60t Crane SP2552-1-15-1 UM

User Manual for Crane
1 Introduction
Table of Contents
1. General ............................................................................................................................................1
2. Purchase Information .......................................................................................................................1
3. Contact Information ..........................................................................................................................1
4. General Security Conditions.............................................................................................................2
5. Training ............................................................................................................................................2
6. Guarantee Restrictions ....................................................................................................................2
7. HSE – Health, Safety and Environment ...........................................................................................3
7.1. Safety in Maintenance ...............................................................................................................3
7.2. Disconnection of Live Circuits ....................................................................................................3
7.3. Accidental Activation .................................................................................................................3
7.4. Electrical Supply Specification ...................................................................................................4
7.5. Replacement Parts ....................................................................................................................4
7.6. Software ....................................................................................................................................4
7.7. Observing the Installation Guidelines.........................................................................................4
7.8. Environment ..............................................................................................................................4
1 Introduction
MACGREGOR NORWAY AS
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1 Introduction
MACGREGOR NORWAY AS
1. General
This user manual is compiled in accordance with Norwegian Standard 5820.
Operators and maintenance personnel should read and understand this manual before operating or servicing the
equipment. The owner of the equipment is responsible for ensuring that no unauthorised personnel operate or
maintain the equipment.
The user manual is divided into three (3) volumes:
• SP2552-1-15-1 System Description

• SP2552-1-15-2 Hydraulic and Mechanical Drawings and Datasheets
• SP2552-1-15-3 Control system Diagrams
Note: Illustrations/photos used in the user manual may deviate from the actual delivery. Optional equipment
that may or may not be present is denoted with a star .
2. Purchase Information
Equipment: Offshore/Subsea Knuckle Jib Crane
Type: HMC 3990 LKO 200-45 (600-25) (100-50)
Customer: Fujian Mawei Shipbuilding Ltd
Machine number: SP2552-1
3. Contact Information
In case of any problems, please contact (remember equipment machine number for service advice):
+47 91 68 60 00
MacGregor Norway AS +47 38 01 87 01

Andøyfaret 15
N-4623 KRISTIANSAND
Norway
http://www.macgregor-
group.com/service krs.service@macgregor.com
24 hour service:
+47 91 68 97 51
1 Introduction
MACGREGOR NORWAY AS 1
After warranty period:
Contact your nearest MacGregor service office.
http://www.macgregor-group.com/service
4. General Security Conditions

No personnel are permitted in the equipment working area during operation.
All use of the equipment must comply with the company security regulations.
5. Training
MacGregor Norway AS can provide tailor-made operation and maintenance courses for all MacGregor Norway
equipment.
For more information, contact our head-office in Kristiansand. We recommend all our customers to attend our
courses.
6. Guarantee Restrictions
During the warranty period, all necessary spare parts must be supplied by MacGregor Norway AS. Use of
spare parts from other suppliers violates and forfeits the warranty.
Unintended use and/or faulty/deficient maintenance of the equipment forfeits the warranty.
Removal and/or loss of equipment identification plates by customer also forfeits the warranty.
1 Introduction
2 MACGREGOR NORWAY AS
7. HSE – Health, Safety and Environment

7.1. Safety in Maintenance
Before carrying out any maintenance or repair work, maintenance personnel must be completely familiar with
equipment operation, technical drawings and procedures.
Secure the area of the maintenance operation to the degree and the extent necessary!
When replacing heavy parts and/or structural components, objects being lifted must be carefully secured to the
lifting appliances and safeguarded in order to avoid hazardous situations. Use only approved lifting equipment
of sufficient carrying capacity.
Do not stay underneath or in the vicinity of a suspended load.
Only personnel authorised according to applicable regulations are to perform work on the electrical installation
or the equipment.
If specifications for inspection, maintenance or repair require the equipment to be voltage-free, this can be
achieved in the following ways:
• For circuits above 50 VAC / 30 VDC, switch off and lock out the main circuit breaker on the supply
side.
• For instrumentation circuits (below 50 VAC / 30 VDC), isolate the control cabinet from the main
supply.
• Open the fuses in the control cabinet, referring to the relevant (loop) drawings.
• Isolate the relevant wires / cores from the terminal block in the control cabinet.
• Follow the relevant procedures to troubleshoot or repair the equipment in question.
Before work proceeds verify that all circuits are voltage-free.
7.2. Disconnection of Live Circuits

