its intended use, The owner/operator of the ship and its equip ment is responsible to ensure that safety functions, installations and equipment are maintained to opera- tional standards and are not being removed, by: passed or wom to non-working condition, This manual features important presentations of safety functions, installations and equipment. A summary is presented below. 1, Safety Functions a, Maneuvring functions: 1. All the crano’s working functions aro stopped and the brakes will automatically be activated when the emergency stop button is pressed. The button is loacated in cabin. This action ac- tivates safety stops and automatic lock posi- tions, 2. Attwin crane operation the crane movements automatically stop and Synchronizing failure indicator lamp lights if the hooks or jibs get ut of syncronizing position. 3. The crane has several fail-safe functions for overruling or stopping the operator's maneuvring in the event that normal hydraulic or electrical functions fail, a sudden uncon- trolled movement occurs or during overspeed operation (see below). 4. There are limit switches for reducing speed of or stopping all dangerous motions. b. Hydraulic functions: 1. Hydraulic valve functions are set for exact pres- sure. Any change in the settings adversely af- fects crane operation and must exclusively be set by professional service personnel (see in- structions Hydraulic function and High pressure pumps). 2. Hydraulic oll pressure sensor automatically in- Gicate an overload, For safe hoisting or lower- ing, the system automatically switch from a highspeed movement toa lowspeed movement or may stop the hoisting movement 2(16) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR GENERAL 3. In case of a ruptured highspressure oil pipe/ hose or other feed pressure drops, the oil feed pressure will collapse. A fead pressure switch stops the crane and the mechanical brakos are automatically applied. 4. Each winch has a hydraulic motor brake valve flanged to the motor. Mounted directly to the ‘motor itaiso provides hydraulic braking in case of @ pipe rupture. (Valid for winches equipped with low speed motors.) 5. If there is brake band failure, e.g, caused by ‘worn-out lining, hydraulic braking capacities by the pump and motor brake systems are still a- vailable, (Valid for winches equipped with low speed motors.) 6. there is a muitiple-disc failure caused by worn out brake discs, sticking cylinder, brake pilot valve or valve spool, hydraulic braking by Pumps and motor is still avaiable, (Valid tor winches equipped with high-speed motors). 7. Incase of overheating oil, a temperature sen- sor stops the main electric motor, locking crane operation. 8. Efticiont ol filters with exclusive bypass to the hydraulic oil reservoir protects the system from harmful cil conditions. A waming light on the operator's panel indicates ifthe fiter has to be changed. Diry fier might cause mal function to the system. 9. If the hydraulic oil tank oil level drops below the minimum permissible level ‘A warning light on the operator's panel is acti- vated ‘An indicator stops the main electric motor and ‘rane functions are closed while all brake sys- tems ate automatically activated Electrical functions: 1. The crane control system protects the crane from overload by using pressure sensors. See also section 3, Crane Control System C2000.. 2. During a complete power failure all solenoid valves are de-energized, causing brakes tobe activated. 3. The electronic cabinets have power failure in- dicators. This function closes the electronic sig- nals down which automatically activates all mechanical brakes. 1,000.2 E rev. b 2004-02-10 4, Heat sensors located in the main electric mo- tors and feed pump motor stops all crane ope- rations and activates all brakes. 5. The overcurrent protections on all electric mo- tors prevent the electric motors trom overload- ing, The main electric motor and feed pump elec {ric motor overcurrent protections stop all crane ‘operations and activates all brakes, 6. A separate electrical food for the cranehouse lights operator's cab and on jb, maintains fune- tion of lights even during feed cisruption to the crane operating functions. As there is not a separate emergency illuminating system for the crane (this is dependent on the ship's sys- tems) the owner of the crane must provide a battery type flash-light for the operator's cab. d. Mechanical functions: 1. Automatic sensors recognize dangerous wire ‘slacks and stop hoisting and luffing movements that threaten safe control and the equipment itsett 2. Each working circuit has at least two inde- pendent brake systems. Dynamic braking, deceleration, is achived by the regenerative function of motor and pump. (hydraulic braking). ‘True static braking (parking brakes) is pro- vided by multiple disc-brakes or band brakes. ‘There are band brakes for low speed winches andan extra mechanical pawl-brake forliffing ‘The mechanical brakes are automatically ac- tivated in the event of dangerous oll prossure. High speed winches are provided with multi ple disc brakes. One for each gear unit Each slewing gear unit is equipped with one multiple dise brake. 2. Safety Installations ‘a. Waring lights, measuring instruments and meters: 1. The operator's panel is provided with warning lights which indicate clogged fiers or low cil level in the oil tank. 2. During crane start-up @ waming light on the ‘operator's panel indicates that starting proce- ‘dures are still running and that working condi- The Original Manufacturer of HAGGLUNDS Cranes 3 (16)MacGREGOR GENERAL 1,000.2 € rev.:b 2004-02-10 b. Covers and houses: tions are not acceptable before the lamp goes out. Maneuvres are not to be ordered before the warning light goes out. ‘A pushbutton siren is located in the orane op- erator’s cabinet, allowing the operator to alert persons in the working area (e.g. against pro- hibited riding on the load or against load move- ments). Measuring instruments and meters (e.g. for checking the crane functions, adjusting valve positions, and setting functional positions) are supplied as par agreement with the crane buyer/owner. Tools and equipment which are eliminated from the original order to MacGREGOR are delivered at the discretion of the owner Unauthorized visitors in the cranehouse, es- pecially during crane operation, is prohibited, The crane is a dangerous working area, and requires special permission to enter. Instruc- tions given by the superintendent or responsi- ble officer must be followed. Covers for electric boxes must be opened only by authorized personnel. ¢. Alert and warning signs: The crane is equigped with a system of dan- ger, warming, caution and notice signs. These signs are presented on pages 6 - 15, 3. Safety Equipment a. Locks, seals and keys: Functions and equipment that are essential for oll 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. 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 pos'- tions changed only after consulting the MacGREGOR service organization for proper handling. b. Safety belt, rescue line, safety chains: 1. For work or entry to the open-air crane top, authorized personnel must wear a safely belt ‘The connector hook should be anchored to rails {and fixed position while staying or working on crane top. The rescue line and equipment for emergency evacuation of the crane operator must always be easily accessible on the interior wall-side of the crane cabin. The equipment status and completeness must be inspected regularly by the responsible officer onboard. The safely chains on the open-air crane top and work platforms inside the crane, must be used for attendant's safoty during stay and work. . Firefighting equipment: A fire extinguisher shall be made available by ‘owner in the operator's cabin. The fire extinguisher is for emergency use in- side the crane. ‘Tho equipment must be regularly inspected for proper pressure reading at the meterand must be serviced annually. This is to be supervised by the responsible officer on board. d, Test device: At delivery, the MacGREGOR crane is equipped with two pressure gauges. 4 (16) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR GENERAL 1,000.2 E rev. b 2004-02-10 Danger, Warning, Caution and Notice Signs Principles of Risk Clas: 1. DANGER SIGNS aro attachod to equipment or aro related to operations that will expose personnel to a life-threatening danger (e.g. high voltage elec- tricity) ication Safety installations, covers or houses prevent ex- posure during normal working conditions, but can- nt eliminate the imminent risk for any unprofes sional/non-cerlificated person, should the danger 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 waming sign 's 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 aro attachod to equipmont or related to operations that may produce a physical risk to any person who is not cautious or aware of the risk. ‘Any porson 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 oparation of the equipment or damage to tho equipment itself. Responsible officers onboard must ensure that the signs are in good condition and readable to any person admitted to the crane area. Replacement signs must follow international and national standards. Signs ofnon-MacGREGOR de- sign are not allowed. MacGREGOR does nat ac- cept responsibility for unauthorized signs. Specific Presentation of Signs and Their Message Al signs attached to the crane are ilusirated on the following pages. Each sign is given a specific number to which itis referred. The Original Manufacturer of HAGGLUNDS Cranes 5 (16)MacGREGOR GENERAL 1,000.2 € 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 PM40 7101-E00 NOTICE SIGN PM40 7102-00, which can be found in the list and in the illustrations below. REPORT TO SUPERINTENDENT OR OPERATOR'S ROOM FOR PERMIT TO ENTER Any visitor to the crane must obiain 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 dangeraus working environment and requiets that the authorized visitor understands relevant safety “This sign is at the bottom entrance to the crane foundation. 