Professional Documents
Culture Documents
Page
Dept. C7250 Date: 2010-02-05 2/07067.07RHM 1(6)
TABLE OF CONTENTS
No. of manuals 4 pcs, CD-ROM 1 pc
Certificate for
crane issued by: GL
Certificate for
foundation issued by: GL
IMO No. L9485825
Name of ship JIANGSU YANGZIJIANG 2007-805C
Newbuilding No. YZJ2007-805
Shipyard Yangzijiang
Owners Belbulk
Project No. 2/07067.07RHM
Mfg. No. 62508224- Crane 1, 62508225- Crane 2
Type of crane GLB 2526-2
Order specification 490 6416-803, -804 /C
Mechanical spec. 490 6868-801, -802 /-
Hydraulic spec. 490 6870-801, -802 /B
Electrical spec. 490 6869-801, -802 /D
Slewing spec. 490 7478-801 /-
SAFETY DOCUMENTS
Document names written with bold letters are documents with safety aspects.
INSTRUCTION NO. REV NAME OF INSTRUCTION
TABLE OF CONTENTS
INSTRUCTION NO. REV NAME OF INSTRUCTION
SERVICE 6
6.1 6.100 E b MEASURES BEFORE STARTING, DURING AND AFTER COMPLETED SERVICE/M
6.106.4 E - TROUBLE-SHOOTING CHART, OVERHEATING
6.117 E b TROUBLE SHOOTING, PUMPS
6.120.15 E d SLEWING GEARSET
6.120.64 E n HYDRAULIC MOTORS, HOISTING, LUFFING, AND SLEWING CIRCUITS
6.120.107 E - WINCHES, HOISTING/LUFFING
6.121.3 E a TROUBLE-SHOOTING CHART, HYDRAULIC HIGH SPEED MOTORS
6.127.52 E - HIGH PRESSURE PUMPS
6.132.18 E - REPLACEMENT OF FEED PUMP, CRANE TYPE GLB
6.142.5 E a RECOMMENDATION FOR INSPECTION AND REPLACEMENT OF HYDRAULIC HO
6.189 E f HYDRAULIC PISTON ACCUMULATORS
6.2 6.209.15 E - INSPECTION OF CLIMB PROTECTION, JIB AND CRANE HOUSE TOP
6.214 E i TIGHTENING TORQUES STUDS/SCREWS AND BOLTS
6.216.82 E b ROPE REEVING DIAGRAM FOR CRANES TYPE GLB-2
6.215.21 E b SERVICE DOOR (OPENING AND CLOSING), SERVICE AND LUBRICATION OF DO
6.222.1 E a HANDLING, INSTALLATION AND MAINTENANCE OF STEEL WIRE ROPES
6.223.11 E a REPLACEMENT OF WIRES, ONE OR TWO FALL RIGGING
625/1473 E b INDENTATION AND WEAR ON WIRE SHEAVES
625/1560 E f LIFTING BLOCK/BEAM
625/1579 E h MEASURING PROCEDURE FOR WEAR IN SLEWING BEARINGS FOR ROPE LUFF
TABLE OF CONTENTS
INSTRUCTION NO. REV NAME OF INSTRUCTION
APPENDICES 8
TABLE OF CONTENTS
GROUP DESCRIPTION PART NUMBER FIG
TABLE OF CONTENTS
GROUP DESCRIPTION PART NUMBER FIG
TABLE OF CONTENTS
GROUP DESCRIPTION PART NUMBER FIG
Safety Instructions
1. Safety Functions
Regular Care and Control (Maintenance)
a. Maneuvring functions:
This manual contains checklists for regular care and
1. All the crane’s working functions are stopped
control of crane equipment, wire ropes and hydraulic
and the brakes will automatically be activated
filters. These checklists routine contain inspections
when the emergency stop button is pressed.
and maintenance regularly prescribed for safe func-
The buttons are loacated in cabin and on the
tion, e.g.:
CT1-cabinet door. This action activates safety
stops and automatic lock positions.
Chapter 4 contains:
2. The crane has several fail-safe functions for
Safety Precautions Checklist for Single Cranes.
over-ruling or stopping the operator’s maneuvring
in the event that normal hydraulic or electrical
Chapter 5 contains, if applicable:
functions fail, a sudden uncontrolled movement
Inspection of Stressed Components and Structures.
occurs or during overspeed operation (see be-
Lubrication chart; Crane.
low).
Lubrication chart; Cable Winch and Stabilizing Equip-
3. There are limit switches for reducing speed of
ment.
or stopping all dangerous motions.
Lubrication chart; Power Swivel.
Filters. b. Hydraulic functions:
1. Hydraulic valve functions are set for exact pres-
Before maintenance and service work is started, cer- sure. Any change in the settings adversely af-
tain measures and procedures must be done. fects crane operation and must exclusively be
set by professional service personnel (see in-
Chapter 6 contains: structions Hydraulic function and High pressure
Measures before Starting, during and after completed pumps).
Service/Maintenance Work. 2. Hydraulic oil pressure sensor automatically in-
Handling, Installation and Maintenance of Steel Wire dicate an overload. For safe hoisting or lower-
Ropes. ing, the system automatically switch from a high-
Electrical Equipment, General Maintenance. speed movement to a lowspeed movement. If
Emergency Lowering in Case of Complete Power already in lowspeed the hoisting and luffing
Failure, Operation of Crane Using a Hand Pump crane movements stop.
(Optional). 3. In case of a ruptured high-pressure oil pipe/hose
or other feed pressure drops, the oil feed pres-
sure will collapse. A feed pressure switch stops
the crane and the mechanical brakes are auto-
matically applied.
The crane is a dangerous working area, and re- The fire extinguisher is for emergency use in-
quires special permission to enter. Instructions side the crane.
given by the superintendent or responsible of-
ficer must be followed. The equipment must be regularly inspected for
2. Covers for electric boxes must be opened only proper pressure reading at the meter and must
by authorized personnel. be serviced annually. This is to be supervised
by the responsible officer on board.
c. Alert and warning signs:
The crane is equipped with a system of danger, d. Test device:
warning, caution and notice signs. These signs At delivery, the MacGREGOR crane is
are presented on pages 6 - 15. equipped with two pressure gauges.
3. Safety Equipment
a. Locks, seals and keys:
1. Functions and equipment that are essential for
oil pressure settings, coordination of controls
and crane movements or expose dangerous
high-voltage electricity are locked. All keys to
locked positions and switches must be kept and
controlled by the responsible officer onboard and
are only to be used by qualified personnel.
2. Safety valves for hydraulic pressure settings
and switches for electric safety circuits are
sealed to secure correct position and trim.
Sealed equipment may be opened and positions
changed only after consulting the MacGREGOR
service organization for proper handling.
c. Firefighting equipment:
A fire extinguisher shall be made available by
owner in the operator’s cabin.
Safety installations, covers or houses prevent ex- Specific Presentation of Signs and Their Message
posure during normal working conditions, but can- All signs attached to the crane are illustrated on the
not eliminate the imminent risk for any unprofes- following pages. Each sign is given a specific number
sional/non-certificated person, should the danger to which it is referred.
sign not be followed.
All signs used in MacGREGOR cargo handling cranes are presented below. Each sign in your specific crane has a
number on it, which can be found in the list and in the illustrations below.
PM40 7108-E00 RISK OF GETTING CAUGHT BETWEEN WIRES DURING CRANE OPERATION - WATCH
OUT!
This sign warns about the risk of moving wires that may catch and jam personnel.
The authorized visitor must be aware of the risk and be cautious to avoid being seriously hurt.
WARNING SIGN
This sign is attached to the steel bracket side at the open-air crane top entry.
PM40 7109-E00 RISK OF FALLING DOWN - USE SAFETY BELT!
During any visit to the crane top (e.g. for service jobs), the authorizing officer and the person
entering to the area must fully understand the risks involved.
WARNING SIGN
The safety belt must be worn during any visit to the crane top.
This sign is attached to the steel bracket side at the open-air crane top entry.
PM40 7111-E00 ROTATING FAN - KEEP HANDS OFF!
The rotating fans are protected by grids and the risk is for anyone who sticks fingers or hand
inside. This can be avoided by sign information.
CAUTION SIGN
Attached to fan houses on the open-air crane top and to wall surfaces near the top roof of the
crane.
PM40 7112-E00 RIDING ON CARGO FORBIDDEN
For the attention of the crane operator, to observe that the crane is a Cargo Handling device.
DANGER SIGN The crane operator is obliged to stop operation and to alert any person riding to keep off. The
operator’s alarm bell, in the crane operator’s cabin, may be used, preferably.
Attached to surfaces inside the crane house, close to pumps, valves, pipes and manifold blocks.
Also in the foundation close to oil tank and pipes.
PM40 7114-E00 DANGEROUS OIL PRESSURE - BE CAREFUL!
The oil pressure inside oil pressure pipes is 25 - 350 bar.
Under normal working conditions, this exposes no risk for personnel because of rigorous pipe
WARNING SIGN quality control and dimensions and specifications applied to the equipment. For specific ser-vice
work, exchange of parts or equipment, the exposure may be dangerous for unqualified or
uninformed personnel.
Instructions for service must be followed and must be restricted to qualified personnel only.
Attached to cooling fans, at the open-air crane top, and at the inside top roof.
PM40 7117-E00 HIGH VOLTAGE INSIDE - DO NOT OPEN! AUTHORIZED PERSONNEL ONLY
High voltage equipment, couplings and boxes are covered and do not expose risk unless co-
vers or hoses are removed. Access is restricted to qualified and authorized personnel only.
DANGER SIGN
Attached to electrical equipment and boxes where 110 V or 440 V is exposed after covers are
removed.
PM40 7118-E00 RISK OF FALLING DOWN - APPLY SAFETY CHAIN!
During any visit to the work platforms, the authorizing officer and the person entering the area
must fully understand the risks involved.
WARNING SIGN The safety chains (at work platforms) must be used to prevent personnel from falling.
Attached to the steel bracket side at the open-air crane top platform, and at the crane work
platforms inside the crane house.
PM40 7119-E00 HIGH VOLTAGE INSIDE - DO NOT OPEN BEFORE MAIN SWITCH (Q1) IS SWITCHED OFF!
AUTHORIZED PERSONNEL ONLY
High voltage equipment, couplings and boxes are covered and do not expose risk unless
covers or hoses are removed. Access is restricted to qualified and authorized personnel only.
DANGER SIGN
Attached to electrical equipment e. g. electric main motor.
PM40 7122-E00 RISK OF BODILY INJURY - SUSPENDED LOAD - WATCH OUT!
The crane operator must ensure that the suspended load does not expose personnel below to
risks of falling material. The crane operator must stop operation and alert personnel.
DANGER SIGN The operator’s alarm bell in the crane operator’s cabin is preferably used.
PM40 7124-E00 RISK OF BODILY INJURY. EMERGENCY OPERATION, AUTHORIZED PERSONNEL ONLY
OPERATE WITH UTMOST CARE, SEE INSTRUCTION
Emergency operation of luffing and slewing, in the event of complete power failure or main
DANGER SIGN pump unit failure, is extremely difficult and dangerous.
This operation must be undertaken with great care and only by skilled personnel. Instructions
must be observed at all times.
Attached to the wall side of the crane operator’s cabin.
PM40 7125-E00 DANGER - KEEP OUT OF WORKING AREA!
The working area of the crane, over deck as well as over the deck-sides, is dangerous for
personnel, equipment or property. Items lifted or articles dropped may cause death, injury or
DANGER SIGN severe damage.
The crane operator must stop operation and alert personnel.
The operator’s alarm bell must also be used for attention.
Attached on both sides of the crane jib.
PM40 7127-E00 220V INSIDE. DO NOT OPEN! AUTHORIZED PERSONNEL ONLY
This high voltage equipment is covered and does not expose risk unless cover is removed.
The electrical equipment inside cover is powered even if the main switch has shut off other
DANGER SIGN electrical supply.
Access is restricted to qualified and authorized personnel only.
Attached to cooling fans, at the open-air crane top, and at the inside top roof.
PM40 7130-E00 DANGEROUS OIL PRESSURE. BE CAREFUL!
The oil pressure inside oil pressure pipes is 25 - 350 bar.
Under normal working conditions, this exposes no risk for personnel because of rigorous pipe
quality control and dimensions and specifications applied to the equipment. For specific service
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.
PM40 7134-E00RISK OF GETTING CAUGHT BETWEEN WIRE AND DRUM. WATCH OUT!
When the winch is started and during operation, there is a risk of getting caught and jammed by
moving wire. A safe distance from wires and drums must be maintained and adequate caution
WARNING SIGN must be exercised.
This sign is attached to the steel bracket at the open-air crane top entry.
PM40 7140-E00 HIGH VOLTAGE, SEPARATE FEED, EVEN WHEN MAIN SWITCH (Q1) IS SWITCHED OFF.
AUTHORIZED PERSONNEL ONLY.
High voltage equipment, couplings and boxes are covered and do not expose risk unless co-vers
DANGER SIGN or hoses are removed.
Boxes with this sign are powered even if main switch has shut off other electrical power. Access
is restricted to qualified and authorized personnel only.
Attached to electric cabinet CT1.
PM40 7142-E00 HIGH VOLTAGE INSIDE. DO NOT OPEN! AUTHORIZED PERSONNEL ONLY
This high voltage equipment is covered and does not expose risk unless cover is removed.
The electrical equipment inside cover is powered even if the main switch has shut off other
DANGER SIGN electrical supply.
Access is restricted to qualified and authorized personnel only.
Preface
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.
General Instructions
Cleanliness in Hydraulic Systems
General
The fundamental and foremost rule in all work with Use a brush for cleaning, wipe off with a non-
hydraulic systems and components is absolute linting rag, repeat the cleaning if necessary. Fin-
cleanliness. ish by spraying the area of operations - hose con-
nections etc. - with the solvent.
Many components, e.g. valves and pumps, have 4. Mount protective covers immediately after remov-
very narrow tolerances, therefore microscopic im- ing a component, a pipe or a hose. Components,
purities, invisible to the human eye, may have dis- shall also be fitted with covers and plugs in order
astrous effect on the function of a hydraulic sys- to prevent ingress of dirt.
tem. These covers must be kept in clean and closed
packages. After use, covers are to be cleaned in
The hydraulic system installation contains a cleaner the workshop.
with a cartridge designed to stop impurities pro- 5. Observe minute cleanliness when handling all
duced within the hydraulic system during operation. types of quick-release connectors. Spray both
Every care must be taken to prevent external im- connectors with solvent before making up a con-
purities from entering the system when servicing or nection. Clean all covers before reinstallation.
repairing it.
Storing and filling up of hydraulic oil
This also applies for components that have been
1. Store barrels, hoses and pump as clean as pos-
removed and or to be reinstalled. Sooner or later, a
sible and best of all in a warm room. The oil vis-
component that has been replaced will be inspected
cosity will then be considerably lower, which
in a test equipment somewhere. It is important that
make the filling through filter easier.
the component stays in the same condition as it was
2. Barrels, hoses and pump must be carefully han-
when it was removed, as it may otherwise be
dled and cleaned when necessary.
impossible to decide the real cause of a malfunction.
3. Store barrels horizontally, so plugs (or cocks) are
It may also be possible that a component sent in
below the liquid level and impurities (e.g., damped
for inspection is not defective at all, and will be
air) does not penetrate the barrels.
returned.
4. Observe minute cleanliness when filling up oil -
carelessness is one of the greatest sources when
Rules when working on the hydraulic system impurities penetrates the hydraulic system.
The following fast rules shall be observed during 5. Fill up hydraulic oil. See separate instruction.
working on the hydraulic system: 6. Never use the last drop in the barrel, as it often
consists of water and other impurities depend-
1. Carry out a rough general clean-up. ent on how many times the barrel has been
2. Protect the area where work shall be done. Use opened.
a sheet of plastic material or similar.
3. Clean well with white spirit or a similar solvent.
Remember that it is not enough to clean only the
parts immediately concerned, but also their sur-
roundings from where accumulated dirt may be
transferred in to the repair area. Do not forget to
clean the tools to be used.