Do not disconnect any live circuits unless location is known to be non-hazardous.
7.3. Accidental Activation

Measures must be taken to prevent accidental activation of equipment delivered by or controlled by a
MacGregor Norway AS product during maintenance.
This may include locking our power supply, posting warning signs at relevant locations, inform other people or
organisations.
1 Introduction
7.4. Electrical Supply Specification

In case of disturbances in the electrical supply (voltage, frequency, harmonic and other disturbances) the
equipment must be switched off immediately.
7.5. Replacement Parts

To maintain the integrity of the equipment delivered by MacGregor Norway AS it is important that all spare
parts have identical or better specifications than originally delivered. This is especially important for all
protective equipment such as fuses and circuit breakers. Computer hardware should not be altered or replaced
without consulting MacGregor Norway AS.
If in doubt – ASK!
7.6. Software
The software delivered with the system is programmed by MacGregor Norway AS, and is vital for safe and
dependable operation of the equipment.
Only qualified personnel from MacGregor Norway AS may alter or modify system software.
The software supplied with the system has unique reference numbers kept on file at MacGregor Norway AS. If
software modifications are detected in any system this will void any warranty responsibility with respect to the
safe and normal operation of the equipment. Consult MacGregor Norway AS prior to making any changes in the
software.
Use the attached Software Change Request formula whenever requiring a change in the application software.
7.7. Observing the Installation Guidelines

MacGregor Norway AS products meet the requirements of the contract as long as they are installed and
operated as described in the installation guidelines and documentation received from MacGregor Norway AS.
7.8. Environment
Environmental considerations should be kept in mind when disposing of any part of the equipment delivered by
MacGregor Norway AS.
1 Introduction
2 Main Data
Table of Contents
1. General ............................................................................................................................................1
2. Regulations and Design Criteria .......................................................................................................2
3. Foundation .......................................................................................................................................2
4. Main Winch ......................................................................................................................................3
5. Whip Winch......................................................................................................................................3
6. Electrical ..........................................................................................................................................4
7. Hydraulic ..........................................................................................................................................4
8. Lubrication .......................................................................................................................................4
9. Miscellaneous ..................................................................................................................................4
10. Crane Operation ............................................................................................................................5
11. Surface Treatment .........................................................................................................................5
12. Weight and Dimensions of Crane ...................................................................................................5
2 Main Data
MACGREGOR NORWAY AS
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2 Main Data
MACGREGOR NORWAY AS
1. General
Project ID 2552-1
Customer Fujian Mawei Shipbuilding Ltd.
Crane type HMC 3990
Size LKO 200-45 (600-25) (100-50)
Current vessel name CSS Accomodation Support Vessel
Yard build number MW610-2
Ship owner MAC Offshore
Contract delivery terms DAP Mawei Shipyard, Incoterms 2010
FAT site RCI Taichang
Commissioning site Mawei Shipyard
Dynamic factor and derating: Derating procedures are to be applied to lifts where the dynamic factor exceeds
the limit.
Subsea capacity: Net subsea lift capacity is reduced by the weight of the submerged wire and increased by the
buoyancy of the submerged load. Hydrodynamic loads are to be calculated and factored into the lift.
2 Main Data
2. Regulations and Design Criteria