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. This Sigh Is at the batiom entrance fo the crane foundalion. PM40 7103-00, ‘CAUTION SIGN PM40 7104-00, PM40 7105-E00, WARNING SIGN 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. This sign is at the bottom entrance to the crane foundation. ADDER WILL ROTATE WITH CRANE - WATCH OUT! This is specifically wamn of exposure of the ladder leading up to the cranehouse. Upon crane rotation, this ladder rotates and moves suddenly without waming. This sign is at the bottom entrance to the crane (twin) plationm: RISK OF GETTING CAUGHT BETWEEN WIRE AND DRUM - WATCH OUT! At start of and during winch operation thero is a risk of gotting caught and jammed by moving wire. A safe distance from wire and drums must be maintained and adequate caution must be regarded, ‘Attached to the crane wall surfaces close to winches. RISK OF GETTING CAUGHT BETWEEN DRUM AND BRACKET - WATCH OU This sign warns the visitor about the risk of getting jammed during drum rotation Adequate caution must be regarded, Aitached to brackets and walls of work platforms inside crane 6 (16) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR GENERAL WARNING SIGN) 1,000.2 E rev. b 2004-02-10 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. PM40 7108-00 Attached at brake cylinders, narrow spaces near them. at work platforms RISK OF GETTING CAUGHT BETWEEN WIRES DURING CRANE OPERATION - WATCH out! This sign wars about the risk of moving wires that may catch and jam personnel. ‘The authorized visitor must be aware of the risk and be cautious to avoid being seriously hurt. WARNING SIGN} This sign is attached to the steel bracket side al the open-air crane top entry. 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. ‘The safety belt must be worn during any visit to the crane top. CAUTION SIGN This sign is attached to the steel bracket side at the open-air crane top entry, 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 spacitic risk. ‘The risk is exposed only during service or replacement work. PMA 7111-00 Attached at brake cylinders. ROTATING FAN - KEEP HANDS OFFI ‘The rotating fans are protected by grids and the risk is for anyone who sticks fingors or hand inside. This can be avoided by sign information, ‘Attached to fan houses on the open-air crane top and 1o wall surfaces near the top roof of the crane. 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 ‘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 7113-00 NOTICE SIGN HOT OIL AND SURFACES - WATCH OUT! During crane operation, surtaces of oll heated equipment are extemaly hot, Service personnel dismounting such equigment (c.g. checking and setting valves) must be 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. The Original Manufacturer of HAGGLUNDS Cranes 7 (16)MacGREGOR GENERAL 1,000.2 € rev.:b 2004-02-10 JPm40 7114-00 WARNING SIGN IPI40 7115-00 DANGEROUS OIL PRESSURE - BE CAREFUL! The oll pressure inside oll pressure pipes is 26 - 360 bar. Under normal working conditions, this exposes no risk for personnel because of rigorous pipe auaity control and dimensions and specifications applied to the equipment. For specific sor- vice work, exchange of parts or equipment, the exposure may be dangerous for unqualified or uninformed personnel. Instructions for service must be followed and must be restricted to qualified personnel only. WARNING SIGN tached 1o surfaces close to pipes inside ihe cranehouse, ‘SLIPPERY SURFACES - WATCH OUT! Also under normal working conditions, all walking surfaces are slippery fromdit, 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 surfaces. This sign Is attached generally to the walls of work platfonns, JPM40 7116-00 NOTICE SIGN |Pm40 7117-00 FAN STARTS AUTOMATICALLY WITHOUT NOTICE, AT +10°C (50°F) Under normal working conditions, of risk ig 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 auaiified personnel only. DANGER SIGN. JPM140 7118-00 ‘Attached to cooling fans, at the open-air crane top, and at the insido top root. 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 rastricted to qualified and authorized personnel only. WARNING SIGN JP40 7119-00 ‘Attached to electrical equipment and boxes whore 110 V or 440 V is oxposad alter covers aro removed, 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. The safety chains (at work platforms) must be used to prevent personnel from falling, DANGER SIGN ‘Altached to the steel bracket side at the operralr crane top platform, and al the crane work atforms inside the crane house. HIGH VOLTAGE INSIDE - DO NOT OPEN BEFORE MAIN SWITCH (Ql) IS SWITCHED OFF! AUTHORIZED PERSONNEL ONLY High voltage equipment, couplings and boxes are covered and do not expose tisk unless co- vers or hoses are removed. Access is restricted to qualified and authorized personnel only Attached to electrical equipment e. g. electric main motor. 8 (16) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR GENERAL 1,000.2 E rev. b 2004-02-10 P40 7122-00 | RISK OF BODILY INJURY - SUSPENDED LOAD - WATCH OUT! The crane operator must ensure that the suspended loaddoes not expose personnel below 10 risks of falling material ‘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 7123-00 | 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. This sign is attached to the steel bracket side of the open-air crane top ent PM407124-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 DRNGERSGI | pompuntas,bonronay att ond sangre personnel, equipment or property. Items lifted or articles dropped may cause death, injury or IDANGER SIGN | Severe damage. The crane operator must stop operation and alert personnel, The electrical equipment inside cover is powered even if the main switch has shut off other DANGER SIGN | electrical supply. Accoss is restricted to qualified and authorized personnal only. Attached outside and inside the cabin PMO 7128-00 | STARTS AUTOMATICALLY WITHOUT NOTICE AT +25°C (+80) Under normal working conditions, of risk 's 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 INOTICE SIGN | SUalfied personnel only ‘Attached to cooling fans, at the open-air crane top, and at the inside top roof. The Original Manufacturer of HAGGLUNDS Cranes 9(16)MacGREGOR GENERAL 1,000.2 € rev.:b 2004-02-10 [P40 7130-E00 [DANGEROUS OIL PRESSURE. BE CAREFUL! The oil pressure inside oil pressure pipes is 25 - 950 bar. Under normal working conditions, this exposes no tisk for personnel because of rigorous pipe ]quality control and dimensions and specifications applied to the equipment. For specific ser- WARNING SIGN]? Work, exchange of parts or equipment, the exposure may be dangerous for unqualified or uninformed personnel Instructions for service must be followed and must be restricted to qualified personnel only. [Attached to surfaces close to pipes inside tha cranehouse, [P40 7131-E00_ [RISK OF GETTING CAUGHT BETWEEN DRUM AND BRACKET - WATCH OUT! This sign warns the visitor about the risk of getting jammed when the drum is rotating [Adequate caution must be exercised. WARNING SIGN [Attached to brackets and walls of work platforms inside the crane. [P40 7732-£00 [HOT OIL AND SURFACES - WATCH OUT! [Surfaces of equipment in which there is hot oil can be extremely hot when the crane is in Joperation. When service personnel are working on such equipment (e.g. checking and setting NOTICE SIGN | valves) they must be aware of the danger. [Attached fo surfaces inside the crane housing, close to pumps, valves, pipes, and manifold blocks. Also in the foundation, close to oil tank and pipes. [P40 7134-00 [RISK OF GETTING CAUGHT BETWEEN WIRE AND DRUM. WATCH OUT! Wihen the winch is started and during operation, there is a risk of getting caught and jammed by moving wire. A safe distance from wites and drums must be maintained and adequate caution WARNING SIGN | must be exercised [Attached to the crane wall surfaces close to winches. P40 7195-E00 [RISK OF GETTING CAUGHT BETWEEN DRUM AND BRACKET - WATCH OUT! This sign warns the visitor about the risk of geiting jammed when the drum is rotating Adequate caution must be exercised, WARNING SIGN [Attached To brackets and walls of work platforms inside the crane. |PN40 7735-600 RISK OF GETTING CAUGHT BETWEEN WIRES DURING CRANE OPERATION- WATCH | out! [This sign wars 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 al the operrair crane top entry. |PN407140-E00_|HIGH VOLTAGE, SEPARATE FEED, EVEN WHEN MAIN SWITCH (Qi) IS SWITCHED OFF. | AUTHORIZED PERSONNEL ONLY. High voltage equipment, couplings and boxes are covered and do not expose risk unless co- DANGER SIGN vers or hoses are removed. [Boxes with this sign are powered even if main switch has shut off other electrical power. Ac- Coss is restricted to qualified anc authorized personnel only. [Attached to electric cabinet CTT. 10 (18) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR GENERAL 1,000.2 E rev. b 2004-02-10 [PM407142-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. The Original Manufacturer of HAGGLUNDS Cranes 11(16)MacGREGOR GENERAL 1,000.2 rev 2004-02-10 NOTICE 4 WARNING 100 NOT ENTER OURING CRANE ‘OPERATION Movina eRANE HOUSE AND IacKini PARTS MAY REPORT TO suDSELy Gabe acon SUPERINTENDENT mune OR OPERATOR'S ROOM FOR BEFORE ENTERING THE CRANE : PERMIT TO ENTER TO TOP ALL ACTWTES F LE Fig. 1. PMa0 7101-E00 Fig. 2. PMa07102-E00 A\CAUTION ASWARNING 2, }—___________| LADDER WILL HIGH NoIsE ROTATE WITH LEVEL. = E WATCH OUT! BE CAREFUL! Fig. 13. PM40 7113-E00 Fig. 14. PM40 7114-E00, auto A\WARNING NOTICE AQ C(-50'F) SLIPPERY AUTOMATICALLY SURFACES WITHOUT NOTICE $ E AT +10°C (+50°F) E WATCH OUT! i fg. 15. PMAo7115:€00 16. Pwo 7116-600 The Original Manufacturer of HAGGLUNDS Cranes 13.