Conversion Factors
Length Pressure
1 mm = 0,0393701 in (tum) 1 atm = 14,6959 lbf/in2 (psi)
1 m = 3,28084 ft (fot) 1 atm = 1,01325 bar
1 in = 25,4 mm 1 atm = 1,03323 at
1 ft (fot) = 304,8 mm 1 bar = 0,986923 atm
1 at = 14,2233 lbf/in2 (psi)
Volume 1 at = 0,980665 bar
10 lbf/in2 = 0,689476 bar
1 dm3 = 1 litre = 0,219969 gallon (UK)
10 lbf/in2 = 0,70307 at
1 dm3 = 1 litre = 0,264172 gallon (US)
1 bar = 1,01972 at
1 gallon (UK)= 4,54609 dm3
1 bar = 14,5038 lbf/in2 (psi)
1 gallon (US)= 3,78541 dm3 2
1 kp/cm = 14,2233 lbf/in2
1 bar = 100 kPa = 0,1 MPa
Mass 1 Pa = 1 N/m2
1 kg = 2,20463 lb 1 Pa = 10,2 · 10-6 kp/cm 2
1 lb = 0,45359 kg 1 Pa = 0,145 · 10 -6 lbf/in2
1 ton (metric) = 1000 kg 1 Pa = 7,5 · 10-3 mm Hg
1 ton (UK) = 1 longton (US) 1 kp/cm2 = 98,07 ·103 Pa
1 ton (UK) = 1016,05 kg
Power
Force 1 kW = 1,35962 hk
1 kp = 2,20462 lbf 1 kW = 1,34102 hp (UK, US)
1 kp = 9,80665 N 1 hk = 0,986320 hp (UK, US)
1 lbf = 4,44822 N 1 hp (UK, US) = 1,01387 hk
1 lbf = 0,453592 kp 1 hk = 0,735499 kW
1N = 0,101972 kp 1 hp (UK, US) = 0,745700 kW
1N = 0,224809 lbf
Temperature
Moment of force 0°C = 32°F
1 kpm= 9,80665 Nm 0°C = 273,15 K
1 kpm= 7,23301 lbf · ft 0°F = -17,7778°C
1 Nm = 0,737562 lbf · ft 0°F = 255,3722 K
1 lbf · ft = 0,135582 daNm 0K = -273,15°C
1 lbf · ft = 1,35582 Nm 0K = -459,67°F
1 lbf · ft = 0,13825 kpm
1 daNm = 1,01972 kpm 1
°C = (°F - 32) °F = 1,8 (K - 273,15) + 32
1 daNm = 7,37562 lbf · ft 1,8
1
°F = °C · 1,8 + 32 K= (°F - 32) + 273,15
1,8
Moment of inertia
°C = K - 273,15
1 kg · m 2 = 3417,17 lb · in2
1 lb · in 2 = 0,00029264 kg · m2 K = °C + 273,15
This section covers a part of the symbols and port markings commonly
used in MacGREGOR (SWE) AB, Service Division hydraulic and electric
circuits, divided into three parts:
3. Electric symbols.
Elektrische Schaltzeichen.
1. Hydraulic Symbols
Hydraulische Bildzeichen
Pilot line.
Steuerdruckleitung.
Drain line.
Leckölleitung .
Fixed restriction.
Feste Blende, feste Drosselung.
Variable restriction.
Regelblende, regelbare Drosselung.
Flexible hose.
Schlauch, biegsame Leitung.
Pipe junction.
Leitungsverbindung.
Rotary connection.
Dreh-Verbindung.
Regulation or variability.
Regelbar oder nachstellbar.
Mechanical connection.
Mechanische Verbindung.
Electric motor.
Elektromotor.
M
Filter.
Filter.
Air breather.
Luftreiniger.
Non-return valve.
Rückschlagventil.
Gauge connection.
1
Meßanschluß.
Ventilation valve.
Entlüftungsventil.
Shuttle valve.
Wechselventil.
Brake cylinder.
Bremszylinder.
Pressure gauge.
Manometer.
Thermometer.
Thermometer.
Oli cooler.
Ölkühler.
Accumulator.
Druckspeicher.
Shut-off valve.
Absperrventil.
Proportional valve.
Proportionalventil.
Servo valve.
Servoventil.
Cartridge valve.
Patronenventil.
2. Valve Assemblies
Ventil-Baugruppen
Flushing valve.
Spülventil.
3. Electric Symbols
Elektrische Schaltzeichen
Make contact.
Arbeitskontakt.
Break contact.
Schaltkontakt.
Main contact.
Hauptkontakt.
Emergency stop.
Notschalter.
Limit switch.
Endschalter.
Pressostat.
Pressostat. P
Level switch.
Ölstandswächter.
Inductive contact.
Induktiver Geber.
Ammeter.
Strommesser.
A
Voltmeter.
Voltmesser. V
Hour counter.
Stundenzähler. h
Rectifier.
Gleichrichter.
Frequency converter.
Frequenzumformer.
Diode.
Diode.
ÊÊ
Light emitting diode.
Leuchtdiode.
Pilot lamp.
Meldeleuchte.
Light.
Beleuchtung.
Flood light.
Scheinwerfer.
Alarm signal.
Alarmsignal.
Alarmsiren.
Alarmhupe.
Single-phase outlet.
Steckdose, einphasig.
Position encoder.
Drehfeldgeber.
Puls/speed encoder
Geschwindigkeitsgeber
Resistor.
Widerstand.
Resistor, non-linear.
Widerstand, spannungsabhängig.
Variable resistor.
Widerstand, regelbar.
Heater.
Heizkörper.
Motor.
Motor. M
Condenser.
Kondensator.
Heater, cabin.
Heizkörper in der Fahrerkabine.
Air condition.
Klimaanlageapparat.
VL . . . .
Solenoid valve.
Magnetventil.
Controller, hoisting.
Steuerknüppel, Lastwinde.
TECHNICAL DATA
GENERAL
Type of crane GLB2526-2
Type of current 3 ~ 60 Hz
MECHANICAL DATA
Lifting height H 15 m
Lifting height K 20 m
BASIC DATA
Hoisting Hoisting Jib radius Jib radius Hoisting Hoisting Luffing time Slewing speed
capacity capacity Minimum Maximum speed speed Max – min radius
Part SWL low high
(ton) (ton) (m) (m) (m/min) (m/min) (sec) (rev/min)
25 12.5 4 26 21 42 55 1.0
ELECTRICAL DATA
MAIN ELECTRICAL MOTOR No 390 5126-801
Type of frequency 3 ~ 60 Hz
Displacement 90 cm3//rev.
Displacement 90 cm3//rev.
Displacement 90 cm3/rev.
WIRE ROPE
Wire rope, hoisting winch Ø 30 mm x 236 m
No 390 3377-806
Cams Cam Jib Speed Max jib Force Speed Min jib Winch Limit values Distance
degree parking reduce, outreac limitatio reduce, outreach angle on winch MV
s pos. luffing out h n for luffing in position drum
(degree) Approx.(m) (m) parking Approx (m) degrees (mm) (mm)
position (m)
(m) C
A B spr B D C spr MV
AT BT
BL1 30 -7,00 0,00 115
BL6 100 26,2 59,23 370
BL3 80 26 62,24 383
BL2 100 24,5 80,85 463
BL4 30 7 175,87 872
BL5 30 4 182,37 900 777
**)
Dimension AT and AL to be measured from the drum flange on empty drum side.
Dimension BT and BL to be measured from the drum flange on full drum side, second layer.
Cams Cam degrees Speed reduce Max jib stop limit Winch angle position Limit values on
luffing out (m) degrees winch drum
Approx. (m) (mm)
E spr E AT BT
BL8 110 21,6 107,03 576
BL7 130 24,5 117,91 623
Dimension AT and AL to be measured from the drum flange on empty drum side.
Dimension BT and BL to be measured from the drum flange on full drum side.
F spr F ds
BH5 80 2.5
BH6 60 Detector switch
Technical Description
Jib top
Protective plate
Lifting block
Pump unit
Luffing winch
Crane jib
Hoisting winch
Slewing gear
MacGREGOR hydraulic deck cranes are self- The hydraulic system is designed for start at a
contained units with all machinery enclosed in the temperature range of from high to lowest ambient
crane house and, thus, well protected against external working temperature for world wide trading according
abuse. to classification societies. For cranes operating in cold
environment an optional oil heater should be installed
When delivered, the cranes are mechanically, in the oil tank. The oil heater is started by using the
hydraulically, and electrically complete in every pushbutton in the CT1 cabinet.
respect and ready to be installed on a suitable
foundation fixed in the ship’s deck or on a crane An oil cooler removes heat developed in the oil during
carriage travelling on deck. its work cycle. If the oil temperature exceeds a certain
level, a thermostat operates a contactor to stop the
main drive electric motor.
Construction
All crane movements - hoisting, luffing, and slewing -
Filters on outlet and inlet to the oil tank ensure
are driven by hydraulic motors. These are supplied
continous cleaning of the oil flow. Two filter indicators,
with high pressure oil by a pump unit comprising
one electric activates a warning lamp in cabin and
separate pumps for each hydraulic circuit and a
one visual indicates when elements need to be
separate feed and control pressure pump. The high
changed.
pressure pumps are mounted in the same pump unit
and are geardriven by a flange mounted electric motor.
Various pressure limits are provided to protect the
Starting of the electric motor is affected by an Y/D
crane against overload. All moving parts in the
starter, giving low starting current.
hydraulic system are lubricated by the hydraulic oil
which minimises mechanical wear and ensures the
The hoisting winch is driven by a hydraulic motor via
added advantage of silent operation.
a planetary gear box. A brake is integrated in the winch
gear set. When the winch is running, the brake is
The crane house is an all-welded structure on a rigid
automatically released by a hydraulic unit. The
baseplate, and encloses all mechanical and
hoisting winch is also provided with a pressure roller
hydraulical machinery and associated electrical
and one layer of wire on the drum.
equipment for adequate protection against rain, sleet,
and waves breaking over the ship. Catwalks, ladders,
Limit switches operate if the wire slackens and to
platforms, and handrails facilitate maintenance of the
preclude the complete unwinding of the wire from the
crane.
wire drums.
The tops of the crane house and of the jib head are
The crane jib is raised and lowered by the luffing winch
fitted with sheaves for the hoisting and luffing wire
whose general design is similar to that of the hoisting
ropes. All sheaves have sealed roller bearings
winch.
mounted on shafts and secured by locking plates.
Jib
Hydraulic hoses
The jib is made of two box girders, joined by transverse
The hydraulic hoses are high-pressure tested and
tubular steel struts. The foot of the jib mounts on two
carefully cleaned and inspected before assembly.
trunnion journals at the sides of the crane house skirt.
A halogen floodlight is mounted on the jib.
Cargo handling gear
Electrical equipment The swivel, hook, shackles, rings, and chains all have
Certain electric cables outside of the crane house, ample safety margins for the maximum load to be
e.g. on the jib, are carried in steel conduit. All cables handled by the crane. The non-rotatory, langs lay wire
and electrical accessories are specifically designed ropes are galvanised and oiled.
for marine use.
Surface treatment
The slip-ring unit linking the crane network with the
All surfaces of the crane are carefully prepared by
shipboard network is placed under the platform inside
sandblasting before being given a coat of Primer. As
the crane house.
standard the crane is painted with an anticorrosive
system basically based on two-component epoxy
The electric cabinet is placed on the inside wall of the
paint and an acrylic finishing coat.
crane house. The cabinet contains contactors, relays,
motor switch and various other components of the
electric installation. The main power switch (Q1) is
placed on the CT1-cabinet.
Lighting
Lighting is installed in both crane house and cabin.
Can also be installed in foundation and pedestal if
required.
Hydraulic Function
General Component identification
The following description refers to the standard The main components are identified by four-digit
hydraulic system of MacGREGOR hydraulic deck numbers in the diagram and on the actual components
cranes, GLB version. in the crane. The first digit of each number signifies
the circuit to which the component belongs:
Minor variations in the hydraulic system may occur in
individual cranes of the same type, and the objective of 1... Hoisting circuit
this description is only to provide a general orientation 2... Luffing circuit
concerning the arrangement of the hydraulic system. 3... Slewing circuit
4... Feed and control pressure circuit
Note! 5... Additional programming equipment *)
For reference see hydraulic circuit diagram in section 9.4 6... Twin crane hydraulic equipment
in the parts manual. All hydraulic components mentioned 7... Other additional hydraulic equipment *)
in this instruction can be found in the diagram.
*) Equipment installed at request of customer
The crane drive system consists of three separate
hydraulic work circuits, i.e. hoisting, luffing, and Legend
slewing respectively. There is also a feed and control
pressure circuit, to assist the hydraulic work circuit. MHO Hydraulic motor, hoisting circuit
MLU Hydraulic motor, luffing circuit
Each of the work circuits may have one or more pumps MSL Hydraulic motor, slewing circuit
located in the pump unit, in Figure 1 marked PHO, PLU, PHO Pump, hoisting circuit
PSL. Pump PF for the feed and control pressure system PLU Pump, luffing circuit
is also located in the pump unit. PSL Pump, slewing circuit
PF Pump, feed circuit
Note!
For exact pressure settings, see pressure list in the
hydraulic diagram.
Introduction
Low speed High speed
The hydrualic circuit diagram shows the following main
hoisting components:
Function Lowering
With the control lever in neutral, Figure 2 or 5, and
the pump running, the hoisting circuit performs no
actual work. A continuous supply of fluid from the
Low speed High speed
feed circuit, flushes the circuit.
Hoisting and lowering, high speed or low speed Fig. 5. Control lever in neutral, hoisting.
Lowering
High speed lowering (optional)
If the crane is designed for high speed lowering the
motor will automatically assume high-speed position
Low speed High speed
when the control lever is moved forward for lowering,
even if the control lever is to the left, for low speed.
Valve 1221 (a) will be actuated.
Hoisting Control lever
Introduction
The hydrualic circuit diagram shows the following main Note!
luffing components: It is not allowed to adjust sealed safety valves without
contacting MacGREGOR Cranes, Service Department.
Variable displacement pump 2111
Hydraulic motor 2141
Brake 2211
The luffing and slewing movements are generally Luffing-out (lowering jib)
operated by a common control lever, Figure 8.
Brake release
Moving the control lever from neutral, eg. backwards
to raise the jib, causes the valves 2221 and 2226 (2226
slightly delayed in relation to 2221) to shift position
and control pressure is admitted to the brake 2211 Luffing-in (raising jib)
and to valve 2127 which shifts position from the
unloading mode.
Fig. 8. Control lever, luffing/slewing.
With the control lever in the brake release position,
the luffing winch should produce a slow movement of
the crane jib, so called plussing. See instruction "High
pressure pumps" in section 6.1.
Safety functions
The luffing winch circuit embodies two safety features:
Slewing circuit
Introduction
The hydrualic circuit diagram shows the following main
slewing components: Slewing left Slewing right
(Anti-clockwise) (Clockwise)
Variable displacement pump 3111
Hydraulic motors 3141, 3142
Flush unloading unit 3127
Brakes 3211, 3212
Fig. 9. Control lever, luffing/slewing.
Brake release
Moving the control lever, eg. to the left for slewing left
(anti-clockwise), will affect valve 3221. The brakes will
be released and the unloading valve 3127-1 will be
blocked.
Safety functions
The slewing circuit embodies one safety feature:
Introduction
The following description refers to the starting and Note! If crane is equipped with PMS a starting per-
stopping, and electric safety functions, of a standard- mission is required. Read "OPERATING
type single crane. A complete electric circuit diagram INSTRUCTION START - STOP" and "Controls and
relating specifically to the particular crane will be found Indicators" to operate crane with PMS.
in the section SPARE PARTS of the Manual.
Siren
A pushbutton "SIREN" in the cabin allows the opera-
tor to warn people on deck.
Ventilation fan
For all cranes a ventilation fan is fitted in the crane
house. This is controlled by a +25°C thermostat BT1
which is located in the CT1-cabinet.
General
The following description refers to the microcomputer For detailed information about the control system a
based crane control system CC3000 for complete electric circuit diagram, relating specifically
MacGREGOR Cranes hydraulic deck cranes, single to your crane, will be found in the instruction manual,
crane versions. section "Spare Parts", Group 9.5. Also for detailed
information about the hydraulic system a complete
Minor variations in the use of control system input hydraulic circuit diagram can be found in section
and output signals due to differences in hydraulic and "Spare Parts", Group 9.4.
electric system may occur. The objective of this
description is only to provide a general orientation
concerning the principles of the control system.
MC Hydraulic Hydr.
"SL" pump motor
Fig. 1. Crane control system with interfaces to control levers and hydraulic system.
The speed of the winch, the pump displacement, the Micro Processor Cards - CC and MC
current through the solenoid coil and the lever movement
are proportional to each other.