Regulations 1 ABS
Design verfication of foundation Yes, certified according to Regulations 1
Design verfication remaining Yes, certified according to Regulations 1
Manufacturing control Yes, according to Regulations 1
Test attendance ABS
Product certificate issued by ABS
Area classification Safe zone
Design temp (°C) -10 +45
Max operation wind speed (m/s) 25
Max trim/list 5+3 degrees
Dynamic factor 1.33 (according to ABS and API 2C requirement)
Safety factor 1.33 (according to ABS and API 2C requirement)
Minimum working radius MW (m) 8
Minimum working radius WW (m) 8
Capacity Offshore Single 1 (XX t @ XX m) 20 ton - 45 m (single part)
Capacity Offshore Single 2 (XX t @ XX m) 40 ton - 35 m (double line arrangement)
Capacity Offshore Single 3 (XX t @ XX m) 60 ton - 25 m (triple line arrangement)
Main winch wire sheave PCD (mm) 650
Whip winch wire sheave PCD (mm) 650
3. Foundation
Height of foundation (mm) 4500
Pedestal lower connection Welded
2 Main Data
4. Main Winch
Main winch SWL (t) 20
Wire diameter (mm) 32
Wire type Galvanized, non rotating
Wire MBL (kN) 1014
Wire weight dry (kg/m) 4
Wire weight in seawater (kg/m) 4
Drum diameter, PCD layer 1 (mm) 848
Drum width (mm) 852
Drum barrel Lebus
Hook travel (m) 150, Single part
Drum capacity (m) 200
Wirelength included (m) 220
Lifting speed 1 (ton, m/min) 0-20t, 0-60 m/min
Hook included Yes
Weight of hook (kg) 500
Automatic pay out function Yes
Manual pay out function Yes
AT top tension, case 1 (t) Fixed setting, CT ship to ship
5. Whip Winch
WW SWL (t) 10
WW winch location On main jib
WW Wire diameter (mm) 24
WW wire type Galvanized, non rotating
WW Wire MBL (kN) 574
WW Wire weight dry (kg/m) 2
WW Wire weight in seawater (kg/m) 2
WW Drum diameter, PCD layer 1 (mm) 647
WW Drum width (mm) 1
WW Drum barrel / type no lebus
WW Hook travel (m) 150
WW Drum capacity (m) 150
WW Wirelength included (m) 220
WW Lifting speed 1 (ton, m/min) 0-10 ton, 0-60m/min
WW Slow speed mode Yes
WW hook included Yes
WW Weight of hook (kg) 500
WW automatic pay out function Yes
WW manual pay out function Yes
WW personnel lift 5 ton
2 Main Data
6. Electrical
Main supply 3x440V/60Hz
Main electro motor 1 3x300kW(S6-40%) S-D
Emergency supply 3x440V/60Hz
Main motor enclosure IP 56
SPM nipples in electro motor Yes
Oil cooler motors 4x3,5kW(S1-100%) DOL
Circulation/Feeding motor 1x11kW(S1-100%) DOL
CJC motor 1x0,5kW(S1-100%) DOL
Emergency HPU motor 1x50kW(S1-100%) DOL
Camera at winches Yes
Slipring / drag chain type Kraus
Extra sliprings for customer signals 6
Cabin type 4000
Right/Left mounted Right
Extra communication Yes
Remote diagnostic Yes
7. Hydraulic
Main jib topping speed Approx 120 sec
Knuckle jib topping speed Approx 80 sec
Slew sector 360 degrees unlimited
Slew speed 0-1 RPM (Rmin - 15m), 0-0,5 RPM (20-Rmax)
8. Lubrication
Crane lubrication Automatic central system (PLC)
Winch lubrication Automatic central system (PLC)
Wire lubrication Masto
9. Miscellaneous
Crane lubrication system Manual
Winch lubrication system Manual
Surface treatment Jotun Spec (similar as International System 1
Top layer color RAL 9010 White
2 Main Data
10. Crane Operation

Operating controls: Joysticks on operator’s seat in cabin
Control and monitoring functions: Siemens PLC-based system with graphic user interface (LCD touch-screen)
Simultaneous operation: The main winch can be operated at full speed in addition to one of the other
motions (slew, jib) at 50% speed. When the main winch is operating in AHC/AT
mode, the other crane motions can be performed at very low speeds.
11. Surface Treatment

Total DFT 335µ
Top coat colour: RAL 9010
General quality 8.8 and 10.9
Surfacing Up to and including M12 bolts: stainless steel AISI 316. Above M12: class 8.8
hot-dip galv.
Class 10.9 and 12.9: painted as structure (cannot be galvanized)
• All external surfaces are treated in compliance with MGH standard System 1 and System 6 by
International
• Internal surfaces in sealed spaces are not treated
• Internal open surfaces are fully painted according to standard paint regime
• Stainless steel elements such as junction boxes are not treated
• Hydraulic tank inside surfaces are treated with special paint (MH standard paint for hydraulic tanks)
12. Weight and Dimensions of Crane