(16)MacGREGOR GENERAL 1,000.2 E rev: b 2004-02-10 ADANGER AWARNING i U HIGH VOLTAGE INSIDE RISK OF FALLING DO NoT OPEN! DOWN w E _avtwonzen fren sre cme E PERSONNEL ONLY Fig. 17. PM40 7117-£00 Fig. 18. PMA0 7118-€00 ANDANGER A\DANGER HIGH VOLTAGE SIDE: RISK OF BODILY DoNOT OPEN DEFORE MAI INJURY {SWTeH (G1) I HITCHED OFFI ‘SUSPENDED AuTHoRZED LOAD waren oun Fig. 19. PM40 7119-E00, Fig. 20. PM40 7122-E00 AWARNING prt A\DANGER sx or eermwe L1 || recor sonar noone eee ere re See ee ruencency oreraron. | eaaves [swmonzsa rs } RE orcs 2 uruost || WATCH ouT! ~ | CARE, SEE INSTRUCTION Fig. 21. PM40 7123-00 Fig. 22. PM407124-£00 ADANGER aay nSIDE oN KEEP OUT OF @ L aurnonizen E pchgonme Guy WORKING AREA! E wig 28. Pao 71-600 fig, 24. puso rir-€00 14.(16) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR GENERAL 1,000.2 E rev.: b 2004-02-10 auto NOTICE A\WARNING *25C (80°F YF Say omen le AT 425°C (+80°F) q (BE CAREFUL! iE Fig. 25. PM40 7129-E00 Fig. 26. PM40 7130-E00 ASWARNING ©, RISK OF GETTING CAUGHT BETWEEN DRUM AND BRACKET WATCH OUT! NOTICE HOT OIL AND SURFACES, a WATCH OUT! Fig. 27. PM40 7131-£00 Fig. 28. P40 7132-E00 4 WARNING eo ISK OF GETTING ‘CAUGHT BETWEEN ‘WIRE AND DAUMA 5 wares out ASWARNING RISK OF GETTING CAUGHT BETWEEN DRUM AND BRACKET & warcu out Fig. 29. P40 7134-E00 Fig. 30. PMdo 7135-£00 \ AX WARNING RISK OF GETTING ‘CAUGHT BETWEEN WIRES DURING CRANE OPERATION = WATCH OUT! A\ DANGER HOH VOLTAGE, G=PARATE FEED, EVEN WHEM MAIN @ ‘switch (a1) 8 SWITCHED OFF PERSONNEL ONLY Fig. 31. PM40 7136-£00 Fig. 92, PM40 7140-E00 The Original Manufacturer of HAGGLUNDS Cranes 15 (16)MacGREGOR GENERAL 1,000.2 € rev.:b 2004-02-10 x 4 DANGER HIGH VOLTAGE INSIDE DO NOT OPEN! * AUTHORIZED PERSONNEL ONLY Fig. 33. PMa0 7142-£00 16(16) The Original Manufacturer of HAGGLUNDS CranesGENERAL MacGREGOR 1,005E rev.:6 2003-09-09 Preface This instruction manual covers the MacGREGOR hydraulic deck crane, We hope that it will prove a valuable companion to everyone concerned with the ‘operation of the crane or otherwise in @ responsible position, Every manual belongs to a specific crane or piece of ‘equipment. The identification can be found on thelabel on the manual's back. ‘The manual contains nine sections. The various soctions 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. Spare parts General advice how to order spare parts; spare parts lists and illustrations. The Original Manufacturer of HEGGLUNDS Cranes 11)PAGE INTENTIONALLY LEFT BLANKGENERAL MacGREGOR 1.009 E rev.:a 1996-05-20 General Instructions Cleanliness in Hydraulic Systems General The fundamental and foremost rule in all work with hydraulic systems and components is absolute cleanliness. Many components, 0.g. valves and pumps, nave very narrow tolerances, therefore microscopic im- purities, invisible to the human eye, may have dis- asirous effect on the function of a hydraulic sys tem. ‘The hydraulic system installation contains a cleaner with a cartridge designed to stop impurities pro- duced within the hydraulic system during operation. Every care must be taken to prevent external im- puritios from entering the system when servicing or repairing it. This also applies for components that have been removed and or to be reinstalled. Sooner or later, a ‘component that has been replaced will be inspected, in a test equipment somewhere. It is important that the component stays in the same condition as it was when it was removed, as it may otherwise be impossible to decide the real cause of amalfunction. It may also be possible that a component sent in for inspection is not defective at all, and will be returned, Rules when working on the hydraulic system The following fast rules shall be observed during working on the hydraulic system: 1. Carry out @ rough general clean-up. 2. Protect the area where work shall be done. Use a sheet of plastic material or similar 3, Clean well with white spirit or a similar solvent. Remember that itis 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. Use @ brush for cleaning, wipe off with @ non- linting rag, repeat the cleaning it necessary. Fin- ish by spraying the area of operations - hose con- nections ete. - with the solvent ‘4, Mount protective covers immediately after remov- ing a component, a pipe or a hose. Components, shall also be fitted with covers and plugs in or- der to prevent ingress of dirt These covers must be kept in clean and closed packages. Alter use, covers are to be cleaned in the workshop. 5. Observe minute cleanliness when handling all types of quick-release connectors. Spray both connectots with solvent before making up a con- nection. Clean all covers before reinstallation Storing and filling up of hydraulic oil 1. Store barrels, hoses and pump as clean as pos- sible and best of all in a warm room. The oil vis- cosity will then be considerably lower, which make the filing through filter easier 2, Barrels, hoses and pump must be carefully han- dled and cleaned when necessary. 3. Store barrels horizontally, so plugs (or cooks) are below the liquid level and impurities (e.9., damped air) does not penetrate the barrels. 4, Observe minute cleanliness when filling up oll ~ carelessness is one of the greatest sources when impurities penetrates the hydraulic system. 5. Fill up hydraulic oll. See separate instruction, 6. Never use the last drop in the barrel, as it often consists of water and other impurities depend ent on how many times the barrel has been opened. The Original Manufacturer of HAGGLUNDS Cranes 14)PAGE INTENTIONALLY LEFT BLANKMacGREGOR GENERAL 1402 E reve 1999-09-14 Conversion Factors Length Pressure + mm = 0,0393701 in (tum) 4 alm = 14,6959 Ibtin® (psi) im 3,28084 {1 (fol) tam = 1,01325 bar tin 254mm tatm = 1,03328 at 1 ft (fot) = 304.8 mm tbar = 0,986923 atm Yat = 14,2239 Ibfiin? (psi) jal = 0.980865 bar Volume 4dm?® = 1 litre = 0.219968 gallon (UK) idm? = 1 litre = 0,264172 gallon (US) 1 gallon (UK)= 4,54609 dm? 4 gallon (US)= 3.78541 dm? Mass tka = 2.20463 Ib 1b = 045359 kg 1 ton (metric) = 1000 kg 1ton (UK) = 1 longton (US) Yton (UK) = 1016,05 kg Force tkp = 2,20462 lt 1 kp = 9,80665 N Tit = 4,44822N Tot = 0459592 kp N= 0,101972 kp N= 0.224808 Ibi Moment of force 1 kpm= 9,80665 Nm 1 kpm= 7.23901 Ibt -ft {Nm = 0,737562 Ibf tt Yibf-ft = 0.135582 daNm Yibf-ft = 1,35582 Nm Vibf ft = 0,13825 kpm 1daNm = 1,01972 kpm idaNm = 7,37562 Ibf- tt Moment of inertia 3417.17 Ib «in? 0,00029264 kg - m= 10 Ibtiin? = 0,689476 bar 10 Ibtin? = 0,70307 at bar = 1,01972 at 1 bar 14,5036 Ibfiin? (psi) 1 kplemé = 14,2233 Ibi/ine bar = 100kPa=0,1 MPa 1Pa = 1 Nim? 1Pa = 10,2 - 10" kpicm? Pa 0,145 «10° Ibtiin Pa 7.5102 mm Hg 1 kplom? = 98,07 -10° Pa Power kW = 1,35962 hk kW = 1,84102 hp (UK, US} ‘hk = 0,986320 hp (UX, US) ‘hp (UK, US) = 1,01387 hk 1 hk 0,736499 KW ‘hp (UK, US) = 0,745700 KW Temperature oc = 327 0°C = 273,15K OF = 17,7778 O° = 255,3722 kK OK = -273,15°C OK = -459,67°F CG EOF 92) oF = 1,8 (K - 279,16) + 82 F-18432 Fig (F - 92) + 273,15 =K- 273,15 K = °C 427315 The Original Manufacturer of HAGGLUNDS Cranes, 1(1)PAGE INTENTIONALLY LEFT BLANKMacGREGOR GENERAL/ALLGEMEINES 1,818.3 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 umfaBt einen Teil der allgemeinen Bild- und AnschluBzeichen, 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, The Original Manufacturer of HAGGLUNDS Cranes 4 (29)MacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rov.:@ 2002-12-10 Hydraulic symbols and valve assemblies Hydraulische Bildzeichen und Ventil- Baugruppen 1. Hydraulic Symbols Hydraulische Bildzeichen Working oil line, Arbeltsdruckleitung. Pilot line. Steverdruckleitung Drain tine, Leckolleitung Plug, plugged connection (alternative symbole). VerschiuBchraube, Sperrung (wahlweise). x Fixed —— — Feste Blenda, feste Drosselung Variable restriction, Regelblende, regelbare Drosselung. Restriction unaffected by viscosity yy Temperaturunabhangige Drosselung, “N Flexbie hose. Schlauch, biegsame Leitung \ 2 (29) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rev.:a 2002-12-10 Pipe junction. Leitungsverbindung, Crossed pipes, no connection. Kreuzende Leitungen, ohne Verbindung. Rotary connection Dreh-Verbindung, Tank line, tank. Tankleitung, Tank LL Regulation or variability Regeloar oder nachstellbar. Enclosure of component assembly, Umri6 eines Mehrkomponentenblacks. Mechanical connection. Mechanische Verbindung, Pump, fixed displacement, 1 direction of low. Pumpe, konstantes Deplacement, 1 Stromrichtung. Pumpe, variables Deplacement, 2 Stromrichtungen, The Original Manufacturer of HAGGLUNDS Cranes 3 (29)MacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rov.:@ 2002-12-10 Motor, fixed displacement, 2 directions ot low, exter- nal drain. Motor, konstantes Deplacement, 2 Stromrichtungen, exter 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. Filter Filter Filter with contamination indicator. Filter mit Anzeiger. Filter with by-pass valve. Filter mit Raickschlagventi 4 (29) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rev.:a 2002-12-10 Air breather. Luttreiniger. Pressure electric switch, normally open. Druckschalter, druckgesteuert, normal often. 