Hardware
The control system consists mainly of one CC card and
Hydraulic motors
three MC cards. All MC cards are identical and
The hydraulic motors may be reversed by changing the interchangeable.
direction of the hydraulic pump oil flow. Each motor also
having a low and a high speed range selected by the Each MC card is a complete stand-alone microprocessor
operator's control lever. system with processors, several types of memories and
communication channels, analogue and digital inputs
Overload protection as well as analogue and digital output current drivers.
To prevent the crane from being overloaded, i.e. lifting a Each card can fully handle all input and output signals
too heavy load, the hydraulic system is equipped with needed for one hydraulic circuit, i.e. one crane movement.
an electro-hydraulic overload system. Pressure sensing
switches, which normally enable the operation, stop the A safety system consists of a secondary micro proces-
hoisting movement if a too heavy load is lifted at the sor, which monitors the behavior of the primary proces-
current jib outreach. The pressure switch gives a signal sor in critical situations such as hazardous operation at
to the control system overload logic, which senses the low feed pressure and overload pressure. This system
overload input signal and switches over from high speed will stop the crane movement due to activated limit.
to low speed or from low speed to stop.
Software
Limit switch box, hoisting winch All cards, CC and MC are programmed with the same
The limit switch box contains cams with limit switches crane control software. Each card senses which rack-
and encoders. It controls the movements of the hoisting position and therefore which function/crane movement
block. it is controlling.
Parameter memory card The system checks itself and external input and output
All parameter values are stored in the parameter memory signals. Internal problems such as loss of
card. The information is stored in electronic memories on communications are continuously checked. Loose
the card. Stored parameter values are not dependent connections to pumps and valves are detected when
on power supply or battery. There is, however, a battery the output is activated. Signal levels that do not
on the card used for a calendar, giving all cards date correspond to normal levels, i. e. the potentiometer input
and time information. The card is located inside the rack from the operator's handle, are also detected.
and is mounted on the backplane card that also holds
all the card connectors. The lifetime of the battery is 10 When any type of malfunction is detected, the card
years. flashes with its error LED, no. 28. All card error LEDs
are wired together to an error lamp in the operator's
cabin, the "control system error" lamp. To get the
Anti-condensation heating
corresponding error message number, push the
To avoid condensation on the electronic cards, the
Select/Info push-button on the card with the flashing
temperature inside the cabinet is more then the tempera-
LED.
ture outside. Heating elements are therefore mounted
behind the row of plinths. They are powered with 24V
If there are several errors, they are shown one at a
AC when the control system is switched off or when the
time for each push on the Select/Info push-button.
crane is not operational.
When there are no more error messages to read, the
display shows two hyphens "- -". The error LED is
now either on or off.
Signal overview CC3000
- If it is on, the error is still present but has been
Coloured LEDs acknowledged.
Signals to and from each card are indicated by green,
yellow and red LEDs (Light-Emitting Diodes) on the - If it is off, the errors are no longer present.
front panel of each card. When a new error is detected the error LED starts
flashing again to indicate that a new error exists.
Green LEDs are used for normal input and outputs.
Yellow LEDs indicate that the crane motion concerned Error message sign
is driven with slower speed.
The corresponding error message text can be found
Red LEDs indicate that the motion is stopped.
on the ERROR MESSAGES sign in the cabinet, see
section "Service", Group 6.3.
Signal overview sign
All signals indicated with LEDs are listed on the SIG-
NAL OVERVIEW sign inside the cabinet, see section
"Service", Group 6.3.
Error messages
General
Function
With the main switch in position "1" (on-position)
the ventialtion fan starts via a thermostat, positioned
in the CT1-cabinet, see Fig. 2. The thermostat bulb
is situated outside the cabinet.
Thermostat
Read sections Operation and Maintenance in the instruction manual and make sure that the maintenance is
performed according to Maintenance Chart.
Make sure nobody enters the crane without permission from responsible officer on board.
Make sure that there is nobody in the crane house who might be caught in the machinery or strangled by the wire
ropes.
Note!
If the crane operates in temperatures less than -15oC CT2
an oil heater must be installed in the oil tank.
S50
CT1
Oil heater
Q1
Max. 2
OPERATING INSTRUCTION
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.
CRANE OPERATION
Lowering
Luffing in Hoisting
1,5 m
Verify that ship does not list more Dragging loads is not permitted! ... or if a technical malfunction
than 5 degrees and does not trim has developed:
more than 2 degrees. Do not drag loads - lift them.
- Raise swivel to approx. 1.5 m
below jib head, if possible.
- Return control levers to neu-
tral.
- Press STOP button.
The diagram
The centre part of the screen shows a diagram
visualizing the current load in hook and jib radius
Fig. 1. Main screen. once more in addition to the text values displayed
in the blue boxes. This visualization also indicates
all limits and possible movements for the crane.
Joysticks represented by circles
The current values are indicated by a white “ball”
On each side of the screen there are two circles with a black circumference. The areas displayed in
containing green arrows. These represent the two the diagram are defined by parameters. The green
joysticks used when operating the crane. When an area indicates normal operation, the yellow
operation is not allowed a white cross will cross- indicates “speed reduced” and the red border is the
over the corresponding arrow. The small white stop limit.
“ball” on the hoisting circle (bottom right) indicates
movement of the hoisting winch. A horizontal black line indicates at what load the
crane will be limited to reduced speed operation.
WARNING!
Store Keys Safely
When the crane is rigged ready for operation, all keys
H3 CHECK OIL FILTER
for all lockable switches must be stored in a safe place
by the responsible officer on board. Pilot light. Illuminates when the oil pressure over the oil
filter is more than 5 bar.The oil filter is saturated and
ought to be changed or hydraulic system is to be
H1 DO NOT OPERATE checked.
Pilot light. Illuminates during starting sequence of the
crane (feed pump motor, main electric motor and supply
to electronics). H4 CONTROL SYSTEM ERROR
Pilot light. Illuminates when an error is detected by the
crane control system in the electronic cabinet CT2.
H2 LOW OIL LEVEL
Pilot light. Illuminates as a pre-warning for low oil level
H5 HIGH OIL TEMP
in crane and the siren, which is mounted under the crane
cabin will sound. Refill oil tank. The pilot light and the siren Pilot light. Illuminates when the crane stops and the oil
can be switched off by selecting the key float switch S19 temperature in the hydraulic system exceeds 85°C.
in position "1". Note! Check that the hydraulic system functions.
H6 OVERLOAD
Pilot light. Illuminates at overload. S19 FLOAT SWITCH
S17 SIREN
Time
Start - acceleration Retardation - stop 2 sec. 2 sec.
Time
2 sec. 2 sec.
Acceleration Retardation
Fig. 2. Hoisting/lowering.
Speed
S50
Time
4 sec. 4 sec.
Acceleration Retardation
Fig. 4. Slewing.
Hour
meter
2 - Winter
When outside temperature is below +5°C set switch
in WINTER position. Set MAIN SWITCH (Q1) in
position "ON" 24 hours before operation.
Q1 MAIN SWITCH
Cuts off the main power to electric cabinet CT1.
Hand rail
1
Deck level
Strops
PARKING OF JIB
0
1
Rope
Example:
Before operating crane No. 1 carefully check that
crane No. 2's jib has been removed from its parking
support.
Crane No. 2 Crane No. 1
Example:
Before operating the crane carefully check that the Jibs parked in their jib supports on the foundation
crane jib has been removed from its parking towards each other. Hook secured to deck, see
support. Fig. 6.
Rope connection
Stretching screw
turnbuckle
Example: Important!
The grab should be lowered to the deck when the Power cable and stabilizing cable should be parked
crane is parked, this to avoid load on the wires. on jib top during sea voyage. Parking on hook block
is for temporary use only.
Turnbuckle
Support Support
SIDE VIEW TOP VIEW
Example: Example:
Fix block
with wire
ropes
Deck Deck
Fig. 9. Power swivel with lifting block secured to deck. Fig. 10. Power swivel secured to deck.
Handling hatches
When pulling hatch covers by means of deck Always check that the pulley blocks are correctly
cranes, it is very important that the pulley blocks are positioned, so that the hoisting ropes cannot deviate
so placed that the hoisting wire can be maintained more than 5°, at the most, from the crane house
very nearly vertical during operation. The crane jib centre line.
should be set at an angle where it will not require
any subsequent shifting in order to achieve the N.B. The capacity of the wire pulling the hatch cover
required lifting height. may limit the force which can be applied by the
crane.
The included angle between the hoisting wire and
the vertical centre line of the crane house must not
exceed 5°.
Fig. 1. Fig. 2.
Maintenance Chart
Hydraulic system
Oil cooler - Check the following pressures:
- Inspect oil cooler externally. Clean when required. - Feed pressure inlet, at guage connection 1
Introduction
Stressed parts of the crane structure subjected to This inspection should be performed at intervals ac-
high loads require inspection for signs of cracks and cording to the Maintenance Chart.
other damage at regular intervals.
Note!
Cracks detected at an early stage do not generally Rust on a painted surface does not necessarily
impair the handling safety of the crane unless they mean that there is a crack in the underlying mate-
are not repaired. rial.
Example:
Red lamp on right control panel in operator’s cab Jib top with lifting block for single crane
CHECK
OIL FILTER
6. Wire ropes
3. Wire sheave
CAUTION!
Renew all filter cartridges 5. Swivel
when this lamp is lit.
1. Wire sheaves
Filter service
indicator
12
Filter
4135 7. Electric motor
8. Door hinges
Oil filling
12
Filter
4136
Contents
Door hinges
Grease nipple;
Service door
Electric motor
Grease nipple;
Upper bearing
Grease nipple;
Lower bearing
Slewing bearing
Jib bearing
Grease nipple;
Inside crane house
Grease nipple
Grease nipple
Lifting equipment
Oil tank
Oil filter
Wire ropes
Grease
Grease nipple
Oil outlet
Filters
Introduction
For cleaning hydraulic oil, the hydraulic system is The other indicator is visual (see Fig. 1) and should
equipped with two filters. The two filters are marked be read when the oil temperature is approximately
4135 and 4136. 45°C. Upon reaching a certain degree of clogging, a
red indication can be seen on the top of the filter
Filter indicators indicator. Replace both filter cartridges in the system
when the red indication shows.
The filter indicators operate only when the crane
starts.
Replacement filter cartridges
Filter 4135 has two filter indicators. One indicator is You must replace both cartridges (see Fig. 3) in the
electric and operates a warning lamp placed on the crane at the same time. Flush all other parts of the
control panel in the cabin (see Fig. 4a and 4b). filters with white spirit when you replace the cartridges.
Use new seals. Reassemble the filters.
4101 4102
Electric indicator
Visual
indicator
Oil filling
Filter Filter
4135 4136
Filter cartridge
The hydraulic oil tank is placed on the wall inside the Oil level MIN
crane house. If the oil level drops to MIN, the oil and temperature
guard activates the lamp LOW OIL LEVEL on the
Checking oil level control panel in the operator's cab. At the same time
the siren sounds.
Check oil level by use of the dipstick. Check that oil
level is between min. and max on the dipstick.
Verify that the guard is working properly by starting the
crane. Loosen the nut that holds the guard and lift it up
slowly.
1
Oil filling
1. Outlet filter
2. Inlet filter
3. Air filter with dipstick
2
4. Oil level and temperature guard
3 5. Thermometer
6. Vedge valve (oil drain)
4 7. Quick coupling
Filling oil
Oil is filled at an ”aero-quip” type quick-release coupling,
placed on the filter unit, see Fig. 2. When filling oil the
hydraulic system must be at rest and the electric
power switched off.
Fill oil to just under the MAX mark on the dipstick. Use
oil according to the ”Lubricating Chart”.
Fill oil to just under the MAX mark on the dipstick. Use
oil according to the ”Lubricating chart”.
The oil shall be refined oil containing additives against Cable winch, turbo coupling (if applicable)
oxidation, rust and foaming, as well as wear inhibitor Viscosity 22 cSt/40°C (ISO VG 22).
and/or EP additives. Example: SHELL MORLINA.
B. GREASES
Roller/ball bearings
Grease with EP additives.
Must withstand wet conditions.
Example: SHELL Alvania EP (LF) 2 (-20 to +130°C).
Arctic climate: SHELL Albida PPS2.
Ropes
Grease resistant to salt water and with antirust
properties. (Very thin.)
Temperature range -30 to +100°C.
Viscosity 9.8 cSt/40°C.
Example: FUCHS Cedracon.
Arctic climate: FUCHS Ceplattyn.
SERVICE
Mechanical
equipment 6.2
Address:
MacGREGOR Cranes
Cargotec Sweden AB
SE-891 85 ÖRNSKÖLDSVIK, Sweden
E 2009-03-02
Telephone: 46 - 660 - 29 40 00
Telefax: 46 - 660 - 139 77 Electrical
(Spare Parts, Technical Services & 6.3
Technical Documentation Services) equipment
www.macgregor-group.com/cranes
The Original Manufacturer of HÄGGLUNDS Cranes
SERVICE 6.000 E rev.: d 2009-03-03
Part description
Quantity required
Delivery details such as: consignee as well as phone and fax numbers
Terms of delivery: by DHL, air freight direct or consignment, by truck or shipping freight
The more you can provide us with above details the faster and more reliable replies and deliveries will be made.
Address:
MacGREGOR Cranes
Cargotec Sweden AB
SE-891 85 ÖRNSKÖLDSVIK, Sweden
Telephone: 46 - 660 - 29 40 00
Telefax: 46 - 660 - 139 77
Confirmation of
phone call/conv.
..............................................................
6. See enclosure
............................................................................................................
............................................................................................................
...................................................................................................................
Name/ Title/
Section B
RETURN FORM
How to return parts from deck crane manufacturing,
installation or guarantee exchange
1) the part
2) from where it has been taken and
3) why it is returned.
RETURN FORM
To be packed inside return box or parcel
Date:
Sent by:
Newbuilding no.:
Ship’s name:
IMO no.:
Returned part’s
drawing or article
no, serial no.:
Part description:
*) Please note: To be filled in with short but specific details. “Faulty“ is not enough, a much better
description is “leaking“, “not adjustable“, “cracked“, “earthing fault“, “short circuit“ if the reason is obvious,
or, a circumstantial evidence pointing to the returned part as the reason for malfunction, like “luffing
movement too slow in one direction“.
U. A. E.
Dubai, (S) (P)
Cargotec (ARE) LLC.
P.O. Box 30029
Al Quoz Industrial Area 4
Street 14B
Between Interchanges 3 and 4
DUBAI
Phone: +971-4-34 13 933
Telefax: +971-4-34 13 110
24h phone: +971-50-65 10 371
UNITED KINGDOM
Newcastle, (P)
MacGREGOR (GBR) Ltd.
1st Floor, Power House
Silverlink Business Park
Wallsend
NE28 9ND TYNE & WEAR
Phone: (+44) 191-295 2180
Telefax: (+44) 191-295 2188
USA
Norfolk, (S) (P) (LCE)
MacGREGOR (USA) Inc.
1220-E Fleetway Drive
VA 23323 CHESAPEAKE
Phone: (+1) 757-558-4580
Telefax: (+1) 757-558-4581
Introduction
Fig. 3.
As a first check always try to operate the crane and Analysis of information collected
at the same time check the status of the trouble- By methodical trouble-shooting, it is often possible
shooting panel in the CT2 cabinet, according to error to find, at an early stage, the defect producing the
list and signal overview list, (see instruction under faulty operation, thereby avoiding unnecessary waste
section 6.3). of time.
WARNING !
When it is necessary to search for/or correct faults
in the crane's electrical, hydraulic or mechanical
systems with the crane powered up, only author-
ized personnel may carry out such work.
A. Overheating in hydraulic sys- Oil cooler fan motor not working. Check connections, contactor,
tem. effect repairs as required.
Oil cooler flanges loaded with dirt. Dismantle and clean cooler.
N.B.
When the hydraulic system is overheated thermostat BT2 (+85oC) opens
and crane stops.
To cool the system press the "Start" button to start main electric motor in
idling while the control system is switched off. The control system will then
start automatically when thermostat BT2 closes.
Pumps, general
A. Pump not supplying any fluid. Servo error. Contact MacGREGOR Cranes
B. Excessive wear of the pump. Hydraulic fluid contains abra- Check filters. Change cartridge,
sive particles. if necessary. Analyze sample
of the fluid.