Weight of main elements / Approximately 201t (estimated dry weight)
complete crane
See drawing No. SP2552-1-R-XD-001 General Arrangement
2 Main Data
3 System Description
Table of Contents
1. General ............................................................................................................................................1
2. Main Components ............................................................................................................................3
2.1. Crane Pedestal..........................................................................................................................3
2.2. Slew Bearing .............................................................................................................................3
2.3. Crane King ................................................................................................................................3
2.4. Slew Gear..................................................................................................................................4
2.5. Operator Cabin ..........................................................................................................................4
2.5.1. Communication System / ROV Monitor Signals ..................................................................5
2.5.2. Monitor for Remote Installation ...........................................................................................5
2.6. Crane Jib System ......................................................................................................................5
2.7. Luffing Main and Knuckle Jib Cylinders .....................................................................................6
2.8. Winches ....................................................................................................................................7
2.8.1. General ...............................................................................................................................7
2.8.2. Main Winch .........................................................................................................................7
2.8.3. Whip Winch .........................................................................................................................7
3. Hydraulic System Design .................................................................................................................9
3.1. General ...................................................................................................................................10
4. Electrical System Design ...............................................................................................................11
4.1. Electric Slip-Ring Unit ..............................................................................................................11
4.2. Main Electric Motors ................................................................................................................11
5. Control System Design ..................................................................................................................12
Annex A - Technical Description of the Hydraulic System...................................................................A1
MACGREGOR NORWAY AS
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MACGREGOR NORWAY AS
1. General
The HMC 3990 LKO 200-45 (600-25) (100-50) MacGregor offshore knuckle jib crane is designed for sustained
operation and long periods of inactivity in a tough and corrosive offshore marine environment. The crane is
designed with a substantial structural and mechanical capacity margin for heavy offshore/subsea operation from
open decks on offshore vessels and for secure parking when not in use.
The crane is designed with a dynamic factor of 1.33 according to ABS and API 2C requirements along with a
safety factor of 1.33 according to ABS and API 2C requirements.
The crane is designed for efficient and precise offshore/subsea general load handling at a maximum 50 meters
with the whip winch single line. The crane is operated from a fully insulated operator’s cabin on the king. All
equipment is chosen and installed to insure the lowest possible emission of sound and to allow easy access for
service and repair.
2. Main Components
2.1. Crane Pedestal
The crane pedestal is a fixed cylindrical structure bolted or welded to the underlying vessel structure to provide
a foundation for the rest of the crane. The slew ring on the top carries the king – the rotating part of the crane.
The pedestal houses the electric slip-ring unit through which all electric power and signal circuits pass between
the ship and the crane. The cables are all mounted on cable trays.
Powerful electric motors that drive the main HPU pumps inside the king are mounted on the underside of the
king bottom plate, and thus protrude down into the pedestal. An access hatch in the king bottom plate opens into
the pedestal, where a ladder and platform facilitate inspection and maintenance. A walkway platform encircles
the pedestal on the outside approximately 2 m from the top, ensuring access to the crane in all positions. Access
to this platform is by a ladder with a safety frame.
2.2. Slew Bearing

The slew bearing is a heavy duty marine slew ring, with internal gearing for the transfer of torque from the
slewing gear.
As the slewing pinions in the underside of the

crane king engage with the stationary internal
gearing, the crane is turned. Slewing motors and
gearing are described later. Such rotation of the
crane may be unlimited or limited to a specified
slewing arc depending on the needs and
placement of the crane onboard the vessel.
Photo at right: a slew pinion under the crane

king engages with the stationary part of the slew
bearing.
A crane's size is specified based on the slew

bearing's diameter in millimetres.
2.3. Crane King

The king is mounted on top of the slew ring. It
is the structural element on which the jib
system is mounted. The main jib is connected
to the top of the king, with twin luffing
cylinders on the underside attached to the
lower part of the king. The hydraulic tanks (an
inside tank and an outside tank) are built into
the king structure, which also functions as a
machine room where various cabinets, panels
and most control valves are located. Access to
this machine room is via a door behind the
cabin. The operator’s cabin is mounted on the
front right side of the king.
2.4. Slew Gear