2. T Pressure electric switch, normally closed, adjustable. ° Lo Druckschalter, druckgesteuert, normal geschlossen, regolbar. Non-return valve. Rickschlagventi oJ Non-return valve, spring loaded with certain opening pressure difference Os A Riickschlagventil, federvorbelastet mit gewisser Sittnungsdruckcitferenz Non-retum valve, spring loaded with certain closing pressure ditference. Rickschlagventil, fedorvorbolastet mit gowissor SchlieBungsdruckdifferenz. The Original Manufacturer of HAGGLUNDS Cranes 5 (29)MacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rov.:@ 2002-12-10 Quick coupling or gauge connection Schnelikupplung oder MeBanschiu8, ‘Gauge connection. MeBanschlub. Ventilation valve. Entlaftungsventi. Non-return vaive with variable restriction. Drosselrtickschlagventil, regelbar. ‘Shuttle vaive. Wechselventil Brake cylinder. Bremszylinder. Cylinder, double-acting with fixed cushion at one side. Zylinder, doppelt wirkend mit konstanter Damptung aut einer Seite. Pressure gauge. Manometer. ‘Thermometer. Thermometer —o — ©) 6 (29) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rev.:a 2002-12-10 Oli cooler. Oikahler. ‘Accumulator. Druckspeicher. Shut-off valve. Absperrventl Valve, basic symbol Schieber, Grundzeichen. Electrically controlled valve. Schiober, oloktromagnetisch gestouert. Pressure controlled valve. Schieber, druckgesteuert Pilot controlled valve, internal pressure supoly. Schieber, vorgestevert, interner Steuerdruck Pilot controlled valve, external pressure supply Schieber, vorgesteuert, externer Steuerdruck. Lever controlled valve. Schieber, kniippelgestauert. The Original Manufacturer of HAGGLUNDS Cranes 7 (29)MacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rov.:@ 2002-12-10 Mechanically controlled valve ‘Schieber, mechanisch gesteuert Valve with spring return, Schieber mit Feder-Ruckfuhrung, Valve with detent. ‘Schieber mit Lagenatter. 4l2 direction valve Electrically controlled four-way, two-position valve, spring retum to neutral position. 412-Wegeventil 4-Wegeschieber mit 2 Arbeitsstellungen, Feder Riickfahrung in die Nul'stellung, 413 direction valve Electrically controlled four-way, three-position vaive, spring centred 4'3-Wegeventil 4-Wegeschieber mit 3 Arbeitsstellungen, feder- zentriert Proportional valve. Proportionalventil Servo valve. Servoventl, ott Xi _ X 8 (29) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rev.:a 2002-12-10 Balance valve (GP- and HH-cranes) Ausgleichsventil(GP- und HH-Kréne) Flow regulator, aojustabe. fp Flu Regulator, regelbar. Flow regulator with non-return valve. Flu8 Regulator mit Rickschlagventt Cartridge valve, Patronenventi _ Pressure limiting valve, adjustable. Druckbegrenzungsventi, regelbar. I The Original Manufacturer of HAGGLUNDS Cranes 9 (29)MacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rov.:@ 2002-12-10 Pressure limiting valve with remote opening or clos- eg Druckbogrenzungaventil mit ferngestouerter Otinung i >| L >| oder SchlieBung. Pressure reducing valve. Druckreduzierventil Pressure reducing valve with T-port Druckreduzierventil mit T-Anschlu8. * I 10 (29) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rev.:a 2002-12-10 2. Valve Assemblies Ventil-Baugruppen Filter unit with by-pass valve. Filtereinheit mit Shuntventil Filter unit with by-pass valve and electric filter indica- uo tion Filtereinhelt mit Shuntventil und Zustandsanzeige. Filter unit with pressure limiting vaive 7 - ] Filtoreinhoit mit Druckbegrenzungsventi The Original Manufacturer of HAGGLUNDS Cranes 14 (29)MacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rov.:@ 2002-12-10 Filter unit with pressure limiting valve - Filtereinhelt mit Druckbegrenzungsventi | Filter unit with by-pass valve and electric filter indica- tion, Filtoroinheit mit Shuntventil und Zustandsanzeige. 12 (29) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rev.:a 2002-12-10 Pump for hoisting winch, Pumpe far Lastwinde. Pump for hoisting winch, Pumpe for Lastwinde. The Original Manufacturer of HAGGLUNDS Cranes 19 (29)MacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rov.:@ 2002-12-10 Pump for hoisting winch, Pumpe for Lastwinds Pump for luffing winch. Pumpe fiir Einziehwinde. 14.(29) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rev.:a 2002-12-10 Pump tor lufing winch Pumpe far Einziehwinde, Pump for lutfing or stewing. Pumpe fur Einziehwinde oder Schwenkantrieb. The Original Manufacturer of HAGGLUNDS Cranes 15 (29)MacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rov.:@ 2002-12-10 Pump for slewing or luting. Pumpo for Schwonkaniriob oder Einzishwindo. Pump for slewing. Pumpe fiir Schwenkantrieb. it-olo—f: 18 (29) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rev.:a 2002-12-10 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 venti, The Original Manufacturer of HAGGLUNDS Cranes 17 (28)MacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rov.:@ 2002-12-10 Hoisting winch with variable high speed hydraulic mo- tor. Lastwinde mit variabel schnellaufendem hydrau lischem Motor. LLuffing winch with 63/64-series motor and motor valve. Einziohwinde mit Motor Typ 63/64 und Motor- Umechaltventil. 18 (29) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rev.:a 2002-12-10 Unloading and flushing valve, slewing, Entlastungs- und Spilventil, Schwenkantrieb. Unloading and flushing unit, hoisting and slewing, Entlastungs- und Spélventi, Lastwinde und Schwenk v antrie. MLA Flushing valve, Spilventil The Original Manufacturer of HAGGLUNDS Cranes 1929)MacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rov.:@ 2002-12-10 Valve unit for stabilizing winch Ventileinheit far Stabilisierungswinde. Unloading unit for feed pump. Enilastungsventil fir Speisepumpe. 20 (29) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rev.:a 2002-12-10 Valve unit, cylinder luffing. Ventileinheit, Zyiinder-Einziehung. Valve unit, cylinder lutfing, Ventileinheit, Zyinder-Einziehung, The Original Manufacturer of HAGGLUNDS Cranes 21 (29)MacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rov.:@ 2002-12-10 3. Electric Symbols Elektrische Schaltzeichen Conductor junction, permanent. Loltungsverbindung, fost. Conductor junction, separable. Leitungsverbindung, trennbar. Crossed conductor, no connection Kreuzende Leitungen, ohne Verbindung. Slip ring with brush. Schleifring mit Burste. Fuse, supply side indicated. Sicherung, Zufuhrungsseite marker. Magnetic relay, contactor. Steuergerat, elektromagnetische Erregerwicklung, Make contact. Arbeitskontakt Break contact. Schaltkontaki 22 (29) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rev.:a 2002-12-10 Main contact Hauptkontait, Contact, manually operated. Kontakt, von Hand betatigt Contact, manually operated without automatic return, Kontakt, von Hand batatigt, nicht selbstriickstellend. Emergency stop. Notschalter. Contact with delayed opening. Kontakt mit Ausschalt-Verzdgerung, Contact with delayed closing, Kontakt mit Einschalt-Verzigerung Contact with delayed opening/closing, Kontakt mit Ein- und Ausschall-Verzdgerung Limit switeh. Endschalter Contact, thermal controlled, Kontakt, thermisch gesteuert — —-— wy ae - a a The Original Manufacturer of HAGGLUNDS Cranes 28 (29)MacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rov.:@ 2002-12-10 Pressostat Pressostat Level switch. ‘Olstandswéichter. Temperature switch, thermostat Temperaturwachter, Thermostat Touch free contact. Beriihrungstreier Geber. Inductive contact. Induktiver Geber. Ammeter. Strommesser. Voltmeter Voltmesser. Hour counter Stundenzhler Earth (hull) connection. Massenverbindung (Rump). I c) +L 24 (29) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rev.:a 2002-12-10 Rectifier, Gloichrichter. Transformer with two windings. ‘Transtormator mit zwei Wick\ungen. Transformer with several secondary windings, with screen between primary and secondary windings. Transformator mit mehreren Sekundarwicklungen, mit ‘Schitm zwischen den Primar- und Sekundar-Wicklungen, Triple-pole thermal relay (overcurrent) circuit breaker. Dreipoliges thermisches Relais (Uberstrom-Aus- 'Ssung), rr The Original Manufacturer of HAGGLUNDS Cranes 25 (29)MacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rov.:@ 2002-12-10 Diode. Diode. Light emitting diode. y Leuchidiode. Pilot lamp. Meldeleuchte. Light, Beleuchtung, Flood light s Scheinwerter. = Alarm signal Alarmsignal. Alarmsiren Alarmhupe. Single-phase outlet Steckdose, einphasig 26 (29) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rev.:a 2002-12-10 Position encoder. Drehfeldgeber. Pulsispeed encoder Geschwindigkeitsgeber Flexible lead connector. ———_{ Steckverbindung, Resistor. Widerstand, Resistor, non-linear. Widerstand, spannungsabhangig, Variable resistor. a Widerstand, regelbar. Potentiometer with slider and a fixed tap. : Potentiometer mit Schleifer und einer Festanzapfung, Heater a Tq Heizkorper. - Motor. Motor. The Original Manufacturer of HAGGLUNDS Cranes 27 (29)MacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rov.:@ 2002-12-10 Condenser. Kondensator. Heater, cabin. Heizkorper in der Fahrorkabine. Air condition Klimaanlageapparat. Solenoid vaive Magnetventil 28 (29) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR GENERAL/ALLGEMEINES 1,818.3 ED rev.:a 2002-12-10 Controller, hoisting. —-—- Steuerkniippel, Lastwinde. L Controller, lutting and slowing. Steucrkniippel, Einziehwinde und Schwenkantrieb. The Original Manufacturer of HAGGLUNDS Cranes 29 (29)PAGE INTENTIONALLY LEFT BLANKMacGREGOR TECHNICAL DATA Project No.: LO05001-1 2005-06-21 (2.001 E} TECHNICAL DATA GENERAL Type of crane GL 4526/4029-2 Work order L005001-1 Serial number 62506560- Crane No. 1 Weight 50 ton Type of frequency 3-60 Hz Supply voltage 440 V Control voltage 230 -V MECHANICAL DATA di radius vib radius Liting height Liting height Hoisting capacity, single crane at jib radius 26.0 mi29.0 m Hoisting capacity, single crane at jib radius. 