C. Fracture of parts in the pump. Pressure shocks. Check valve functions and valve
settings.
Slewing Gearset
Oil filling Air filter - Fill gear oil as required (see lubricating instructions
Expansion tank for appropriate type; the approximate quantity
Plug a needed is given on the nameplate).
Expansion pipe
- Fill brake disc chamber with hydraulic oil; e.g. 0,1
litre ATF-oil, type A.
Disc brake
Brake surface sealed with Loctite type 573.
- Before assembling the drive motor, grease shaft
Oil level sight
glass and gear teeth with a suitable grease for protection
against corrosion; we suggest OPTIMOLY PASTE
White T.
- Check function of slewing gearset with the drive
motor running, paying particular attention to the
Screws holding function of the brake and the correct control of the
gearset to crane
house floor motor.
Oil outlet
Maintenance
Lubrication
Fig. 1. Slewing gearset. The slewing gearset is splash lubricated. The output
shaft roller bearing is ”for-life” lubricated with ball
Assembly of slewing gearset bearing grease.
- Install slewing gearset in crane without using force. Oil level check
- Use hand pump to release disc brake hydraulically. Inspect oil level when the gear is at rest with the brake
Input drive sleeve must turn easily. engaged.
- Check slewing gear backlash (pinion-to-rim gear).
See description under Checking and adjusting
Oil changes
slewing rim backlash.
- The gear backlash may be adjusted by rotating the Whenever practicable, let the oil drain off while still
gearset one or more screw hole divisions. hot; remove also the filler plug(s).
- Tighten the screws to torque recommended, secure
with Loctite 242 (or a similar compound). Applying For oil change open both pipes. Remove air filter with
a suitable sealing compound, such as Loctite 640, oil expansion tank at marked pos. a, see Fig 1.
on the mating surfaces of the flanged connection,
is recommended. At low ambient temperatures, flush out the gearcase
- Remove threaded plug from top of expansion pipe with a quantity of fresh oil to remove abraded matter
(for transport sealing only). and contamination products.
- After installation of gear unit fit supplied air filter
with oil expansion tank, at marked position a
(optional to fit with a tube turn). See Fig. 1.
Sampling oil
Withdraw a sample of gearcase oil for inspection from If coarser abraded matter (above 25 µ) or flake off
the filling drained off at intervals as described in the material from the gear teeth is found, the gearset must
Maintenance Chart. To obtain a representative be dismantled, irrespective of the actual amount of
sample, drain the gearcase during operation and with foreign matter present, beginning at the input end of
the oil at operating temperature. the gearset.
Oil discoloration
Hydraulic-Release Multiple-Disc Brake
A darkish or black colour of the used oil suggests that
temperatures in excess of 100o C did occur in opera- Technical description
tion, causing accelerated aging of the oil and impaired The brake comprises the following major components:
lubricating properties. In this case the oil should be - Brake piston
changed at shorter intervals. - Brake cylinder
- Disc carrier
If the oil sample displays a cloudy aspect, it may be - Internal discs
that water has managed to seep into the oil. The oil - External discs
must then be changed a t o n c e, and the gearcase - Sealings
flushed out very thoroughly several times with fresh - Thrust spring
oil.
The brake housing is mounted on top of the gearcase,
The gearcase should preferably be dismantled for with long assembly screws through the motor adap-
inspection beginning at the input side, and the ter housing and both parts of the brake housing.
components examined for signs of corrosion.
The sleeve disc carrier, with the internal discs, is fixed
Foreign solid matter on the driven shaft with a shaft key or by splines.
Motor side
Thrust spring Brake piston Brake cylinder
Pressure oil
connection Sealing
Sealing
Total
thickness Leakage oil
of discs
Disc carrier
Internal discs
External discs
Gear side
- Inspect brake discs and replace if excessively - Slew the crane 90 degrees and check.
worn. - Proceed to check the backlash at four 90-degree
- If discs are coloured dark yellow to blue, the discs position in the rim.
have been overheated. Replace discs and springs. - Put the dial gauge on the tooth of the pinion. By
- Inspect sealings for wear. If sealings are defect manual turning at the input, the pinion can be moved
replace brake cylinder and piston with sealings to in both directions up to contact with the teeth. Now,
new ones. the tooth flank clearance can be exactly measured
on the dial gauge.
b. Brake heats - Check the backlash at one spot
Check the hydraulic pressure to make sure that it is - Slew the crane 90°. Check again
sufficient in order to disengage the brake completely. - Proceed to check the backlash at four 90-degree
positions in the rim
- Compare the four backlash values.
Checking and setting slewing rim Backlash values: See drawing "Slewing
backlash assembly".
An oversize backlash between the pinion and the The backlash shall be set at the position of the slewing
slewing rim will cause irregularities in the slewing rim with the lowest backlash value.
movement of the crane. Read this instruction carefully
prior to checking or resetting! Setting backlash
The backlash may be set by turning the entire gearset
Checking backlash one or more screw hole divisions.
The backlash should be checked by a dial gauge or
a feeler. When slewing the crane, the backlash may Proceed as follows:
vary from one position to another due to some slight - Slew the crane into the position with the lowest
excentricity of the slewing rim. It is therefore backlash value.
recommended to check the backlash at four positions - Remove all screws holding the gearset to crane
of the slewing rim. house floor.
- Release the disc brake hydraulically by means of a
Proceed as follows: manual pump.
- Check the backlash at one spot.
Note!
The turning of the entire gearset may be restricted by Upper part
the hoses connected or by space limitations. To over-
come this problem, release the upper part of the Screws
gearset by just removing the holding screws, see Fig.
3 ”Slewing gearset”.
Screws holding
Make sure that the upper part can be turned freely. gearset to crane
house floor
Turn the entire gearset (except the upper part), until
the desired setting is achieved. Watch the hoses!
Hydraulic Motors
Hoisting, Luffing, and Slewing Circuits
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Displacement: 40 cm3/rev.
Pre-filling volume: 1.0 litre (approx.)
Oil filling
Drain connection
Oil filling
Hydraulic motor 189 3383-801
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Hydraulic motor 189 6118-801
Drain connection
Oil filling
Drain connection
Before the first operation the hydraulic motor housing Oil filling
Drain connection
should be pre-filled with hydraulic oil.
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
Winches, Hoisting/Luffing
General
Assembly of winches
- Mount the winch together with winch support. The
clamping screws of the winch support must easily
be connectable.
- Tighten the screws according to torque
recommended. Secure with Loctite 242 or a
similar compound.
Oil filler inlet Oil outlet
- Connect brake line and release disc brake
Oil dipstick
hydraulically. The drive sleeve in the drive unit
must turn easy.
- Remove plug off the drive sleeve of the drive unit. Fig. 1. Hoisting and luffing winches with oil filler inlet,
For protection against corrrosion the drive sleeve dipstick and outlet.
is provided with gear oil from the gear. The plug
prevents a filling with oil of the motor flange before - Oil type: See instruction "Lubricants for Deck
mountage of the motor. Machinery", section 5.
- Before test-running, fill the motor flange completely - Check rope winch with running motor as to function.
with oil. Check above all the control and function of the
- Center motor in the motor flange. Fix motor with holding brake and the drive motor.
screws. Motor shaft must be grease-free. - After test-running check oil level once more with
- Remove plug off the vent pipe and mount the air oil dipstick. During the test-running, the oil level in
filter. the gear and motor flange is adjusting itself and
- Check oil level with oil dipsstick. Refill oil if fills the space around the motor shaft slowly with
necessary. gear oil. Therefore the oil level may be reduced.
- The rope winch is normally filled with oil. If the - If necessary, refill oil.
winch is supplied without oil, this is indicated on a - The journal bearing is filled with grease. Before
corresponding label. taking into operation grease again until grease
- Oil volume: See name plate on winch or instruction emerges at the sealing profile.
"Technical Data", section 2. - Insert rope and fix it. Secure screws accordingly.
Motor side
Hydr. part for
disc brake Pressure spring
Connect
pressure oil
Leakage oil
Arrangement of
Outer disc Inner discs Disc carrier
the brake discs
Gear side
Adjusting nut
Pressure roller
Locking nut
The motor does not run. Mechanical stop in the drive. Check system pressure. If the pres-
sure has risen to the relief valve set-
ting, remove the load from the drive.
The motor does not deliver enough Investigate the pressure level in the
torque because the pressure differ- system and correct the setting of the
ence across the motor is not great pressure limiting valve if necessary.
enough for the load.
Motor rotates in wrong direction. Oil supply connections to motor in- Connect the oil supply correctly.
correctly connected.
Motor runs jerkily. Pressure or flow fluctuations in the Find the cause in the system or in
hydraulic system. the driven unit.
Noise in the motor. The motor is being operated with the Adjust the charge pressure to the
charge pressure too low. correct level. See Hydraulic Circuit
- gauge connection 1.
External oil leakage on the motor. The radial lip seal is worn. Replace the radial lip seal.
Insufficient braking torque. The brake discs are worn out. Dismantle the brake and replace
the worn discs.
The brake does not open. Insufficient brake opening pres- See Hydraulic Circuit - gauge con-
sure. nection 2.
Motor only works at one speed. Pilot pressure low. Suitable pilot pressure. See Hy-
draulic Circuit - gauge connection
2.
The valve 1221 has stuck due to Inspect valve piston and remove
impurities in the oil. impurities.
All pumps are the straight axial piston type with - If the pressure is incorrect, an adjustment must be
variable displacement controlled by a servo valve made on the luffing pump(s) using the “zero setting“
mounted on the pump housing. screw, see Fig. 2. If there is more than one pump, the
upper pump should be adjusted.
The pumps are equipped with two adjustments, one for
“plussing“ and the other for pressure adjustment (max.
working pressure). “Plussing“ of the pumps is done to
compensate for internal leakage in pumps and motors
and to prevent load drops, see Fig. 2.
Actuate
Function checking/Adjustment of
“plussing“
Fig. 1. Valve 1221.
Hoisting winch
See Fig. 7.
- Actuate valve 1221 manually with a small screwdriver
or similar during checking and adjustment, see Fig. 1
and Fig. 7.
- Check the pressure according to hydraulic circuit dia-
gram.
- If the pressure is incorrect, an adjustment must be
made on the hoisting pump(s) using the “zero set- Electrical
ting“ screw, see Fig. 2. If there is more than one connector
Electrical
pump, the upper pump should be adjusted.
connector
Pressure cut-off valve
Luffing winch
Fig. 2. Pump A4VG 125.
- No load in hook.
- Install a pressure gauge, 0-400 bar, at connection
5.1, see Fig. 8.
- Raise the jib to min. outreach.
- By-pass limit switch GD4 (min. outreach) and GD3
(speed reduce to min. outreach). Drive with low
speed to cylinder max. outreach.
- Actuate valve 2221 manually with a small screwdriver Actuate
or similar during checking and adjustment, see Fig. 3
and Fig. 8.
- Check the pressure according to hydraulic circuit dia-
gram. Fig. 3. Valve 2221, 3221.
Note! These valves are sealed and the seals must not
be broken.
High speed
Fig. 4. Hoisting position. Fig. 5. Luffing position. Fig. 6. Slewing left or right.
Valve
1221
Valve
1663
Connection 3.1
Connection 3.1
Valve
2221
Connection 5.1
Valve 3661
Valve 3221
Connec-
tion 6.2
Connection 6.1
Introduction
The feed pump is placed on the pump unit. Before Notice! Before restarting the crane open valve
replacing the feed pump proceed according to 4335, otherwise the feed pump will be damaged.
below.
Pump unit
Suction hose
Valve 4335
Oil tank
Pump 4113
Pump
Valve
Fig. 1.
1 (1)
THIS PAGE IS INTENTIONALLY LEFT BLANK
SERVICE 6.142.5 E rev.: a 2002-01-09
Hydraulic hoses assembled inside crane house If the rubber in the hose is damaged so that the steel
should be inspected for damage every five (5) years, core can be exposed to corrosion the hose should be
see Maintenance Chart in section 5. replaced.
If the rubber in the hose is damaged so that the steel The hose couplings should also be inspected for
core can be exposed to corrosion the hose should leakage and damage of the corrosion protective Den-
be replaced. syl tape. If the corrosion protection is damaged so
The hose couplings should also be inspected for that the coupling can be exposed to corrosion the
damage and leakage. If the coupling is damaged or corrosion protection should be removed and the
severely corroded the hose should be changed. coupling inspected for damage and severe corrosion.
If the coupling is leaking the coupling should be tighte- If the coupling is damaged or severely corroded the
ned at first. If tightening does not help, the hose and hose should be changed.
the mating couplings should be changed, see Fig. 1. If the coupling is leaking the coupling should be tighte-
If the coupling is of flange type the O-ring and screws ned at first. If tightening does not help, the hose and
should be changed, see Fig. 2. the mating couplings should be changed, see Fig. 1.
If the coupling is of flange type the O-ring and screws
Hydraulic hoses and couplings should be changed, see Fig. 2.
assembled on outside of crane house
Replacement of hydraulic hoses
Hydraulic hoses assembled on outside of crane house
should be inspected for damage every two (2) years, All hydraulic hoses assembled inside crane house
see Maintenance Chart in section 5. should be replaced after ten (10) years due to safety
reasons.
All hydraulic hoses assembled on outside of crane
house should be replaced after five (5) years due to
safety reasons.
Hose coupling
Mating coupling
O-ring
Screw
Fig. 1. Hose coupling with O-ring. Fig. 2. Flange coupling with O-ring.
New design
Valve guard
Protective
Gas valve cap
Protective cap Gas valve Open/close
Valve guard hexagonal nut
Open/close
hexagonal nut
7. New design, see Fig. 1. Open the hexagonal nut 10. Close the nitrogen cylinder valve.
on the gas valve counter-clockwise to stop, by 11. Open the bleed screw of the three-way valve to
using a 19 mm fork wrench. discharge the pressure in the filling hose.
7a. Old design, see Fig. 2. Screw in the filling screw 12. Adjust the reducing valve to zero.
of the three-way valve but not so tightly that the 13. Unscrew the charging equipment from the nitro-
gas valve of the accumulator is damaged. gen cylinder and from the accumulator.
8. Fill nitrogen. 14. Check tigthness of accumulator gas valve, us-
9. New design, see Fig. 1. Check the nitrogen ing soap water.
pressure when the temperature and the pressure Note! - The protective cap shall be fitted with an
of the gas become stable. When the correct O-ring which must fit correctly into its groove.
charging pressure has been obtained, close the 15. Screw on protective cap of the gas valve.
gas valve by turning the hexagonal nut clockwise 16. After charging the accumulator, fit a lable carry-
by use of the 19 mm fork wrench. ing the charging date and signed by the operator.
9a. Old design, see Fig. 2. Check the nitrogen
pressure when the temperature and the pressure Note! For charging, it is not necessary to install a
of the gas have become stable. When the correct reducing valve on the nitrogen cylinder.
charging pressure has been obtained, again
back out the filling screw of the three-way valve.
Old design
Filling screw, to be
used for old design
Pressure gauge
Bleed valve connection
Hose
Max. 10 mm Max. 8 mm
Tightening Torques
Studs/Screws and Bolts
Introduction
Phosphatized bolts greased with Molykote R 1000 Untreated bolts greased with Molykote R 1000
(Also valid for bolts greased with Loctite 243 or oil.) (Also valid for bolts greased with Loctite 243 or oil.)
As a rule, always change screws with specified tight- Stainless bolts and hydraulic pipe couplings
ening torque on cranes in operation if the joint has to greased with Gleitmo paste
be opened for some reasons.
Thread Tightening torque in Nm
If any joint has been opened apply Intertuf after tight- d 10 Nm ≈ 1 kpm
ening the joint to avoid rust damage. Austenite (A)
50 70 80
6 3.3 7 9.3
8 7.8 17 22
SAE flange for high pressure hose couplings
10 15 33 44
Tightening torque in Nm 12 27 57 76
Flange Screw 10 Nm ≈ 1 kpm 14 43 91 121
6000 psi Class H 10.9 and 12.9 16 65 140 187
18 91 195 260
3/4" M10 54
20 127 273 364
1" M12 94
22 171 367 490
1 1/4" M14 150
24 220 472 629
1 1/2" M16 230
27 318 682 909
2" UNC 3/4 377
30 434 930 1240
33 585 1250 1670
36 755 1620 2160
39 969 2080 2770
Strength class Min. ultimate strength Min. tensile strength Corresponding strength
N/mm2 (kp/mm2) N/mm2 (kp/mm2) class of nuts
Examples of markings:
Hexagonal screw Allen screw
Strength class 4.6: Strength class 12.9:
BH 12 9 M
Hexagonal nut
Strength class 8:
Tightening Torques
Hydraulic Couplings
Example: GE 10 - LM
Table 1. Sealing
d = 10
Fitting
Sealing cone
Insert the sealing cone into the 24-degree coupling
fitting, firmly tighten the coupling by hand. Using a
wrench, tighten the coupling nut another 1/4 to 1/2
turn. The O-ring should preferably be oiled.