The crane's slewing function is provided by a number of
slewing gears interacting with the toothed ring of the slew
bearing described earlier. Brakes are dimensioned to take
the full load at the maximum list, plus any additional
dynamic force acting on the slew gear. A heavy duty,
hydraulic motor is flanged onto each gearbox. The slewing
gear motors generate smooth, accurate and proportional
slewing motion for the crane.
In cases where the crane has a defined slewing sector,

slewing may be limited by a slew-stop system.
2.5. Operator Cabin

A spacious operator cabin located on the
front right side of the crane king provides
a comfortable working environment for
the crane operator. The cabin is furnished
with one operator’s seat and one fold-
down “co-pilot’s” seat for an instructor,
for instance. The operator’s seat is of
ergonomic design and is vibration-
dampened. The main manoeuvring
controls consist of spring-centred
joysticks fitted to consoles mounted on
the operator’s seat – winch and knuckle
jib operation on right-hand joystick, main
jib and slew on the left.
Steel bars on the front window and a grille

over the top window protect occupant and
equipment against injury and damage if
heavy objects strike the cabin area. All
windows are fitted with adjustable roller blinds to shield the crane operator from direct sunlight. Several of the
windows may be opened, and there are catwalks outside for cleaning the windows. Other cabin equipment
includes window wipers, a signal horn, inside lighting, heating and air conditioning. A fire extinguisher is
mounted in compliance with regulations, and the cabin meets official noise and working environment standards.
2.5.1. Communication System / ROV Monitor Signals

The crane cabin is equipped with VHF/UHF radios for communication. The slip-ring unit has spare slip-rings
available for connecting to vessel intercom systems or a ROV monitor system. Available signal lines are routed
from the cabin to the slip-ring junction box in the pedestal.
2.5.2. Monitor for Remote Installation

The crane is supplied with a separate LCD slave panel for remote monitoring of crane status and selected data.
This panel can be installed in a suitable location elsewhere on the vessel according to the diagram supplied by
Cargotec Norway AS.
2.6. Crane Jib System

The jib system consists of a main jib and a knuckle jib. Both jib elements are built of steel plate and steel
sections, and both are manoeuvred by twin heavy-duty double acting marine-grade hydraulic cylinders fitted
with counterbalance valves. The knuckle jib is manoeuvred by a similar set of cylinders that are especially made
for knuckle jib operation. All cylinders are connected to the jibs with spherical bearings. Wire retainers on the
sheaves nearest the knuckle prevent the wires (both main and whip) from slipping off the sheaves.
Suspension lugs are welded to the underside of the main jib which can be used to support the tugger winch
system spreader beam.
Contact Buffer
Although smaller active boost cranes may be delivered without any contact buffer, most knuckle jibs are
equipped with a contact buffer. During heavy lifts with buffer contact, some of the force is transferred to the
main jib. Ergo, the crane is able to perform heavier lifts due to reduced force on the knuckle jib cylinders.
However, when contact is lost, the lifting capacity drops. Refer to the specific user manual for load curves.
Aircraft Warning Lights
Red aviation warning lights are mounted atop the main winch and at the knuckle-end of the main jib to mark
crane position in hours of darkness.
Jib Floodlight
Two heavy-duty marine-grade pendulum floodlights are fitted to the

knuckle jib.
2.7. Luffing Main and Knuckle Jib Cylinders

Each jib is hydraulically operated by a pair of double acting
cylinders with integrated counter balance valves.
In addition, a safety valve is hydraulically connected the rod

side of all jib cylinders to protect them in the event of
incorrect operation.
The cylinders are connected with spherical bearings. A load

holding valve is mounted directly to the cylinder ports on the
load holding side of both cylinder pairs to maintain safety in
case of a hose failure.
Bondura bolts are typically used to connect the hydraulic