9.5 m/3.6m Hoisting speed, high 0 - 18/16 ton Hoisting speed, low 0 ~ 45/40 ton Lutfing time from max to min jib radius Slewing speed, single crane max m min m H 10.0 m kK 31.0 m max 4840 ton max 45/40 ton 34/34 19/19 78 sec, max 0.7 revimin The Original Manufacturer of HAGGLUNDS Cranes 16)LS MacGREGOR Project No.: LO05001-1 2005-06-21 TECHNICAL DATA, (2.001 E) ELECTRICAL DATA MAIN ELECTRICAL MOTOR ‘Type of frequency Rated power, cont. Speed Rated power, S6 15% int. Speed, S6 15% int Rated voltage Starting current GEAR BOX DATA GEAR BOX Gear ratio Speed FEED AND CONTROL CIRCUIT ELECTRICAL MOTOR ‘Type of frequency Nominal power Speed, Starting current, direct Starting current, YD FEED PUMP Displacement No. 390 5127-801 No. 390 2483-801 692 2580 No. 289 3657-801 3~60 26 3350 94 6 No. 388 1669-801 49.4 Hz kw rev/min kW rev/min v A revimin Hz kW rev/min A A cemsirev. The Original Manufacturer of HAGGLUNDS Cranes 204)LS MacGREGOR TECHNICAL DATA Project No.: LO05001-1 2005-06-21 (2.001 E) HYDRAULIC DATA - HOISTING CIRCUIT PUMP No. 289 1833-801 (2x) Displacement 125 cmirev. MOTOR, HOISTING No. 389 3916-801 Displacement Vg. 200-0 cmirev. Torque theoretical 31.8 Nm/MPa HYDRAULIC DATA - LUFFING CIRCUIT PUMP No. 289 1833-801 (1x) Displacement 125 emi/rev, MOTOR No. 188 1221-801 Displacement 108.7 omtirev. Torque theoretical 17.0 NmvMPa HYDRAULIC DATA - SLEWING CIRCUIT PUMP No. 289 1834-801 (1x) Displacement 125 omirev. MOTOR, No. 188 1223-801 Displacement 56.1 cmirev. Torque theoretical 89 Nm/MPa The Original Manufacturer of HAGGLUNDS Cranes 3u4)LS MacGREGOR TECHNICAL DATA Project No.: LO05001-1 2005-06-21 (2.001 E) WIRE ROPE Wire rope, hoisting winch © 34 mm x 277 m No. 388 9794-824 Wire rope, lutting winch 932 mmx2t1m No. 388 9795-834 OIL VOLUME / OIL FILLING Oil tank 560 litres Planetary gear box, module 16 15,5 iitres Hoisting winch 17.8 Iitres Lutfing winch 10.5 litres The Original Manufacturer of HAGGLUNDS Cranes 404)MacGREGOR TECHNICAL DESCRIPTION 2.007 61 Erev.:c 2002-06-13 Technical Description sib top Z Litting block @@ Main electric ——~ motor Pump unit ~~ "> Grane operator's cab _ Oil tank with feed pump unit Slack wire ——— device Luffing winch ~ “ — Grane jb a Hoisting witch N Slewing gear Fig. 1. Crane type GL-2 The Original Mamufacturer of HAGGLUNDS Cranes 103)MacGREGOR TECHNICAL DESCRIPTION 2,007.61 E rev.:¢ 2002-06-13 MacGREGOR hydraulic deck cranes are self- contained units with all machinery enclosed in the crane house and, thus, well protected against external abuse. When delivered, the cranes are mechanically, hydraulically, and electrically complete in every respect and ready to be installed on a suitable foundation fixed in the ship's deck or on a crane carriage travelling on deck. Construction Allcrane movements - hoisting, luifing, and slewing - are driven by hydraulic motors. These are supplied with high pressure oil by a pump unit comprising separate pumps for each hydraulic circuit. The high pressure pumps are mounted in the same pump unit and are geardhiven by a flange mounted electric motor. The hoisting winch is driven by a hydraulic motor via planetary gearbox. A brakes integrated in the winch gear set. When the winch is running, the brake is automaticaly released by a hydraulic unit. Limit switches operate if the wire slackens and to preclude the complete unvrinding of the wire from the wire drums ‘The crane jo is raised and lowered by the lutfing winch ‘whose general design is similar to that of the hoisting winch. ‘The slewing drive of the crane uses a high-speed hydraulic motor, installed onto a planetary gearbox and fitted with a drive pinion. The pinion meshes with the internal gear teeth of the slewing ring which supports the crane house. On customer's order limit switches can be provided to define the slewing range of the crane. To heat the oil to a suitable operating temperature, the separately driven feed pump of screw type generates the heat by circulating the oilin the system, An oil cooler removes heat developed in the oil during its work cycle. If the oil temperature exceeds a certain level, a thermostat operates a contactor to stop the main drive electric motor. Various pressure limits are provided to protect the crane against overload. All moving parts in the hydraulic system are lubricated by the hydraulic oll ‘which minimises mechanical wear and ensures the added advantage of silent operation. ‘The crane house is an all-welded structure on a rigid baseplate, and encloses all_ mechanical and hydraulical machinery and associated slectric equipment for adequate protection against ran, sleet; and waves breaking over the ship. Catwalks, ladders, platforms, and handrails facilitate maintenance of the crane. The tops of the crane house and of the jib head are fitted with sheaves for the hoisting and luffing wire ropes. All sheaves run on sealad ball bearings, and their shafts are secured by lockplates Various limit switches are provided. The cranes are supplied with test certificates to the requirements of National Swedish Board of Shipping and Navigation. The design meets the requirements of LO and the relevant classification societies whose certificates will be fumished if specially ordered Crane operator's cab ‘The crane operator's cab affords an excellent allround view of the entire work area from the comfortable seat, and ready access to the two control levers, one controling the hoisting winch, and the other, the luting and slewing movements. ‘The cab also contains contro! panels with various switches, control buttons, and signal lamps. Jib For most crane types the jib is mado of two box Gitders, 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 flooclight is also mounted on the ii. 213) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR TECHNICAL DESCRIPTION 2.007 61 Erev.:¢ 2002-06-13 Electric equipment Contain electric cables outside of the crane house, €.. on the jib, are carried in steel conduit. All cables andelectric accessories are specifically designed for mating use. ‘Tha 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 cabinetiis 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. Thenon-rotatory, langs lay wire ropes are galvanised and oiled. Surface treatment All surlaces of the crane are carefully propared 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 ‘AMacGREGOR hycraulic twin crane sot 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. For twin operation, all movements of the two cranes ate synchronised through the use of transmitters and. receivers. The slewing of the twin combination is driven by hydraulic motors in the twin platform. The Original Mamufacturer of HAGGLUNDS Cranes 3@)MacGREGOR FUNCTION 9.110.79 E rev.:b 2000-01-13 Hydraulic Function Goneral The following description refers to the standard hydraulic system of MacGREGOR hydraulic deck cranes, normal version. Minor variations in the hydraulic system may occur inindivicual cranes of the same type, and the objective of this description is only to provide a general orientation concerning the arrangement of the hydraulic system. A complete hydraulic circuit diagram relating specifically to your crane will be found in the instruction manual, section “Spare Parts", Group 9.4, Three separate hydraulic work circuits, ie, the hoisting, luffing, and slewing circuits, plus feed and control-pressure circuits, make up the complete crane operating system. Each of these work circuits may have one or more pumps located in the pump unit, in Figure 1 marked PHO, PLU, PSL. Pump PF for the feed and control- pressure system is located inside the hydraulic reservoir. Identifying circuits in the hydraulic diagram Figure 1 shows the arrangement of the three work ircuits, hoisting, luffing, and slewing circuits, tagether 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 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. Component identification The main components are identified by four-digit ‘numbers in the diagram and on the actual components in the crane. The first digit of each number signifies the circuit to which the component belongs: Hoisting circuit Ltting cireuit . Slowing circuit Feed and control-pressure circuit Additional programming equipment *) Twin crane hydraulic equipment . Other additional hydraulic equipment “) *) Equipment installed at request of customer Legend MHO_ Hydraulic motor, hoisting circuit MLU Hydraulic motor, lutfing circuit MSL Hydraulic motor, slowing circuit PHO Pump, hoisting circuit PLU Pump, lufling circuit PSL Pump, slewing circuit PF Pump, feed circuit HOISTING LUFFING ciRcUT cIRCUT SLEWING CIRCUIT FEED AND CONTROL CIRCUIT Fig. 1. Identifying hydraulic circuits The Original Manufacturer of HAGGLUNDS Cranes 1 (10)MacGREGOR FUNCTION 9.10.79 Erev.:b 2000-01-18 Feed and control Feed pressure circuit ‘The function of this circuit is mainly to replace the hot tluid leaking from the closed work circuits. The feed fluid is introduced through non-return valves into the low-pressure side of the system. The feed circuit operates al a pressure of approx. 2.5 MPa (25 bar), which is set at valve 4148 and is measured at test, point 1 Control pressure circuit The function of this circuit is to supply fiuid to the brakes and pump servos, ie, to control winch speed, slewing speed and working direction. The system operates at approx. 