Important! Important!
It is of utmost importance to grease the wire thimble The wire rope thimble must be safely secured by
according to instructions "Lubricating Chart" and bending the lock washers, see Fig. 2 on page 2.
"Lubricants for Deck Machinery".
Number of reeving parts: Note! Before rigging slacken the pressure roller on
Luffing: 5 parts the hoisting winch. See Fig. 4.
Hoisting: 6 parts
Fig. 2. How to secure the lock washer for the wire Fig. 3. Rope reeving for Slack wire safety switch,
rope thimble. hoisting and luffing. Slack wire condition.
After replacement of wire the pressure roller on the - Tighten adjusting nut 12 turns to get correct spring
hoisting winch must be re-adjusted. force. Adjustment shall be done at full drum
condition.
- Tighten adjusting nut carefully until the pressure - Secure with the locking nut.
roller touches the hoisting wire on the drum.
- Check that the play (approx. 2 mm) between wire
and pressure roller corresponds to Fig. 4. Adjust
if necessary by changing location (rotation) of
frame bearings, see Fig. 4.
Approx. 2 mm
Full drum
Empty drum
Pressure roller
Frame
Locking nut
Warning!
There is a risk of falling down when opening or
closing the service door. Always use a safety belt!
Note! Before opening the service door you should A. Procedure for opening
always check the condition of the door hinges. Also
make sure that the doors are secured before opening, 1. Put on safety belt.
see Fig. 1. 2. Loosen the two nuts (1) and the washer (2), see
Fig. 2.
3. Unhook the eye bolt (3).
4. Swing service door outward.
Note! Do not forget to secure yourself using safety
belt.
5. Release the locking rod (5) from its parking posi-
tion by loosening the chapel strop (6), see Fig. 3.
6. Remove the screw (7) from its bracket.
7. Swing the locking rod (5) and secure it by use of
the screw (7).
1
2
3
4
Fig. 1. Securing service door to top of crane. Fig. 2. Opening service door.
Unloading steel wire ropes It is advisable to lift a reel by means of a shaft which
is put through its axis bore.
When handling a steel wire rope, the first trouble
often occurs immediately upon receiving it: the fork
of the fork lift truck is either placed under the reel
or inside the coil.
If outdoor storage cannot be avoided the ropes must Unwinding steel wire ropes from the reel
be covered in a way that moisture cannot create
corrosion problems. Although plastic foil protects An unreeling stand (turnable) should be used to
the ropes from rain, condensation from beneath unwind a wire rope from its reel.
might not be able to escape and could damage the
ropes permanently. To avoid condensation prob- Another accepted unreeling method is to mount the
lems, it is advisable to use breathable water-proof reel on a shaft supported by two jacks or a stand.
fabric covers readily available from tarpaulin manu-
factures.
Under no circumstances must the rope be pulled If one end of the ropes has a fitting attached, as it
off a coil while it is lying on the ground or looped is mostly the case with deck cranes, there is no
over the head of the reel, because this will inevita- other possibility than pulling the loose rope end
bly induce one torsion per wrap into the rope. through the whole reeving system.
The most advantageous way of installing a steel Below is shown an example of a typical deck crane,
wire rope varies from crane to crane. In any case a where the rope must be spooled from the reel via
procedure should be chosen that (under justifiable sheaves S1 through S9 onto the drum.
expenditure) guarentees the least risk of torsions
and avoids damage to the rope by contact with parts
of the construction.
Here, special attention must be paid to the hook tional wire ropes one must at least make sure that
block. It must be secured in an upright position so they have the same direction of lay as rope to be
that the rope can be spooled without any fleet an- installed.
gles occuring between the rope and the block´s
sheaves. If the new rope is pulled in with help of the used
one, the two rope ends are often buttwelded to-
gether. A connection of that kind can transfer the
Winding the steel wire rope from the reel twist of the old rope, built up in the reeving system,
onto the drum into the new rope. By that method of installation the
new rope may be extremely damaged.
During the manufacturing process every steel wire
rope receives its preferred bending direction when There are even more reasons why that procedure
being drawn from the wire rope closer by means of is highly problematic: It is true, that when using spe-
a capstan. When delivered to the customer the rope cial electrodes the welded connection presents
is bent in that direction. Make certain that it bends acceptable results in a pull test with a straight rope;
in the same direction when it is wound from the reel but because of the great length of rigid connection
onto the drum. zone the very same connection could break due to
the enormous bending stresses when running over
sheaves.
When installing a lang lay rope one must take care Under no circumstances should one attempt to gen-
that the Chinese finger cannot unwind from the rope erate the tensioning load by jamming the rope, for
like the nut from a screw. It is recommended to wrap instance between two boards. Structural changes
a tape around the whole rope length to be held by would deform the rope beyond repair.
the Chinese finger to increase the friction.
"Breaking-in" the steel wire rope The rope and this wire end are now wrapped mov-
ing away from the location of the intended cut.
After the rope has been installed and before it is
going to do its proper job, several run-throughs of
the normal operational circle should be carried out
under light load. The new rope
should be "broken-in", so that the
component parts can settle and
adjust themselves to the actual The rope is tightly wrapped for a distance of approx.
operating conditions. It is most un- three rope diameters.
fortunate that in practice only too
often the exact opposite of this
recommendation is performed:
quite frequently after installing the
rope overload tests are carried out
with loads beyond the safe work-
ing load of the system. Both ends of the seizing wire are then pulled tight
and twisted together for a length of one rope diam-
eter.
Cutting steel wire ropes
Quite often the lubricant is applied at a sheave, If during an inspection ends of broken wires are
sometimes a continuous drip method is used. If only detected which might cross adjacent wires and
a little lubricant is required, pressure spray nozzles destroy them when running over sheaves, these
can be applied. broken wire ends must be removed.
Maximum penetration of the lubricant into the gaps Under no circumstances should the broken wire
of the rope, can only be quaranteed if high pres- ends be pinched off with a pair of nippers. The best
sure lubrication is applied with the help of a pres- method is to move the wire ends backwards and
sure lubricator. forwards until they break deep in the valley between
two outer strands. With thicker wires a tool should
With this method the two halfs of a sleeve, which is be moved backwards and forwards on the surface
equipped with rubber sealings, are clamped round of the rope, thus bending the wires until they break.
the rope and screwed together. While the rope runs
through the lubricator the lubricant is pressed into
the sleeve at a pressure upto about 30 bars.
Severe corrosion.
Contraction rupture caused by excessive stress, Wear and identations of surface wires also promote
(e.g., if a slack line suddenly snaps taut under full fatigue and lead to premature wire rupture.
load).
Crown wires of outer strands may wear so thin that Corrosion may cause wire ropes to break. As a
the residual cross sectional area of steel in the rope safety measure, inspect ropes regularly and care-
will not support the normal design load and con- fully to prevent catastrophes; observe manufactur-
traction rupture may ensue. er's instructions
Replacement of Wires
One or Two Fall Rigging
General
This instruction covers almost all MacGREGOR - Run the winch by pulling in the new hoist wire, so
cranes type GLB, which are equipped with limit switch that there are the same numbers of revolutions of
boxes containing electric limit switches. The wire on the wire drum as noted earlier and that the
procedure is general and should be seen as a winch corresponds to the position marked earlier .
guidance only. - Attach the wire rope end to the wire drum with the
wire rope clamps and tighten the bolts.
- Assemble the limit switch box in its proper place,
Hoisting winch / wire
the marking on the shaft/box must correspond.
For cranes with one or two fall rigging proceed as
- Run in the rest of the wire.
follows:
NB. The wire thimble should be safely secured,
- Place the jib in the jib rest.
see Fig. 6 or 7.
- Slacken the pressure roller on hoisting winch, see
- Remove the wooden piece holding the slack wire
Fig. 9.
roller.
- Disengage the slack wire switch by blocking the
- Test the winch and check all limits, which should
spring tensioned roller, which can be done with a
now function correctly, if the new wire is the same
piece of wood, see Fig. 1.
length as the old one. If necessary, adjust the limits,
- Loosen the wire rope thimble attached to the crane
see instruction under section 6.3.
house top, see Fig. 6.
- Readjust the pressure roller, see Fig. 9.
- Run the winch by paying out the hoist wire, and at
the same time pulling on the loose wire end.
- Stop the winch just before it enters into the empty Luffing winch / wire
drum limit. - Place the jib in the jib rest.
- Mark the position of the wire drum in relation to the - Disengage the slack wire switch by blocking the
bracket, this to avoid setting of all hoisting limits spring tensioned roller, which can be done with a
again after installing the new hoist wire. piece of wood, see Fig. 1.
- Remove the cover from the limit switch box. - Loosen the wire rope thimble attached to the crane
NB. Mark the position of the shaft in relation to the house top / jib, see Fig. 6 or 7.
box. See Fig. 2. - Lower the luffing wire rope to the deck by means
- Loosen the bolt that holds the limit switch box. of a rope.
- Remove limit switch box. - Mark the position of the wire drum in relation to the
- Note how many revolutions of the wire there are bracket.
left on the drum at this position. Make a mark on - Remove the cover from the limit switch box.
the drum. NB. Mark the position of the shaft in relation to the
- Secure the wire so the wire clamps that hold the box, see Fig. 2.
end of the wire can be removed safely. - Remove the limit switch box.
- Attach a long rope (longer than the wire rope) to - Note how many revolutions of the wire there are
the wire end, and place it 4 to 5 turns around the left on the drum at this position. Make a mark on
wire drum. the drum.
- Run the winch by paying out the old (damaged) - Secure the wire so the wire clamps that hold the
wire until it is on the deck. end of the wire can be removed safely.
- Attach the new hoist wire to the same rope by using
tool 662 0754-000, see Fig. 5.
- Attach a long rope to the wire end (longer than the Hoisting Piece of wood
wire rope ≈ 100 x 200
wire rope) and place it 4 to 5 turns around the wire
drum.
- Run the winch by paying out the old, damaged
luffing wire, and at the same time pulling on the Luffing wire rope
Limit box
Winch drum
Bracket
Fig. 3. Limit switch box, hoisting winch. Fig. 4. Limit switch box, luffing winch.
Hoisting
Example
Luffing
Example
Fig. 8. How to secure the lock washer for the wire rope thimble.
Approx. 2 mm
Full drum
Empty drum
Frame bearing
Pressure roller
Adjusting nut
Adjust play by rotating Frame
the washer/bearing.
Frame bearing
Locking nut
Fig. 9. Hoisting winch with pressure roller.
General
To ensure safe working conditions and long lifetime of The wear, see Table 1, can certainly occur on every
the wire rope it is important to inspect the condition of spot where the wire rope is in contact with the wire
the wire sheaves. sheave, not only on places shown in Fig. 1.
t a
max
16 4
12 3
10 2.5
8 2
6 1.5
Lifting Block/Beam
Warning!
Where equipment has swivelling and moving parts
there are potential safety hazards. Care should be
taken when working with or repairing equipment. If
used incorrectly, breakage could occur injury or
death.
Lubrication
Limitation of use
Table 1.
Proof load for lifting blocks with 2-part rigging
Class Working load limit Proof load
ABS PL = 2 x WLL
BV WLL < 25 T PL = 2 x WLL
25 T < WLL < 160 T PL = (0.933 x WLL) + 27
WLL > 160 T PL = 1.1 x WLL
DNV PL = 2 x WLL
GL WLL < 25 T PL = 2 x WLL
WLL > 25 T PL = (1.22 x WLL) + 20
LRS WLL < 25 T PL = 2 x WLL
WLL > 25 T PL = (1.22 x WLL) + 20
WLL = Working Load Limit (SWL)
T = 1 metric ton = 1000 kg
PL = Proof Load
General
The slewing bearing is an essential part of the crane It is important to use about the same position for all
and must be well maintained. Over the years the further measurements to be able to compare the
slewing bearing will have some wear, and to be able measurements.
to know if there is a need for changing the slewing
bearing it is needed to keep a record of the wear. With the jib at maximum outreach two measurements
are to be taken, see Fig. 1.
The initial measurements should be taken when
the crane is installed at yard or within 2 months With the jib at minimum position one measurement is
from crane installation. to be taken, see Fig. 2.
If the wear measurement shows wear, grease Enclosed table can be used to record the
samples can be taken for analyze. See procedure on measurements.
page 5.
Note!
Measurements should be recorded with an accuracy
Measuring of 0.1 mm.
The measurements should be taken regularly, every If B - C = 0, or negative, the measurement is wrong.
6 months. Measurements can be sent to If B - A is greater than 7 mm the crane must not be
MacGREGOR Cranes, Örnsköldsvik, Sweden for used.
evaluation.
Maximum allowed play is:
Note! for roller bearings 1.5 mm
When measurements are to be taken the ship shall for ball bearings 3.0 mm.
have as little list/trim as possible.
Procedure
First time a measurement is to be taken two reference
points on the crane's bottom plate must be marked.
These reference points shall then always be used at
any future measuring, see Fig. 3.
Measurement B
(back of crane) Empty hook
Measurement A
(front of crane)
Measurement C
(back of crane)
Jib direction
Min. outreach,
empty hook
Reference point
Reference point
Stb
Aft
Ps
Crane No.: 2
Measurement (accuracy 0.1 mm) Play Jib direction
Jib at max. outreach Jib at min. outreach
A (front of crane) B (back of crane) C (back of crane) B-C
Fore
Stb
Aft
Ps
Crane No.: 3
Measurement (accuracy 0.1 mm) Play Jib direction
Jib at max. outreach Jib at min. outreach
A (front of crane) B (back of crane) C (back of crane) B-C
Fore
Stb
Aft
Ps
Crane No.: 4
Measurement (accuracy 0.1 mm) Play Jib direction
Jib at max. outreach Jib at min. outreach
A (front of crane) B (back of crane) C (back of crane) B-C
Fore
Stb
Aft
Ps
Following information is necessary in order to give a - Clean up the seal and the surrounding areas where
correct statement and allow further advice: the sample will be taken. When cleaning the area
of the seal, prevent the cleaner from contacting the
1. Type of grease used at lubrication (manufacturer seals or from entering the raceway's system.
and type). - Push new grease into the grease nipples / bearing
2. Lubrication intervals (crane running hours or without rotation and collect the first used grease
months). which will come out at the seal.
3. Crane running hours.
4. Information where the samples are taken. Attention: Do not take fresh grease for analyzing!
The required quantity of grease for analyzing is
As a correct procedure of grease sampling is very approx. 2 cm3.
important below procedure should be followed.
The normal interval for grease sampling is 12 months.
Procedure
- The grease sample should be taken at the inner
seal of the bearing, see Fig. 4.
- One sample should be taken in the area under jib
and one sample 180° in opposite direction.
Grease sampling
area (inner seal)
Grease sampling
area (inner seal)
The encoder calibration has to be done when the wire Caution! Position the minimum jib outreach. Do a
or the absolute encoder has been replaced. visual inspection of the distance between the front of
the crane house and the first jib stay on jib.
Absolute encoders for hoisting and luffing winches
are installed in the limit switch box or on jib bearing. - Carefully position the jib to minimum jib outreach
until the measure of "MV" is achieved.
For slewing motion the absolute encoder is mounted - Measure the distance "MV" on top of the crane
under the crane towards the slewing bearing. house, see Fig. 1, according to table in Technical
Data, section 2.
MV
(m
m)
First jib stay
Measure of
the distance MV
Preparation of hoisting
Preparation of slewing
0°
Hoisting Luffing/slewing
1. Push the "Select/Info" button on the front of the To calibrate the encoder on the other cards proceed in
MC-card which you want to calibrate, for example the same way as in items 1, 2, and 3 in above
Ho-card. The display on the Ho-card shows paragraph except for choosing the corresponding card.
"ERROR".
2. Push the "Down/Exit" button on the Ho-card front.
The display on the Ho-card shows "CAL".
3. Push the "ENCODER CALIBRATION" button in
the CT2 cabinet. The display in the Ho-card then
starts flashing, showing "ANG".