3.0 MPa (30 bar), and is ‘measured at test point 2. Control fluid is provided to the pump servos via servo valves, NOTE. For exact pressure settings, see pressure list in the hydraulic diagram 1) Feed pressure, iniot ® Control pressure Pump case drain Food proseure outiot | Lon 14 Fig. 2. Feed and control circuit 2(10) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR FUNCTION 9.110.79 E rev.:b 2000-01-13 Hoisting winch circuit Introduction Figure 6 shows a hoisting winch circuit diagram, with the following main components: Pumps 1144, 1112 Hydraulic motors 1141 Brakes 1214, (1212) 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. 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 delayed in relation to 1221) and connects full control pressure to the brake valve 1226 which releases the brake, and also to valve 1128-1 which shifts from its unloading mode. ‘With no load on the cargo hook and the control lever inbrake release position, Figure 4, the hoisting winch should produce a slow hoisting movemont, so callod plussing. See instruction under section 6.1 "High pressure pumps”. Lowering Low speed High speed Hoisting Conirol lever Fig. 3. Control lever in neutral, hoisting Lowering Low speed High speed x“ ° Contol lever Hoisting Fig. 4. Control lever, hoisting, brake release position Lowering Low speed High speed Control lever Hoisting Fig. 5. Control lever, hoisting, low-speed hoisting The Original Manufacturer of HAGGLUNDS Cranes 3(10)MacGREGOR FUNCTION 9.10.79 Erev.:b 2000-01-18 HOISTING CIRCUIT 128 7] 124 4 well op e aT oh | a -| Feed pressure outlet / m2. an Moor rot flushing 9 G&D __thchin Food pressure, inlet Foe 4 Pressure yn to valves Fr fand 4 brakes / / Conttl pressure 1256 TF 5 a 7 / 7 a Pump case fushing Pump case dain Fig. 6. H 19 winch circuit 4 (10) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR FUNCTION 9.110.79 E rev.:b 2000-01-13 High speed range, brake release When the control lever is moved to the right, Figure 8, valves 1221 (a) and 1226 (b) are actuated, (1226 slightly delayed in relation to 1221). Control pressure is connected to the brake vaive 1226 which releases the brake, and also to valve 1128-1 which shifts trom its unloading mode. ‘The brakes are released and the motor assumes the 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 maximum rate, With no load on the cargo hook and the control lever in brake release position, Figure 8, the hoisting winch should produce a slow hoisting movement. High-speed range overload Ifthe load on the cargo hook is too heavy for handling in the high-speed range, the pressure switch 1311 will cause valve 1221 to shift to low-speed range. (Full displacement) 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 sorvo valves 1111-9.and 1172-9 atfect the sorvo and, thus the pump displacement. The pumps 1111 and 1112 thereby produce a flow of fluid that is proportional to deflection of the control lever. If, instead, the control lever is moved forward, the load will be lowered, ie, the function is the same as for hoisting, except for the direction of flow. Safety functions The hoisting winch circuit embodies four safety features: + Main pressure limiting valves 1111 1142-2, 11123 + Pressure cut-off valves 1111-10, 1112-10 + Pressure switch 1311 (overload valve) stops the crane in the event of overloading at low speed. 1111-3, Shifts to lon-speed when running in the high-speed mode ~ Pressure switch 1981 stops the crane in the event of insufficient teed pressure Note! It is not allowed to adjust sealed safely valves jwithout contacting MacGREGOR Cranes, Service Department. Lowering Low speed High speed ~~ Hoisting Gonwol lever Fig. 7. Control lever in neutral, hoisting Lowering Low speed High speed Hoisting Control lever Fig. 8. Control lever, hoisting, brake release position Lowering Low speed High speed Hoisting Control lever Fig. 9. Control lever, hoisting, high-speed hoisting The Original Manufacturer of HAGGLUNDS Cranes 5 (10)MacGREGOR FUNCTION 9.10.79 Erev.:b 2000-01-18 LUFFING CIRCUIT 224 2241-2 Control pressue to~ Motor flushing valves and brake Feed pressure, inlet Feed pressure, outlet Pump case flushing, ~ ~ Pump case drain oN Control pressure ~N ~ I~ Fig. 10. Luffing cireuit 6 (10) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR FUNCTION 9.110.79 E rev.:b 2000-01-13 Luffing winch circuit Introduction Figure 10 shows a lutfing winch circuit diagram, with the following main components: Variable displacement pump 2114 Hydraulic motor 214i Brake zen The luffing and slewing movements are generally 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 shit position and control pressure is admitted to the brake 2211 and to valve 2127 which shifts position from the unloading mode. With the control lever in the brake release position, the luffing winch should produce a slow movement of the crane jib. Ralsing and lowering the jib Moving the control lever further backward starts operation of the luffing winch. The servo valve 2111 Saffects the servo and thus the pump displacement, The pump 2111 thereby produces a flow of fluid at a rate thats proportional to lever deflection To lower tha jb, move the lever forward from neutral. The function is the same as for luffing-in, except for the ditection of the fluid flow. Safety functions The lufting winch circuit embodies three safety features: + Pressure limiting valves 2111-3, 2111-2 + Pressure switch 2481; stops the crane in the event of insuflicient feed pressure - Pressure cut-off valve 2111-10 Note! Itis not allowed to adjust sealed safety valves: without contacting MacGREGOR Cranes, Service Department. Lutting-out (lowering jib) Lutting-in (raising jb) Fig. 11. Control ever, lutfing/stewing The Original Manufacturer of HAGGLUNDS Cranes 7 (10)MacGREGOR FUNCTION 9.10.79 Erev.:b 2000-01-18 SLEWING CIRCUIT oD Conirol pressue to valves and brake ~~ Food prossure, outlet Foed pressure, inlot — Pump cage flushing ~_ “Pump case drain Control pressures. Fig. 12. Slowing circuit 8 (10) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR FUNCTION 9.110.79 E rev.:b 2000-01-13 Slewing circuit Introduction Figure 13 shows a slewing circuit diagram for the crane, with the following main components: Variable displacement pump 3111 Hydraulic motors 3141, 3142, 3143, Valve unit 3127 Brakes 3211, 3212, 9213 The lutfing and slowing movements ara 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 alfect 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 rane will start 10 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 slowing loft, 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, ~ Prossure cut-off valve 3111-10 Slowing left Siewing tight (Anti-clockwise) ‘eck (Ani-cieckwise) Fig. 13. Control lever, lufing/slewing The Original Manufacturer of HAGGLUNDS Cranes 9 (10)MacGREGOR FUNCTION 9,110.79 Erev.:b 2000-01-13 Slewing mechanism (twin cranes only) When the two cranes of a twin set are operated separately, their normal slewing mechanism is used When employed together as a twin crane, the slewing mechanism of the twin platform is connected to the No. 1 (Master) crane pump 3111 SLEWING CIRCUIT 641 Fig. 14. Slewing circuit, win cranes 40 (10) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR FUNCTION 3.13112 E rev.ra 2003-12-05 Starting and Stopping, Electric Safety Functions Single Cranes Introduction The following description refers to the starting and stopping, and electric safety functions, of a standard- 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. ‘Tho purpose of the present description isto furnish a general idea of the design and function of the electric, system. The crane is supplied with electric power via the slip-ring unit and the main switch in the cranehouse. Cables lead from the main switch to: a transformer supplying power for all control circuits; a ‘switch for the oil cooler fan motor; a Y/D switch for the main electric motor; @ pole snitch for the feed pump electric motor; and a thermostat switch for the ventilation fan in cranehouse. ‘All components are marked by symbols in the dia- ‘gram, making it easier to follow the various stages of the starting sequence, e.g = Contactors: K1 (IN); K3 (D); K2 (Y) ~ Contactors: K12; K13; KI + Time relays: K9; K71 Preparing for starting the crane Summer Outside temperature above +5°C - Set WINTER/SUMMER switch $50 to SUMMER, ~ Close main switch Q1 - ON Winter Outside temperature below +5°C - Set “WINTER/SUMMER’ switch $50 to WINTER. ~ Close main switch Qt - ON. + Feed pump motor M2 starts in 4-pole configura tionvia Contactor K12 and runs at its lower speed ‘of 1450 rpm (50 Hz) or 1750 rpm (60 Hz] ~ Wait 24 hours, N.B.- The hydraulic oil must be warm before the crane may be started. Starting and stopping the crane Start sequence - Press button $10 "1" (Start) - Warning lamp H1 "Do not operate" goes on ~ Feed pump motor M2 is started in 2-pole configu- ration by contactors K13 and Kt 1. The motor runs at its full speed of 2900 rpm (50 Hz) oF 3500 rpm (60 H2), The feed circuit pressure build up its operating pres sure. Pressostals BP 1 - hoisting circuit, BP2 - luffing circutt, close and starta delayed closing &s time relay KT + After 8s, ¥ contactor K2 switches on N contactor K1; the main motor M1 starts in ¥ connection. = Atthe same time as the Y contactor was switched on, an &s dolayed-oponing double relay K9 was started. + After 8s, the Y contactor drops, and D contactor KG Is switched on by double time relay K9 closing after 0.1s. ‘The D contactor and selt-holding N contactor switch main motor M1 to delta configuration. ~ Pushbutton "1" (Start) energize the motor switch Q5 and the COOL FAN MOTOR M3 starts, Motor M3 Is also activated by thermostat BLT! if the temperature of the hydraulic oll exceeds +10°C. = Warning light H1 goes out. The crane is operational. Stop sequence ~ Press button $10 "0" (Stop) ~ Allontactors of ¥/D switches and all other motor contactors are de-energizad. All motors stop. The Original Manufacturer of HAGGLUNDS Cranes 1(2)MacGREGOR FUNCTION 3.191.12 E rov.:a 2003-12-05 = If the switch $50 is in "winter" connection, feed pump motor M2 does not stop but is switched to 4- pole configuration and continues to run at its lower speed of 1450 rpm (50 Hz} or 1750 rpm (80 Hz). - The feed pump motor and the ventilation fan mo- tor stops only when the main switch Q1 is switched OFF, Other electric functions Overheating protection Athermostat 872 in the hydraulic system of the crane ‘opens the control circuits of the main electric motor and the oll cooler fan motor when the oil temperature ‘exceeds +85°C. ‘The ailis cooled by setting the $50 switch to position “TEST” and depressing the START button on the control panel in the cabin. The feed pump motor starts together with the cooler fan. Oil level switch If the oil lovol in the hydraulic oil tank drops below the minimum permissible level, an alarm system is snitched on by a float type oil level switch BLT1. ‘Warning light H2 goes on. {tthe 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~ {or to wamn people on deck. Ventilation fan For all cranes a ventilation fan is fitted in the eran house. This is contralled by a +25°C thermostat BT1 which is located in the CT1-cabinet. Lighting and heating Electric power is supplied by separate slip-rings for lighting in the crane house, in the operator's cabin, and on the jib and heating in the cabin. The crane house lighting is operated by swiiches under the bottom plate. The cabin lighting and the jib light aro oporated by switches in the cabin. Control system error Ian error is detected by the crane control systom in the CT2-cabinet pilot light Hi illuminates. Check the CT2-cabinet according to instruction "Crane Control System CC2000" in Section 6.3, 212) The Original Manujaciurer of HAGGLUNDS CranesMacGREGOR FUNCTION 9,142.22 E rev.: a 2008-10-29 Crane Control System CC2000 Single Cranes with More than One Outreach General ‘The following description refers to the microcomputer based crane control system C2000 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 description is only to provide a general orientation concerning the principles of the control system. Control lever hoisting winch a Cabinet CT2/MB For dotallod information about the control system a complete electric circuit diagram, relating specifically to your crane, will be found in the instruction manual, section “Spare Parts", Group 9.5. Also for detailed Information about the hydraulic system a complete hydraulic creut diagram can be foundin secton “Spare Parts", Group 9.4, Unioadingidisplacement shift valve HOISTING Brake valve y Limit switch box win spend encoder 1 iis wins 3 r Fydraute] ' pump mec | | "Sct 1 1 [Unioeding valve L4 Unloading Brake valve Prassure-smitch | vane Memory card ! LUFFING ~ : | — AL hating winch Control lever a Hyarautio] cya ~ y Laing stewing 1 [bump oy ~__T I a 7 ays Unloading valve Limit snitch box Brake valve. N Slowing gear SLEWING Hyaraulie pump: A Unloading valve Limit stich box. Fig. 1. Crane control system with interfaces to control levers and hydraulic system. The Original Manujacrer of HAGGLUNDS Cranes 1(6)MacGREGOR FUNCTION 3.142,22 & rev.: 2 2003-10-29 Crane contro! system - interfaces and principle of operation Control levers (joysticks) The right control lever controls the hoisting winch and the left control lever controls the luffing and slewing movements. The control lever linear potentiometers are fed with OV, +6V and +12V. The output level is approx. +6V with the control lever in neutral. The out put signal is controlled by the lever and is decreased to approx. +1.5V and increased to approx. +10.5V, depending on the lever movement. ‘The control lever for hoisting also gives 24V signals {or selection of low speed/high speed and hoisting! lowering, The control lever for luffing/slewing also gives 24 signals for selecting luffing invlutfing out and slewing leftisiewing right. Crane control system cabinet ‘The Crane contro! system consists mainly of four MPC. ‘cards - Micro Processor Cards. One MPC card is used {or internal communication between the cards and a parameter memory card. Three of the MPC cards are controlling all input and output signals for each crane movement hoisting, luffing and slewing. Each MPC ‘card feeds a potentiometerin the control lever for the crane movement in control, Potentiometer and control lever direction signals go to a microprocessor with a software control program that handles brake release logic, overload logic and rampforming. The output ‘rom the microprocessors fed to a voltage to current amplifier on the card. ‘The rampformer gives smooth acceleration and re- tardation to the crane movements, The brake release logic circuil releases and applies the brake in the correct sequence with the displacementunloading signals when the hydraulic motor is started and stopped. The voltage to current amplifier feeds the hydraulic, pump solenoids, Hydraulic pumps ‘The hydraulic pumps are variable displacement pumps {e.g., the flow is steplessly variable from zero to max. raled flow). The pump oll flow is controlled by a 24V_ pulse width modulated (PWM) current signal. The drroction of the oil flow is dependent on which one ofthe ‘two solencid valves is activated. ‘The speed of the winch, the pump displacement, the current through the solenoid coll and the lever movernent are proportional to each other. Hydraulic motors The hydraulic motors may be reversed by changing the direction of the hydraulic pump ail flow. Each motor also having a low and a high speed range selected by the operator's control lever. Overload protection To provent the crane from boing overloaded, i. iting too heavy a load, the hydraulic system is equipped with an electro-hydraulic overload system. Pressure sensing switches, which normally enable the opera tion, stop the hoisting movement it a too heavy load is, lifted at the current jio outreach. The pressure switch gives. signal othe control system overioad logic, which senses the overload input signal and switches over from high speed to low speed or from low speed to stop. Akey switch is used to select desired combinations of tonnage and outreach, for example 45 ton 4-25 m, 40 ton 4-28 m and 32 ton 4-32 m. Interlocking cams on the luffing limit switch box are used to provent accidontal solection of wrong combination of load and outreach for the operation. 26) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR FUNCTION 9,142.22 E rev.: a 2008-10-29 ‘The cranes equipped with ‘Muiti SWL plussing’, which is type of load-dependent leakage compensation that is less dependent on the load than normal mechanical plussing,Itis a combination of mechanical oftsot on the ump anda load-dependent electrical signal tothe pump servo, Together with a speed sensor on the hoisting limit switch box, they guarantee that the load is not lowered when the brake is released. Instead, the load Is hoisted at creep speed, independent of the load. The Multi SWL plussing is also used for hoisting during a lutfing operation. However, @ couple of exceptions occur when only the mechanical plussingis active, namely, when the hoisting winch reachas empty or full drurm and inan overtoad situation Limit switch box, hoisting The limit switch box controls speed reduction and stop function for full or empty drum, It also contains a speed-encoder used for plussing control. Limit switch box, luffing ‘The limit switeh box controls speed reduction and stop function for all max. and min. outreach, and stop parking, if fitted. Additional cams are used to select the hydraulic pressure switch corresponding to the actual outreach. Limit switches, slackwire ‘The limit switch for hoisting slackwire stops the lowering movement, and the limit switch lufting slack- Wire stops the luffing out movement when @ wire is slack. Limit switches, slewing IC fitted, the limit switches for slewing controls speed reduction and stop function for each direction at max mum slewing range. The Original Manujacrer of HAGGLUNDS Cranes 36)MacGREGOR FUNCTION 3.14222 E rev.: @ 2003-10-29 Computer system cabinet, CC2000 ‘Two versions of cabinets are used, MB and CT2. A | Fig. 2. Computer system CC2000 in cabinet MB. 127 Cabinet 19" rack with electronic cards MPC cards (Micro Processor Cards) Parameter list 625 XXXXX Parameter memory card (mounted on the backplane card) Cables from MPC cards to plinths Plintns Anti-condensation heating Sign: Signal overview Sign: Error messages aw gaene @ Fig. 3. Computer system CC2000 in cabinet CT2, 46) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR FUNCTION 9,142.22 E rev.: a 2008-10-29 Computer system cabinet ‘The Crane control system CC2000is protected against humidity by a casing with protection class IP54 (dust and splash water proot). 