Push the "Select/Info" button on the Ho-card.
Angle encoder is calibrated in this position.
ENCODER
CALIBRATION
Display
button
Select/Info
button
Up button
Down/Exit
button
Troubleshooting
Crane Control System CC3000
CT2
Contents
1. Description of input and output signals ............................................................................................. 2
2. Control system input and output signal levels................................................................................... 5
3. Troubleshooting for the control system............................................................................................ 8
4. Spare parts ....................................................................................................................................... 12
1.1 General
The following description refers to the
microcomputer based crane control system
CC3000 for MacGREGOR hydraulic deck cranes.
The overload pressure switch makes the MC card Each MC card has two separate outputs. They are
control program to switch over from high speed to used for selecting low speed or high speed for the
low speed operation or, if already in low speed, hoisting movement and for the unloading function
stopping the hoisting and luffing crane movement. for the luffing movement. Each output giving a fixed
The input signal from the overload pressure switch 24V output with a maximum current of 2A. The
is often only seen as a short pulse. system is capable of detecting short-circuited
output and then giving an error-message, see sign
ERROR MESSAGES.
1.9 Pump solenoid outputs
Each hydraulic pump has two solenoid valves, one 1.12 Low feed pressure input
for each direction of the oil-flow. The solenoids are
controlled with a 24V PWM (Pulse Width The low feed pressure switch indicates that the
Modulated) signal with current feedback control. If pump feed pressure is too low for safe operation.
wanted output current is not reached (due to short- Output signals to pumps, displacement/unloading
circuit, open-circuit or MC card failure) the system valves and brake relief valves are immediately
then gives an error message, see sign ERROR switched off. If the low-pressure signal comes
MESSAGES. Each MC card is capable of back within approx 0.3 s the crane operation
controlling a maximum of four pumps with a total of continues with the same output signal levels as
eight output drivers, one for each solenoid valve. before the pressure drop. However, if short
Each driver is capable of outputting a maximum pressure drops are repeated 4-5 times within a
current of 1A. To obtain the value of the current it is short period of time the crane operation is stopped
possible to get it on the display on the cards in CT2 and starts 4-5 seconds after the feed pressure has
cabinet. a stable high level again.
1.10 Brake release/direction valve 1.13 Lamp output "Control System Error
outputs in CT2"
Each MC card has an output driver for the brake The LED no 28 on the CC Card are wired to a lamp
release signal (or direction valve for cranes in crane operator's cabin. The first time an error
equipped with cylinder luffing). The system is occurs, the lamp flashes. When the error is
capable of detecting short-circuited output and then acknowledged by pushing the Select/Info push-
giving an error-message, see sign ERROR button on the appropriate MC or CC card the lamp
MESSAGES. is on if the error remains or out if the error is not
present for the moment. See chapter 3.5 for
detailed information about error messages.
Pump PWM signals for Hoisting Pump1 24V, 0 to approx. 600 mA, error
CT2-X10:233
Hoisting output message if wanted current not
CT2-X10:234 Ho
Lowering output achieved. 1mA gives approx.
CT2-X10:235
Current return and current measure input 1mV.
Pump PWM signals for hoisting pump2 (if fitted) 24V, 0 to approx. 600 mA, error
CT2-X10:236 Ho
Hoisting output message if wanted current not
CT2-X10:237 Ho
Lowering output achieved. 1mA gives approx.
CT2-X10:238 Ho
Current return and current measure input 1mV.
Pump PWM signals for luffing pump1 24V, 0 to approx. 600 mA, error
Luffing In output CT2-X10:333 Lu message if wanted current not
Luffing Out output CT2-X10:334 Lu achieved. 1mA gives approx.
Current return and current measure input CT2-X10:335 Lu 1mV.
Pump PWM signals for luffing pump2 (if fitted) 24V, 0 to approx. 600 mA, error
Luffing In output CT2-X10:336 Lu message if wanted current not
Luffing Out output CT2-X10:337 Lu achieved. 1mA gives approx.
Current return and current measure input CT2-X10:338 Lu 1mV.
Pump PWM signals for slewing pump1 24V, 0 to approx. 600 mA, error
Slewing Left output CT2-X10:433 SL message if wanted current not
Slewing Right output CT2-X10:434 SL achieved. 1mA gives approx.
Current return and current measure input CT2-X10:435 SL 1mV.
24V, 0 to approx. 600 mA, error
Pump PWM signals for slewing pump2 (if fitted)
CT2-X10:436 SL message if wanted current not
Slewing Left output Slewing Right output
CT2-X10:437 SL achieved. 1mA gives approx.
Current return and current measure input
CT2-X10:438 SL 1mV.
Limit switch inputs hoisting 24V at normal operation, 0V at
CT2-X10:214
Hoisting Ho limit. At limit movement is
CT2-X10:215
Lowering, slack wire stopped and brake closed.
Speed-reduce limit inputs hoisting
CT2-X10:211 Ho 24V at normal operation, 0V at
Hoisting
CT2-X10:212 limit.
Lowering
Limit switch inputs luffing 24V at normal operation, 0V at
CT2-X10:314 Lu
Luffing In limit. At limit movement is
CT2-X10:315
Luffing Out, slack wire stopped and brake closed.
Speed-reduce limit inputs luffing
CT2-X10:311 Lu 24V at normal operation, 0V at
Luffing In
CT2-X10:312 limit.
Luffing Out
Limit switch inputs slewing 24V at normal operation, 0V at
CT2-X10:414 SL
Slewing left limit. At limit movement is
CT2-X10:415
Slewing right stopped and brake closed.
Speed-reduce limit inputs slewing
CT2-X10:411 24V at normal operation, 0V at
Slewing left SL
CT2-X10:412 limit.
Slewing right
CT2-X10:256
Slack wire
CT2-X10:356
CT2-X10:219 Ho
24V at normal operation, 0V at
Pressure switch input for low feed pressure CT2-X10:319 Lu
low feed pressure.
CT2-X10:419 SL
Pressure switches for overload CT2-X10:220 Ho 24V at normal operation, 0V at
CT2-X10:320 Lu overload.
Output "Error in control system CT2" CT2-X10:128 Sc 24V outputs wired together to
error lamp in drivers cabin.
Output for "Speed dependent" overload 24V when the hoisting speed is
CT2-X10:229 Ho
function (if fitted). less than approx. 3 rpm.
Ho 24V when the hoisting pressure
Output for "Hoisting Overload" indication lamp CT2-X10:255
Lu exceeds adjusted value.
24V input from cabin switch,
CT2-X10:217 Ho
Speed reduction, input signal ext. 1 (bit 0) to such as Grab operation, Parking
CT2-X10:317 Lu
reduce normal operation speed (utilization). Lock Slewing, Power Limiter,
CT2-X10:417 SL
Twin operation, etc.
Speed reduction, input signal ext. 2 (bit 1) to
CT2-X10:218 Ho
reduce normal operation speed (utilization). 24V input from cabin switch,
CT2-X10:318 Lu
Same as above, but could be used with same as above.
CT2-X10:418 SL
different utilization.
Prevent high speed function. If installed. CT2-X10:210 Ho 24V input from switch in cabinet
CT2. Two-position switch
“Normal/Low speed”
3.1 General
This section provides information for identifying and When troubleshooting a malfunction: Locate the
correcting malfunctions, which may develop while symptom or symptoms that best describes the
operating the cargo crane. Before performing malfunction. If the appropriate symptom is not
troubleshooting, read and follow all safety listed, notify your supervisor.
instructions found in section "General", section 1, of
this manual. This chapter cannot list all Read this section in conjunction with the electrical
malfunctions that may occur, nor all inspections and hydraulic diagrams provided in Group 9.5 and
and corrective actions. If a malfunction is not listed, 9.4.
or is not corrected by the listed corrective actions,
notify your supervisor.
Both lamps One or both lamps are Check the error code in
are off. flashing or on. Control System cabinet
CT2.
See chapter 1.4 for explanation of the control lever • Push the “Select/Info” button once on the
functions. card with error LED flashing. An error code
• Check for missing Green input signal LEDs - (e.g. E51_11) is shown on the display on the
from joystick. card.
• Check electric cable connections to control • Hold on pressing “Select/Info” button, the
lever. description of this error will be rolling on the
• Check analogue input signal from joystick display. Release the button, the description
potentiometer. disappears and the error code is shown.
• Check for missing Green output signal • Continue to press “Select/Info” or
LEDs: Exchange the MC card with other “Down/Exit” button once to see the next error
movement MC card. Replace broken MC and so on.
card with a new one. • Pressing “Up” button once to show the
previous error and so on.
Check direction and brake valves • When there are no more error messages,
the display shows three hyphens “---”. When
all errors have been shown on the display,
See hydraulic circuit diagram in Spare Parts Manual,
the error LED is either on or off.
group 9.4.
• All errors can be shown round and round if • How to see the remaining errors after
you continue pressing “Select/Info” or acknowledging (i.e. error LED is always on)?
“Down/Exit” button or “Up” button. • Errors can show again from normal mode
when pressing “Select/Info” twice.
LED flashing New error, not acknowledged • Pressing “Up” or “Down/Exit” button to see
the previous respective next error, following
LED on Error remains, now
the same instruction above.
acknowledged
LED off No error present at the moment
Note!
Before reporting to MacGREGOR Cranes in
• The display returns to normal mode (Sc, Ho, Örnsköldsvik, please look for the error code in the
Lu, Sl, Cl, Au, Ec, Tl, Tr, Li, Io) 15 seconds display of the MC or CC card and use the
after one of the three buttons was last
“Select/Info” button to view all error codes. It is
pressed, or holding on pressing “Down/Exit”
button longer than one second. essential that all faults to be corrected to allow the
• If the system is restarted (i. e. 24V power crane to function correctly.
supply is switched off for a short time) all
alarms disappear and only reappear when
the error recurs.
Error MP SP
Encoder
Calibration
Sc-Card
Display
Select/Info button
Up
Down/Exit
4 Spare parts
Look for:
- The software version and the hardware
specified on both handles on the replaced card.
or
- refer to the crane's mfg. no., which can be found
on the sign in crane operator's cabin.
or
- Refer to section 9.5 in the instruction manual.
Introduction
General maintenance of the electric equipment of the
crane is important in order to prevent unexpected
breakdowns. The following general advice may be
useful. Relevant block diagrams and detailed circuit
diagrams can be found in section 9, SPARE PARTS.
Slip-ring unit
Danger!
Before opening the slip-ring unit, make sure that
power supplied by separate transformers is switched
off in the ship's engine room. Also check by means of
a voltmeter that the slip-ring unit is not alive.
Oil thermostats
BT 2
The task of the oil thermostat is to protect the crane
against overheating.
BT 3 (Optional)
The task of the thermostat is to start the oil cooler
when the oil reaches +45oC when crane is set to winter
position.
Slip-Ring Unit
Danger!
Before opening the slip-ring unit, make sure that The function of the slip-ring assembly may not be
power supplied by separate transformers is changed in any way. Especially safety devices must
switched off in the ship's engine room. Also check not be made ineffective. Other than during mainte-
by means of a voltmeter that the slip-ring unit is not nance and inspection work the housing must al-
alive. Make sure that the current can not be ways remain closed.
switched on again during the maintenance
operation. Use only insulated tools and original spare parts.
Connection crane
Slip-ring unit
Mounting screws
Connection box
Connection ship
power Guide pins
Driver
Rubber protection
Note! Must be
tightened.
Removal Maintenance
1. Park the jib in a suitable manner. Always cut current before accessing the collector
2. Disconnect the ship's power supply at all points for inspection or maintenance. Make sure that the
of feed. current can not be switched on again during the
3. Disconnect all the cables connection from crane- maintenance operation.
and ship supply.
4. Remove the driver. Note the cables' mounting At regular intervals
sequence.
- Check collector for damaged parts
5. Remove mounting screws holding the slip-ring
- Check contact pressure of brushes
unit to the platform. See Fig. 1.
- Check brush holders
6. Remove the slip-ring unit.
Introduction
LOW OIL LEVEL CHECK OIL FILTER
To prevent operation of the crane with too little oil in
the hydraulic oil tank, an oil level float switch is
installed in the oil tank. The level float switch opera-
tes alarm signals on the control panel in the crane
operator’s cabin and a siren. Warning lamps and a
selector switch are placed on the right-hand control
panel in the cabin (see Fig. 1). In normal operation,
the switch should be in the position shown in the il- FLOAT SWITCH
Normal
lustration.
Siren By
off pass
FLOAT SWITCH
SIREN Normal
Siren By
off pass
BT2
85°C
HIGH OIL TEMP
The movements and outreaches of the crane jib and This function prevents the jib from mechanical
hoisting block are controlled by limit switches in the touching of the hook block when luffing out, see
limit switch boxes. At large outreaches there is a risk page 6. If the crane is equipped with high hook,
that hook block and jib top will meet and that is taken values for outreaches for both luffing and hoisting
care of by crane's safety system, see page 7 and 8. winches can be found in tables in instruction
Some cranes are equipped with extra limit switches "Tecnical Data", section 2.
to prevent this, see paragraph "High Hook (optional)".
Limit switches
The limit switch boxes of the hoisting and luffing Limit switch box,
luffing winch
winches are similar except for the demultiplication
ratios of their driving gearboxes. Limit switch box,
hoisting winch
The cams in the luffing winch limit box are marked
BL1, BL2, BL3 etc.; those of the hoisting winch box,
BH1, BH2, BH3 etc.
K
Measure line Jib radius
5°
Adjustment screw
Fig. 4. Jib radius lifting height.
Fig. 3. Cam.
AT and AL measures (wire lock side), - from the Limit switches - Luffing winch
side of the empty drum flange side to the side of the
wire, see Fig. 5 and 6. The included limit switches are shown in the below
figs. Note that switches BL2 and BL4 actuate speed
BT and BL measures - second layer, from the side reduction of the crane jib.
of the full drum flange side to the wire, see Fig. 5
and 6. Note! When adjusting the luffing limits it is important
to start with BL1 and to continue according to Fig. 8.
Values of AT, BT (luffing) and AL, BL (hoisting) can For measurement values see table "Basic limit
be found in instruction "Technical Data", section 2, switches" in Technical Data.
see tables for hosting and luffing winches.
When changing wires it is important that the proce-
dure in instruction "Replacement of Wires" in section
6.2 is followed, thus to avoid readjustments of limits.
BL1
Wire lock side BT - Full drum flange
side/second layer BL2
BT BL3
AT
BL4
BL5
BL6
BL7
~
~ ~
Fig. 5. Luffing winch outreaches.
BL13 ~
BL14
BL15
AL - Empty drum flange side/
At least three locking turns/Tank top BL16
BL1
MV
(m
m)
First jib stay
Measure of
the distance MV
Raise the jib into the MIN Jib radius position, which is BH3
the correct jib position for setting the limit switches BH4
according to the below figures. Note that the switches
BH5
BH2 and BH3 actuate speed reduction of the crane
hook. BH6
BH3
BH 3
Speed reduce,
full drum H spr (m)
H (m)
Speed reduce,
empty drum K spr (m)
K (m)
BH 2
Speed reduce
= Stop position.
E spr (m)
This function prevents the jib from mechanical
E (m)
touching of the hook block when luffing out.
*) If high hook is applicable then BL7 and BL8 are used.
Limit switch BH5 (speed reduce switch, hoisting) takes NA = High hook is not applicable.
care of the area . See Technical Data, section 2.
Speed reduce.
Limit switch BH6 (detector switch) takes care of the
area and gives signal to BL8 (stop cam, luffing) Stop. To by-pass those positions correct operation
mode has to be selected by help of the key switch
if the hook block is in the wrong area. in cabin.
There is no stop function on the hoisting winch. Fig. 12. Extra luffing limit switches, high hook.
Detector switch BH6 prevents the jib from mechanical
touching of the lifting block.
BH4
F ds - Detector switch
ib E (m) BH(X)*)
c/c j Note! To be set
Stop limit at maximum
F spr (m)
outreach (BL3),
BH(X) *) luffing winch.
Speed reduce switch
towards jib top
Note! If the crane is equipped with a high hook The cranes are designed, calculated and manufac-
function, this is not applicable. tured in accordance with and approved by classifica-
tion societies.
In a certain area there is a possibility that hook block
and jib top will meet. See Figs. 14 and 15. This will A slacking luffing or hoisting wire rope should stop
not cause any problem as the cranes safety system the luffing out and hoisting movements by use of the
takes care of it. slack wire switch BWL1.
It is only possible for the hook block to reach jib top at Hook block hoisting the jib:
large outreaches. - This actuates the slack wire switch BWL1 and the
hoisting movement stops.
The hook block and the crane jib is designed and
calculated to take care of the forces which occur when Jib landed on the hook block:
the hook block is hoisting the jib top or the jib top - Luffing wire slackens and the slack wire switch
lands on the hook block. BWL1 actuates. The luffing out movement stops.
Lifting height
H (m)
Block touches
jib top
jib
c/c
Jib bearing
centre Outreach (m)
Hook stop
Hook stop
Functional test, hoisting The lifting block may lay flat on the ground/deck and
the slack wire device may still not be activated.
Lower the hook block on to the deck to slacken the
hoisting wire rope. Hoist the hook in order to check
This is most evident at minimum outreach. In these
that the switch returns properly.
cases there will probably never be a slack at the winch
and therefore never an automatic stop of the lowering
motion.
Switch
Arm
Slack wire safety switch. Normal condition. Slack wire safety switch. Slack wire condition.
The release of the brakes of the hoisting, luffing, and Contact between the two "brake releasers" and the
slewing functions is facilitated by employing a hand crane operator is absolutely essential, e.g. by use of
pump designed for this purpose. Quick couplings and head-sets.
shut-off valves are also installed in the hydraulic
system of the crane for this purpose. All necessary material comprising this emergency
equipment including the hydraulic pressure source are
included in the supply. See Fig. 1.
Pressure
gauge1D
T-coupling to MA on
pump, hoisting or luffing
Needle valve 3B
Flow control valve 3A
Connection to quick
coupling (4333) to tank By-pass line Bushing Screw
MA (gauge
connection 3.2)
CAUTION! MB (gauge
- This work has to be done with great care by skilled connection 3.1)
personnel.
- Only one function to be activated at a time.
- Verify that nobody is within the working area of the
crane.
- Ball valves 1663, 2661 and 3661 must not be actu-
ated except in emergency brake release operation.
CAUTION!
Hose must be connected to MA-port (gauge By-pass line,
included in
connection 3.2) on hoisting pump to avoid emergency
uncontrolled lowering. equipment
3B
Flush-unloading unit 1128
3A
Ball valve 1663
Connection P
Pilot hoses
(disconnected)
Directional valve 1221
Wedge
valve 4332
Oil tank
Quick
coupling
4333
Quick
coupling1664 Pilot hose,
disconnect and plug **)
Hand pump 1A
**)Plug to pilot hose and included in pump set,
Function
The emergency lowering system works in such a way - Connect the hoses from the hand pump as shown in,
that the motor hydraulically controls the load. If the Fig. 2, and in the hydraulic diagram Fig. 4.
motor tends to overspeed, by the force from the load, - Disconnect the pilot hose from connection “P”, flush-
the brake will close. unloading unit 1128. Plug the disconnected hose.
See Fig. 2, 3, and 4.
Hand pump 1A builds up pressure on the low pressure - Remove check-restriction valve 1241-1 from flush-
side of the motor and on the brake. The pressure can unloading unit 1128, see Fig. 3.
be read on pressure gauge 1D. The brake opens at - Attach the bushing and screw into coupling in
approx. 1.2 MPa. Oil from the high pressure side (pump connection “P”, flush-unloading unit 1128-1. Screw
MB-port) goes through the needle valve 3B and flow in the threaded bushing up to the neck, screw to
control valve 3A to the low pressure side (pump MA- actuate the piston to blocked position. See Fig. 3.
port). Flow control valve 3A is fixed and load - Close ball valve 1663 and open wedge valve 4332.
independent. With a load in the cargo hook, needle See Fig. 2 and 4.
valve 3B can be completely or partially closed in order
to reduce the speed.
Operation
Release the brake by pumping oil from the hand pump.
Connection, see Fig. 2 and 4 The load must be lowered slowly and carefully controlled.
- Install the hand pump to the base plate using the Speed can be reduced by closing needle valve 3B,
provided screws. partially or completely.
- Disconnect pilot hoses at MA- and MB-port on the
pump. The load must be lowered slowly by pumping in a
- Connect the by-pass line. See Fig. 2 and 4. slow and even pace.
Caution!
Twin operation
It is of most importance that the hoses to MA and
The twin beam must be as horizontal as possible during
MB are not switched, because the load could be
emergency lowering.
dropped.
After operation
After the lowering operation is completed, reset the
crane to “NOT EMERGENCY COUPLED“ and close
wedge valve 4332 and open ball valve 1663. See
Fig. 2 and 5.
Bushing
Screw
Piston
3B
3A
Gauge
connections
removed
3B 3A
By-pass line
Oil tank
Connection P Quick
coupling
4333
Function
The emergency lowering system works in such a way - Remove check-restriction valve 2241-1 from
that the motor hydraulically controls the load. If the unloading unit 2127, see Fig. 7.
motor tends to overspeed, by the force from the load, - Attach the bushing and screw into coupling in con-
the brake will close. nection P, unloading unit 2127. Screw in the
threaded bushing up to the neck, screw to actuate
Hand pump 1A builds up pressure on the low pressure the piston to blocked position. See Fig. 7.
side of the motor and on the brake. The pressure can - Close ball valve 2661 and open wedge valve 4332.
be read on pressure gauge 1D. The brake opens at See Fig. 6 and 8.
approx. 1.2 MPa. Oil from the high pressure side (pump
MB-port) goes through the needle valve 3B and flow Operation
control valve 3A to the low pressure side (pump MA-
Release the brake by pumping oil from the hand
port). Valve 3A is fixed and load independent. Valve
pump.The jib must be lowered slowly and carefully
3B can be completely or partially closed in order to
controlled. Speed can be reduced by closing needle
reduce the speed.
valve 3B, partially or completely.
Connection, see Fig. 6 and 8 The load must be lowered slowly by pumping in a slow
- Install the hand pump on the base plate with screws and even pace.
provided.
- Before connecting the by-pass line, remove the Twin operation
gauge connections from MA- and MB-port.
The jibs must be as parallel as possible to each
other during the lowering.
Caution!
It is of the utmost importance that the hoses to MA-
If only the luffing circuit is out of operation, try to lower
and MB-port are not switched, because the load
the load onto deck or quay with the hoisting winch.
could be dropped.
Remove the twin beam and lower the jibs one by one.
3B
3A
Connection Note!
- Install the hand pump 1A onto the base plate with The brake opens at approximately 1.2 MPa.
the screws provided. See Fig. 10.
- Connect the hoses from the hand pump as shown Warning!
in Fig. 10 and hydraulic diagram Fig. 11.
If the crane is tilted, the brake must be released with
- Close ball valve 3661 and open wedge valve 4332.
great caution. If the speed increases too much, the
See Fig. 10.
brake can be activated by ceasing to pump or opening
ball valve 3661.
Operation
- Release the brake by pumping oil from the hand After operation
pump.
After the slewing operation has been completed, reset
- The crane may now be slewed to a set position
the crane to NOT EMERGENCY COUPLED. Wedge
with the help of another crane. Use caution.
valve 4332 must be closed and ball valve 3661 must
be opened. See Fig. 10 and 12.
Quick-coupling 3664
Plug*)
Hand pump 1A
T-coupling
To be plugged at
emergency operation
General
MacHeavyvisor is a computer program that is part MacHeavyvisor has two main purposes:
of the logging and information system delivered by
- Displaying real time information about current
MacGREGOR (SWE) AB. The program is
properties of the crane such as jib radius, load
executed on a dedicated computer installed inside
in the hook, and hoisting speed. There can also
the crane cab. MacHeavyvisor communicates with
be additional information.
crane control system (CC3000) via a data
communication cable. The MacHeavyvisor
- Logging information about crane operations,
program and the computer is automatically started
allowing future analysis.
and stopped when the electric power of the crane
system is switched on/off.
Note! This view can vary depending on the crane's The blue boxes
different load areas and on the extra equipment If all three boxes are showing 0 there is no
delivered with the crane, for example list or trim communication with the CC3000 system.
sensors.
The upper right box indicates the current jib
In the top left corner the current date and time is radius in meter. When the value gets close to the
displayed in UTC time. In the opposite corner the limit the background in the box will start flashing
MacGREGOR logo is displayed, if the logo is yellow. If the value equals or exceeds the limit the
touched version information will be displayed. box background will flash in red.
Joysticks The top box indicates the current load in the hook
On each side of the screen there are two circles in ton. When the value gets close to the limit the
containing green arrows. These represent the two background in the box will start flashing yellow. If
the value equals or exceeds the limit the box
Software keyboard
When a dialog needs input, a keyboard will appear
on the screen on the bottom right corner, see Fig.
2.
USER MANUAL
DISPLAY
CC Pilot XS
1 COMPATIBILITY...............................................................................................................................................2
6 DISPLAY UNIT..................................................................................................................................................3
6.1 BUTTONS: ....................................................................................................................................................3
6.2 LEDS: ..........................................................................................................................................................3
6.3 CONNECTORS: .............................................................................................................................................3
7 STARTUP..........................................................................................................................................................3
1 Compatibility
The display is compatible with Windows CE and Linux.
4 Code data
Device's code data is placed at the back of the unit.
Code data are important from the service point of view, and so beware from disposing those.
If the display would not work correct, please contact MacGREGOR, Service Department, Örnsköldsvik,
Sweden.
6 Display unit
X1
1 X2
2 X8
3
4 X5
5
X9
X6
The display screen has 10.4” LCD TFT display with a touch screen.
6.1 Buttons:
1. Power button can be used to turn on/off the unit. If pressed for a long time, there will be a
forced power off.
2. Increase brightness.
3. Decrease brightness.
6.2 LEDs:
4. Red LED that blinks at start up.
5. Light detector of automatic brightness adjustment.
6.3 Connectors:
X1 Power
X2 Ethernet1
X5 Misc (Used as Serial communication port)
X6 CAN1
X8 USB1
X9 USB2
7 Start up
The display starts up at the same time as the crane. First it loads the operating system and after that
the display starts the program. When starting, screen is black and the red LED is blinking.
8 Problem solving
If there are some problem with the display check the following first, then call MacGREGOR Service Department.
8.1 The display is dark or dim when crane is working
• Check the brightness adjustment of the screen.
• Check cables and connectors to the display unit.
• Push the power on button on the display unit.
8.2 Communication faults
• Check that the cables are properly connected.
8.3 LED is blinking red but program does not start
• Try to switch off the unit and start again with the power button.
9 Technical Data
This display is especially developed for use of heavy machinery, which guarantees system durability and flexible
expandability to the different applications.
Kernel Power
Processor Intel XScale, 533 MHz Voltage 10 - 36 VDC
Compact Flash 32 MB -> commercially available Current < 500 mA at 24 VDC (6.5’’)
Kernel Flash 32/ 64 MB Environment
RAM -> 256 MB SDRAM IP-class IP65
Graphic controller Silicon motion, 8 MB RAM Temperature range -40 °C - +65 °C (operating)
Interfaces -40 °C - +70 °C (storage)
2 x CAN 2.0B, ISO 11898 – 24V,1 Mbit EMC conformity In accordance with 89/336/EEC:
2 x Ethernet 10/100 Base-T EN 50081-2: 1993
2 x USB 2.0 Software
RS232 OPTION. 115000 baud, replaces Operating system: Windows CE 5.0
Keyboard & Mouse Via USB Internal control
Display Status LED In front panel
10.4’’ SVGA 800x600 TFT Photo diode Automatic backlight control
Backlight CCFL ~400 nit Internal temperature protection against overheating
Touch screen Resistive in abnormal ambient conditions.
Mechanical
Enclosure Aluminum Dimensions
Mounting Stand Screen size: 10.4’’
Connectors DIN M12 Depth: 40 mm
Height: 217 mm
Width: 285 mm
9.1 Machinery
Spare Parts Manual
9.3 Mechanical
equipment
9.4 Hydraulic
components
9.5 Electric
components
9.6
Address:
MacGREGOR Cranes 9.7 Extra equipment
Cargotec Sweden AB
SE-891 85 ÖRNSKÖLDSVIK, Sweden
Telephone: +46 - 660 - 29 40 00
2009-02-27
www.macgregor-group.com/cranes
The Original Manufacturer of HÄGGLUNDS Cranes
PARTS MANUAL Date Group Fig. Page
HOISTING WINCH
PARTS MANUAL Date Group Fig. Page
HOISTING WINCH
Item Qty Article no Description Supplementary data
HOISTING WINCH
PARTS MANUAL Date Group Fig. Page
HOISTING WINCH
Item Qty Article no Description Supplementary data
HOISTING WINCH
PARTS MANUAL Date Group Fig. Page
HOISTING WINCH
Item Qty Article no Description Supplementary data
062 8 875 13001-003 .. MULTIPLE DISC, OUTER Change all 15 discs at the same time.
063 7 875 13001-004 .. MULTIPLE DISC, INNER Change all 15 discs at the same time.
064 14 875 13002-003 .. SPRING Change all 28 springs at the same time.
065 14 875 13002-004 .. SPRING Change all 28 springs at the same time.
9 10 13 14 12 11 8
195 Nm
4 7
875 13030-006
625-1451.010
Weight 40 kg
5 6 4 3
195 Nm
PARTS MANUAL Date Group Fig. Page
004 12 2121 2532-564 . SCREW MC6S 12x190 -8.8 FZB; DIN 912
HYDRAULIC MOTOR
PARTS MANUAL Date Group Fig. Page
HYDRAULIC MOTOR
Item Qty Article no Description Supplementary data
LUFFING WINCH, C
PARTS MANUAL Date Group Fig. Page
LUFFING WINCH, C
Item Qty Article no Description Supplementary data
LUFFING WINCH
PARTS MANUAL Date Group Fig. Page
LUFFING WINCH
Item Qty Article no Description Supplementary data
LUFFING WINCH
PARTS MANUAL Date Group Fig. Page
LUFFING WINCH
Item Qty Article no Description Supplementary data
052 8 875 13001-003 .. MULTIPLE DISC, OUTER Change all 15 discs at the same time.
053 7 875 13001-004 .. MULTIPLE DISC, INNER Change all 15 discs at the same time.
054 14 875 13002-003 .. SPRING Change all 28 springs at the same time.
055 14 875 13002-004 .. SPRING Change all 28 springs at the same time.