19" subrack with electronic cards Allelectronic eards are mounted ina standard 19" alu- minium subrack. A backplane card is used for ‘connecting powor 8V and 24V to the MPC cards. It also provides communication lines between the MPC. ‘cards and between one MPC card and the parameter memory card. MPC - Micro Processor Card Hardware ‘The control system consists mainly of four MPC cards Allfour cards are identical and 100% interchangeable. Each MPC card is a complote stand-alone microprocessor system with processor, several types of memories and communication channe's, analogue and digital puts as well as analogue and digital out put current drivers. Each card can fully handle all input and output signals. needed for one hydrauliccircuit, ie. one cranemovement. A separate safely system on each card gives proces- sor-independent protection against hazardous opera- tion at low feed pressure and overload pressure as \woll as onsuring the stopping of the crane movement due to activated imit switches. Software Allfour MPC cards are programmed with the same crane control software. Each card senses which rack-posi- tion and therefore which crane movernentitis controlling, AIMPC cards identity themselves by showing atwo- character abbreviation ofthe functionimovementname onthe front panel display: Sc-supervisor, Ho- hoisting, Lu-luffing, SL- slewing ‘The leftmost MPC card, the MPC “Sc, is only used for supervisory functions such as communication with other MPC cardsand distribution of controi system parameters {rom the parameter memory card, New versions of the crane control sottware can be loaded/programmed into the MPC cards by using a standard notebook PC. Parameter list ‘The parameter ist specifies allinformation detalls about the crane needed for the control system. It states the software version and software configuration parameters such as number of pumps, type of pumps, maximum, speed, extra equipment ete “The parameter list identification number E25XXXXX, is the same as the crane manufacturing number seen on the signin the operators cabin (Mfg. No.) Allperameters. ate storedin the parameter memory card. Parameter memory card All parameter values from the parameter list are sto- red in the parameter memory card. The information is stored in electronic memories on the catd. Stored parameter values are not dependent on power supply or battery. There is, however, a battery on the card used for a calendar, giving all MPC cards date and time information. The card is located inside the rack andi mounted on the backplane card that also holds all the MPC card connectors. The lifetime of the battery is 10 years. Cables from MPC cards Each MPC card has a maximum of 42 cables connecting al the inputs and outputs between the card and its part of the plinth row. Cables are numbered 1 to 42 and put together in a cable loom. Plinths All external connections are made to a row of plinths. In the lower part of the enclosure. Each MPC card has its ovin series of plinths. 101 - 142, forthe MPC “Se*, 201-242 for the MPC "Ho", 301-342 forthe MPC ‘Lu* and 401-442 for the MPC "SL". Note that not every number has.a corresponding plinth and. that a particularcrane does not necessarily use every plinth tor extemal connections. The Original Manujacrer of HAGGLUNDS Cranes 5(6)MacGREGOR FUNCTION 3.14222 E rev.: @ 2003-10-29 Plinth numbers from 1 to 99 are used for power and cross-connections for external limit switches, key switches, overioad switches etc. Anti-condensation heating To avoid condensation on the electronic cards, the temperature inside the enclosure is kept 2 few degrees above the temperature outside. Heating olomonts are therefore mounted behind the row of Piinths. They are powered with 24V AC when the control system is switched off or when the crane is not operational Signal overview CC2000 Coloured LEDs Signals to and from each MPC card are indicated by green, yellow and red LEDs (Light-Emitting Diodes) on the front panel of each MPC card. Green are used for normal input and outputs. Yellow indicates that the crane motion concerned is driven with slower speed. Red indicates that the motion is, stopped. nal overview sign All signals indicated with LEDs are listed on the SIG- NAL OVERVIEW sign inside the cabinet, see section "Service", Group 6.3, Identitying the plinth number corresponding to a LED The plinth number is identified by @ three-cigit number. The first digit of each number signifies the MPC card to which the signal is connected: 1. Supervisory MPC card, "So" 2. Hoisting MPC card, "Ho" 3, Lutfing MPC card, Lu" 4, Slewing MPC card, ‘SL* ‘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 Error messages Built-in diagnostics systom “The CC2000 control system has its ov builtin Glagnos- tics system. The systemis capable of detecting several ‘types of maifunctions. ‘The system checks itself and external input and output signals. Internal problems such as loss of communications are continuously checked. Loose conneetions to pumps and valves are detected when the output is activated. Signal levels that do not comespond to normal levels, ie. he potentiometer input {rom the operator's handle, are also detected. When any type of malfunction is detected, the MPC card flashes with its error LED, no. 28. All MPC card error LEDs are wired together to an error lamp in the operator's cabin, the‘contral system error" lamp. To get ‘the corresponding errarmessage number, pushthe STEP, Push-button on the MPC card with the flashing LED. Ifthere are several errors, they are shown one at atime {for each push on the STEP push-button. When there are no more error messages to read, the display shows ‘two hyphens". The error LED is now either on or off. ~ It itis on, the error is stil present but has been acknowledged. ~ Iti off, the errors are no longer present. When anew errors detected the error LED starts lashing agein to indicate that anew error exists. Error message sign ‘The corresponding error message text can be found on the ERROR MESSAGES sign in the cabinet, see section Service’, Group 63. 666) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR FUNCTION 9.155.9 E rev.:- 2001-08-23 Thermostatic Controlled Ventilation Fan General The ventilation fan is thermostatic controlled and. 4 situated inside the crane house top, see Fig. 1 + Function ; With the main switeh in position "1" (on-position) 4 | . the ventialtion fan starts via a thermostat, positioned {2 Jf : in the CT1 cabinet, see Fig. 2. The thermostat bulb le A is situated outside the cabinet. Ee | |. iy Bi) om | z ‘The thermostat is activated at +25°C. The thormo- c stat can be adjusted, see Fig. 3. 9 | oF \ Thermostat Fig. 1. Crane house Fig. 3, Thermostat The Original Manufacturer of HAGGLUNDS Cranes (1)MacGREGOR OPERATION PM40 1845-E00 rev.:- 2001-07-04 CREW CHECKLIST BEFORE TAKING CRANE INTO OPERATION Note! When the crane is rigged ready for operation, all keys for all lockable switches musi 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 wite ropes. The following checks and procedures must be performed before taking crane into operation: Summer Oil level and oil temperature Verify hydraulic oil level and that the oil temperature is above +5°C in oil tank. Also check oil level in slewing gearcase, When outside | selector shall Switch main ewitch Unclamp jibs and temperature is| be cet to SUM- | to position "1". inclamp jibs and loose gear above +5°C... | MER. Unclamp jib and loose gear from its parking position Winter . NI | . Wires and sheaves . Verity that wires run cor: rectly in the sheaves and that the wire ends are securely clamped, When outside | selector shall | switch main switch temperatureis | be set to |toposition"1" some below +5°C... | WINTER. |24 hours before operation. The Original Manufacturer of HAGGLUNDS Cranes 12)MacGREGOR OPERATION PMd0 1845-E00 rev.:- 2001-07-04 DURING OPERATION IF CRANE STOPS Listitrim Check the following: Verity that ship does not list more than 5 degrees Jand does not trim more than 2 dogroos. Max. 5° : ote a. Crane overheated 4. Set FEED PUMP MOTOR switch in TEST PUMP posi- tion, 2 Pross START button (to start feed pump unitin high speed). 3. Check that cil cooler fan is run- ring, 4, Aiter approx. 30 min, set FEED PUMP MOTOR, switch in SUMMER position. 5, Try to start the crane by pressing START button, b. Oil level 4, Check oil level in oil tank. 2, Filloilit necessary. (See Lubricating Chart). ¢, Current setting list, 1. Check current setting ist inside the electric cabinet door CT 1. 2, Change current setting, i necessary. AFTER OPERATION AFTER SEA STOWING Park the crane Park the crane according to separate instruction in section 4 of the instruction manual. Sit ‘Anti-condensation heating (if electronic cabinet CT2 fitted) Check that the heating elements (two large or thrae small) in electronic cabinet CT 2 are working, i. gots warm. \ \ ER Heating fi elements J Also see instr. "Crane control sysiem’, section 3. 2(2) The Original Manufacturer of HAGGLUNDS CranesMacGREGOR 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. The Original Manufacturer of HAGGLUNDS Cranes 441)MacGREGOR OPERATION P§M406089-E00 rev.:< 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 betore 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 he ‘ Set switch (automatic return) into position [The crane is operational Read instructions care- Check that control levers | when the red warning light fully before taking crane are inneutral. not, notify | {goes out Sot switch into position 0 into operation. responsible officer. [Donotoperateonrediight,|| (automatic return) EMERGENCY STOP SLEWING OPERATION Do not operate slewing if the red lamp "PARKING LOCK NOT ENGAGED" illuminates and the "ALARM" is activated or if the red lamp "PARKING LOCK ENGAGED’ illuminates during normal cargo handing. Stop and check parking lock I the crane gets out of control... = LET GObothontrollevers;they | | device. will return automaticaly to their neutral positions, See also separate instruction Press Emergency Stop button! | | ‘Parking of crano in wires". The Original Manufacturer of HAGGLUNDS Cranes 1(2)