071 6 2121 2532-562 .. SCREW MC6S 12x170 -8.8 FZB; DIN 912
HYDRAULIC MOTOR
PARTS MANUAL Date Group Fig. Page
HYDRAULIC MOTOR
Item Qty Article no Description Supplementary data
5 6
2 275 Nm
1
3
391 0246-801
625-3254.023
PARTS MANUAL Date Group Fig. Page
3 dl
135 Nm 6
1 dl
391 0279-801
625-3254.022
PARTS MANUAL Date Group Fig. Page
SLEWING GEAR
PARTS MANUAL Date Group Fig. Page
SLEWING GEAR
Item Qty Article no Description Supplementary data
001 1 875 13004-002 . DRIVE IN, COMPLETE Includes item 2-24. Also order springs
002 9 875 13001-001 .. MULTIPLE DISC, OUTER Change all 16 discs at the same time
003 7 875 13001-002 .. MULTIPLE DISC, INNER Change all 16 discs at the same time
007 12 2121 2532-515 .. SCREW MC6S 10 x 120 -8.8 FZB; DIN 912
025 16 875 13002-001 . SPRING Change all 32 springs at the same time
026 16 875 13002-002 . SPRING Change all 32 springs at the same time
HYDRAULIC MOTOR
PARTS MANUAL Date Group Fig. Page
HYDRAULIC MOTOR
Item Qty Article no Description Supplementary data
PUMP UNIT
189 7476-801
625-4935.193
PARTS MANUAL Date Group Fig. Page
PUMP UNIT
Item Qty Article no Description Supplementary data
GEAR BOX
PARTS MANUAL Date Group Fig. Page
GEAR BOX
Item Qty Article no Description Supplementary data
HYDRAULIC PUMP
289 6004-801
625-4945.062
PARTS MANUAL Date Group Fig. Page
HYDRAULIC PUMP
Item Qty Article no Description Supplementary data
HYDRAULIC PUMP
289 6005-801
625-4945.063
PARTS MANUAL Date Group Fig. Page
HYDRAULIC PUMP
Item Qty Article no Description Supplementary data
VANE PUMP
PARTS MANUAL Date Group Fig. Page
VANE PUMP
Item Qty Article no Description Supplementary data
SERVO VALVE
391 1550-801
625-4948.011
PARTS MANUAL Date Group Fig. Page
SERVO VALVE
Item Qty Article no Description Supplementary data
DISTANCE PIECE
PARTS MANUAL Date Group Fig. Page
DISTANCE PIECE
Item Qty Article no Description Supplementary data
DISTANCE PIECE
PARTS MANUAL Date Group Fig. Page
DISTANCE PIECE
Item Qty Article no Description Supplementary data
OIL COOLER
1
2
289 6815-801
625-5740.031 /0
Weight 81 kg
PARTS MANUAL Date Group Fig. Page
OIL COOLER
Item Qty Article no Description Supplementary data
007 1 490 0197-801 . MOUNTING SET Incl. screws, nuts and washers
6
5 8
10
10
12
13
4
9
7
1
11
391 0300-801
625-5740.022
PARTS MANUAL Date Group Fig. Page
391 2766-801
625-5740.032
PARTS MANUAL Date Group Fig. Page
36
33
8
4 32 (2x)
9
55
11
35
54
53
13 5
189 3871-801
625-5865.046
PARTS MANUAL Date Group Fig. Page
21
17
16 15
20
18 19
14
13
9
5 6
8
4
10 11
2
7
12
189 7593-801 22
625-6102.473
PARTS MANUAL Date Group Fig. Page
011 2 391 0246-801 . SLEWING GEAR ASSEMBLY SET SEE FIG. 625-3254.023
016 1 391 0300-801 . OIL COOLER ASSEMBLY SET SEE FIG. 625-5740.022
019 1 289 4601-801 . VENTILATION FAN ASSEMBLY SET SEE FIG. 625-6625.022
SLEWING SPECIFICATION
le”
cip
rin
“P
CRANE
FOUNDATION
490 7478-801
625-6122.039
PARTS MANUAL Date Group Fig. Page
SLEWING SPECIFICATION
Item Qty Article no Description Supplementary data
COVER MOUNTING
PARTS MANUAL Date Group Fig. Page
COVER MOUNTING
Item Qty Article no Description Supplementary data
COVER ASSEMBLY
PARTS MANUAL Date Group Fig. Page
COVER ASSEMBLY
Item Qty Article no Description Supplementary data
8
6
4
3
2
5
390 6852-801
625-6170.045
PARTS MANUAL Date Group Fig. Page
22
23 24
31
14 15
16 17
32
18 19 20 21
25
289 5323-801
625-6245.635 /A
PARTS MANUAL Date Group Fig. Page
001 1 875 15017-012 . CAM DISC WITH ARM, COMPLETE 30° - 55°
002 1 875 15017-012 . CAM DISC WITH ARM, COMPLETE 30° - 55°
003 1 875 15017-012 . CAM DISC WITH ARM, COMPLETE 30° - 55°
004 1 875 15017-012 . CAM DISC WITH ARM, COMPLETE 30° - 55°
005 1 875 15017-013 . CAM DISC WITH ARM, COMPLETE 55° - 100°
006 1 875 15017-013 . CAM DISC WITH ARM, COMPLETE 55° - 100°
015 2 875 15001-002 . THREADED STUD WITH NUTS M3. Cut to right length.
022 1 875 15012-013 . WORM GEAR, COMPLETE Incl. screws. Ratio 50:1.
22 33
23 24
32
1
14 15
2
16 17 5
8
18 19 20 21
9
289 5449-801 25 31 10
625-6245.643 /0
PARTS MANUAL Date Group Fig. Page
001 1 875 15017-008 . CAM DISC WITH ARM, COMPLETE 30° - 55°
002 1 875 15017-009 . CAM DISC WITH ARM, COMPLETE 55° - 100°
003 1 875 15017-009 . CAM DISC WITH ARM, COMPLETE 55° - 100°
004 1 875 15017-008 . CAM DISC WITH ARM, COMPLETE 30° - 55°
005 1 875 15017-008 . CAM DISC WITH ARM, COMPLETE 30° - 55°
006 1 875 15017-010 . CAM DISC WITH ARM, COMPLETE 100° - 175°
007 1 875 15017-010 . CAM DISC WITH ARM, COMPLETE 100° - 175°
008 1 875 15017-010 . CAM DISC WITH ARM, COMPLETE 100° - 175°
009 1 875 15017-011 . CAM DISC WITH ARM, COMPLETE 175° - 290°
010 1 875 15017-011 . CAM DISC WITH ARM, COMPLETE 175° - 290°
015 2 875 15001-002 . THREADED STUD WITH NUTS M3. Cut to right length.
022 1 875 15012-005 . WORM GEAR, COMPLETE Incl. screws. Ratio 50:1.
002 1 390 3374-801 . MOUNTING WIRE LOCK JIB TOP SEE FIG. 625-6404.001
PARTS MANUAL Date Group Fig. Page
4 3 2
390 7581-801
625-6459.051
PARTS MANUAL Date Group Fig. Page
INCLINOMETER, C
PARTS MANUAL Date Group Fig. Page
INCLINOMETER, C
Item Qty Article no Description Supplementary data
CAB INSTALLATION
5
1
3 7 8
289 6807-801
625-6540.034
PARTS MANUAL Date Group Fig. Page
CAB INSTALLATION
Item Qty Article no Description Supplementary data
CAB ASSEMBLY
190 0115-801
625-6545.068
PARTS MANUAL Date Group Fig. Page
CAB ASSEMBLY
Item Qty Article no Description Supplementary data
WINDSCREEN CLEANER
PARTS MANUAL Date Group Fig. Page
WINDSCREEN CLEANER
Item Qty Article no Description Supplementary data
3 4 5 6
2 4 5 6
289 4601-801
625-6625.022
PARTS MANUAL Date Group Fig. Page
VENTILATION FAN
PARTS MANUAL Date Group Fig. Page
VENTILATION FAN
Item Qty Article no Description Supplementary data
001 1 . FAN
LIFTING BLOCK
PARTS MANUAL Date Group Fig. Page
LIFTING BLOCK
Item Qty Article no Description Supplementary data
001 1 875 12401-022 . SHEAVE, COMPLETE Incl. bearing and lock rings.
005 1 875 12404-013 . SHAFT, COMPLETE Incl. retainers, screws, grease nipple.
011 1 875 12064-016 .. SAFETY LATCH KIT Incl. spring, screw, nut.
VALVE UNIT
PARTS MANUAL Date Group Fig. Page
VALVE UNIT
Item Qty Article no Description Supplementary data
VALVE UNIT
PARTS MANUAL Date Group Fig. Page
VALVE UNIT
Item Qty Article no Description Supplementary data
FLUSHING VALVE
PARTS MANUAL Date Group Fig. Page
FLUSHING VALVE
Item Qty Article no Description Supplementary data
UNLOADING UNIT
PARTS MANUAL Date Group Fig. Page
UNLOADING UNIT
Item Qty Article no Description Supplementary data
001 1 . FILTER
003 1 . COVER
006 1 . WASHER
007 2 . O-RING
001 1 . FILTER
005 2 . COVER
010 1 . DIN-CARTRIDGE
014 4 . O-RING
015 1 . SEAL
DIRECTION VALVE
PARTS MANUAL Date Group Fig. Page
DIRECTION VALVE
Item Qty Article no Description Supplementary data
DIRECTION VALVE
PARTS MANUAL Date Group Fig. Page
DIRECTION VALVE
Item Qty Article no Description Supplementary data
UNLOADING UNIT
PARTS MANUAL Date Group Fig. Page
UNLOADING UNIT
Item Qty Article no Description Supplementary data
ACCUMULATOR
Old design
New design
1 2
388 0362-803
625-7951.005
PARTS MANUAL Date Group Fig. Page
ACCUMULATOR
Item Qty Article no Description Supplementary data
000 1 388 0362-803 ACCUMULATOR Charge Press. 2.0 MPa (20 bar)
HYDRAULIC HOSES
HYDRAULIC HOSES
MacGREGOR Cranes
Quality and Manufacturing Demands - Hydraulic Hoses
MacGREGOR Cranes are certified holders according to ISO 9001, and therefore the
hydraulic hoses with couplings supplied by us must have type approval on all ma-
terial.
Standard rubber hose for our 1" high pressure hoses are made for a working
pressure of 380 bar.
100% of the high pressure hoses are proof tested and leakage tested at 450 bar
during minimum 30 seconds and maximum 60 seconds. This pressure corresponds
to 1.3 times the working pressure.
100% of the hoses are marked with MacGREGOR Cranes part numbers, for quick
and correct identification.
100% of all high pressure hoses are, furthermore, marked with manufacturing date.
100% of all hoses are carefully cleaned after testing. They are cleaned by means of
cavitation with a mixture of water and an anti-corrosive agent.
The cleanliness after washing is equal to, or better than, class 9 according to NAS
norm 1638.
DRIVER’S DESK
7 8
14 72 73 9 10
15 74
11 12
13
124 0766-801
625-8563.045
PARTS MANUAL Date Group Fig. Page
DRIVER’S DESK
Item Qty Article no Description Supplementary data
003 1 224 0430-801 . CONTROL PANEL RIGHT CT3 SEE FIG. 625-8597.039
CONTROLLER, HOISTING
PARTS MANUAL Date Group Fig. Page
CONTROLLER, HOISTING
Item Qty Article no Description Supplementary data
002 1 414 2081-801 BELLOWS WITH BRACE SPARE PART NO: 662 0034-000
PARTS MANUAL Date Group Fig. Page
CONTROLLER, LUFFING/SLEWING
PARTS MANUAL Date Group Fig. Page
CONTROLLER, LUFFING/SLEWING
Item Qty Article no Description Supplementary data
002 1 414 2081-801 BELLOWS WITH BRACE SPARE PART NO: 662 0034-000
PARTS MANUAL Date Group Fig. Page
CONTROLLER
PARTS MANUAL Date Group Fig. Page
CONTROLLER
Item Qty Article no Description Supplementary data
224 0430-801
625-8597.039
PARTS MANUAL Date Group Fig. Page
224 0414-801
625-8598.069
PARTS MANUAL Date Group Fig. Page
224 0414-801
625-8598.069
PARTS MANUAL Date Group Fig. Page
224 0414-801
625-8598.069
PARTS MANUAL Date Group Fig. Page
ASSEMBLY CT2-PLATE
6 4 3
50 50
50
459
458 457
455 453
451 449
Hardware Hardware Hardware Hardware 448 438
xxx xxxx-xxx xxx xxxx-xxx xxx xxxx-xxx xxx xxxx-xxx 437 436
435 434
Error MP SP Error MP SP Error MP SP Error MP SP 433 432
431 430
Input Output Input Output Input Output Input Output
07 18 27 33 36 33 36 33 36 429 427
07 07 07 426 425
08 19 28 39 43 39 43 39 43
09 20 29 34 37 34 37 34 37 420 419
08 08 08 418 417
10 26 30 40 45 40 45 40 45
415 414
11 49 31 09 31 09 31 09 31
30 30 30 412 411
12 51 32 10 32 10 32 10 32
408 407
13 56 33 19 Sw19 19 Sw19 19 Sw19
404 403
Encoder 14 57 34 20 Sw20 55 20 Sw20 55 20 Sw20 55
402 401
15 58 35 11 14 Sw14 11 14 Sw14 11 14 Sw14
calibration
16 59 36 56 Sw56 56 Sw56 56 Sw56
17 60 37 12 15 Sw15 12 15 Sw15 12 15 Sw15
50 50
24V 38 26 27 26 27 26 27
42 359
Com 39 58 59 58 59 58 59
358 357
C1 R1 40 49 17 29 49 17 29 49 17 29
356 355
C2 R2 53 51 18 53 51 18 53 51 18 53
353 349
C3 R3 61 52 54 52 54 52 54
348 338
C4 MP 57 C1 R1 57 C1 R1 57 C1 R1
337 336
C2 MP C2 MP C2 MP
335 334
Com Com Com
333 332
331 330
CC MC MC MC
329 327
326 325
320 319
318 317
315 314
Sc Ho Lu Sl
312 311
308 307
Select / Info Select / Info Select / Info Select / Info 304 303
Normal 302 301
Up Up Up Up
Rigg OL-Test
Down / Exit Down / Exit Down / Exit Down / Exit
50 50
50 50
259 258
257 256
50 42
255 254
PC COM PC COM PC COM PC COM 50 42
253 252
50 42
251 249
50 42
248 247
50 42
Software Software Software Software 245 243
98 97
241 240
96 95
239 238
94 93
237 236
92 91
235 234
90 89
233 232
SC IO SC Supervisory HO Hoisting LU Luffing SL Slewing AU Auxiliary IO Input/Output 88 87
231 230
C28
C36
C44
C52
C17
C6
86 85
C3 C3 A1 C1 A1 C1 A1 C1 A1 C1 A1 C1 A1 C1 229 227
SC_C3 1
IO_C3 1
SC_C1 1
HO_C1 1
LU_C1 1
SL_C1 1
AU_C1 1
IO_C1 1
84 83
226 225
82 81
HO_A1
AU_A1
SC_A1
LU_A1
SL_A1
IO_A1
220 219
80 79
218 217
78 77
P115 P1115 P108 P208 P308 P408 P508 P1108 215 214
76 75
P101 P201 P301 P401 P501 P1101 212 211
C29
C37
C45
C53
C18
74 73
C7
C4 C4 A2 C2 A2 C2 A2 C2 A2 C2 A2 C2 A2 C2 210 209
72 71
1
SC_C2 1
HO_C2 1
LU_C2 1
SL_C2 1
AU_C2 1
IO_C2 1
208 207
70 69
HO_A2
SC_C4
AU_A2
SC_A2
LU_A2
SL_A2
IO_C4
IO_A2
204 203
68 67
202 201
66 65
P109 P209 P309 P409 P509 P1109 50 50
64 63
P116 P1116 P102 P202 P302 P402 P502 P1102 50 50
62 61
485.2 485.2 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1 42 42
60 23
SC_485.2 1
IO_485.2 1
SC_485.11
HO_485.11
LU_485.11
SL_485.11
AU_485.11
IO_485.1 1
42 42
22 21
HO_A3
AU_A3
SC_A3
LU_A3
SL_A3
161 160
IO_A3
20
158 157
19
P103 P110 P210 P310 P403 P410 P510 P1110 153 151
P203 P303 P503 P1103 18
149 143
P117 P1117
C12
C34
C33
C42
C41
C50
C49
C58
C57
C23
C22
C11
17
141 137
485.3 485.3 Sp SSI Sp SSI Sp SSI Sp SSI Sp SSI Sp SSI 16
SC_485.3 1
IO_485.3 1
136 135
15
134 133
14 13
HO_SSI
AU_SSI
SC_SSI
LU_SSI
SL_SSI
HO_Sp
IO_SSI
132 131
AU_Sp
SC_Sp
LU_Sp
SL_Sp
IO_Sp
12 11
130 128
10 9
127 126
P118 P1118 8 7
125 119
6 5
118 117
P107 P106 P207 P206 P307 P306 P407 P406 P507 P506 P1107 P1106 4 3
116 115
2 1
114 113
112 111
110 109
108 107
104 103
102 101
324 1656-801
625-8607.010
PARTS MANUAL Date Group Fig. Page
ASSEMBLY CT2-PLATE
Item Qty Article no Description Supplementary data
SLIPRING UNIT
PARTS MANUAL Date Group Fig. Page
SLIPRING UNIT
Item Qty Article no Description Supplementary data
MOUNTING ENCODER
390 9851-801
624-2180.014
PARTS MANUAL Date Group Fig. Page
MOUNTING ENCODER
Item Qty Article no Description Supplementary data
MOUNTING ENCODER
390 9852-801
624-2180.015
PARTS MANUAL Date Group Fig. Page
MOUNTING ENCODER
Item Qty Article no Description Supplementary data
10
7
9
8 6
4
2
12 13 14
490 4592-802
624-2479.001
PARTS MANUAL Date Group Fig. Page
HAND PUMP
50
22 13
9
49
8
6
19
27
2
28
21
52
7
3 10
20
36
189 1952-801
624-2492
PARTS MANUAL Date Group Fig. Page
HAND PUMP
Item Qty Article no Description Supplementary data
EBOM Page 1 of 1
EBOM
Title El inst Display (cab) Originator
324 1876-801 Display Assembly B Title2 - Originated 2009-11-06 Last rev date 2009-11-18
Specification 324 1876 State Release