cylinders to the crane. A cone is fitted to each side of the
conical bolt ends. These cones expand in place when the
locking plates are fitted and the locking plate bolts are
tightened to the specified value.
2.8. Winches
2.8.1. General
The crane has two separate winch systems – one main winch mounted on the main jib above the cabin, one whip
winch mounted in front of the main winch. Both main and whip winch systems are equipped with two hook
stops – a mechanical one that uses a proximity switch suspended from the jib tip and a software controlled
system based on monitoring of payout length.
The software controlled hook stop is programmed into the control system and utilises continuous feedback from
a rotational encoder on the winch to calculate the length of wire paid out at any given time. The control system
thus “knows” when the hook is about to be pulled into the sheave, or when the wire is about to be paid out
beyond the preset limit, and stops the winch accordingly. The mechanical hook stop simply sends a signal when
the hook makes contact with the switch, and the control system halts the winch. Line load is monitored by a
load cell fitted to one of the wire sheaves.
2.8.2. Main Winch

The main winch consists of a flanged steel drum on an axle that turns on bearings set into the winch’s frame-
plates. A large gear ring on each of the drum’s flanges is driven by drive gears mounted on the winch’s frame
plates. Each drive gear is driven by a variable-displacement hydraulic motor and fitted with fail-safe multidisc
brakes. Failsafe here means that any hose or pipe failure or loss of operating pressure will cause the brakes to
lock the load immediately. The brakes are dimensioned to take the full load plus the additional dynamic forces
acting on the winch. A set of counterbalance valves in the winch loop ensure safe, smooth and precise winch
operation.
The winch drum is equipped with a Lebus sleeve to facilitate correct wire spooling. A high quality galvanized,
non-rotating, subsea wire rope is included, together with a subsea counterweight/swivel hook. A desalting
device consisting of six spray nozzles mounted in a horizontal frame on the winch rinse the wire with freshwater
as the drum turns.
2.8.3. Whip Winch

The whip winch consists of a steel drum with two axially-mounted planetary gearboxes, each driven by a fixed-
displacement hydraulic motor (see illustration below). Both gearboxes are fitted with fail-safe multidisc brakes
dimensioned to take the full load plus any additional dynamic forces acting on the winch. In the event of a hose
or pipe failure, the brakes block the load immediately. A counterbalance valve in the winch loop ensures safe,
smooth and precise winch operation regardless of winch load. The winch is provided with a galvanized, non-
rotating wire rope and a subsea counterweight/swivel hook of rated quality and capacity.
The whip winch system also features a personnel lift mode of 10-tonne capacity in conformity with applicable
rules and regulations.
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3. Hydraulic System Design
Breathers x 4
Return filters x 2
Circulation pump Drain filters x 3
High pressure
filters x 5
Main pump
(single) x 3
Emergency pump
King floor plate Main pump (double) x 1
Slew motor/gear/brake
assembly x 4
Main HPU motor Slew ring

(300 kW) x 3
Main HPU motor

(550kW) x 1
CJC offline filter

system
3.1. General
Below is a standard hydraulic description, refer to Annex A for more detail:
The hydraulic oil tanks are built into the crane king structure. The king machine room also houses the hydraulic
main pumps which are mounted on rubber flanges on the king bottom plate for low-noise operation. The
hydraulic pumps are of low noise variable displacement type operating in Load Sense mode (LS mode). The
crane has four main pumps (one double pump and three single pumps) and one circulation pump. A separate 63
kW emergency pump is also installed to enable emergency operation of all crane functions in case of main
power failure. Emergency unit power is normally taken from the vessel’s emergency generator.
There are three main (HPU) pumps powered by 300 kW electric motors. All pumps feed hydraulic power into a
common control valve which distributes the power to the relevant crane motions as directed by the crane’s
control system.
This gives the power unit system a high degree of redundancy, as only one pump is actually necessary to run the
entire crane at full loads, though at reduced speeds. The main hydraulic control valve block is located in the
king machine room. It is a pressure- compensated, electro-servo-hydraulic operated type controlled by joysticks
(servo pilot levers) located on panels mounted on the operator’s seat inside the crane cabin. The main control
valve block distributes oil to each relevant crane motion as determined by the joystick position. When the
joysticks are not operated, oil pressure stops at the main control valve and the variable pumps de-stroke to zero
flow. As soon as one joystick is operated, a stepless variable oil flow is directed to the relevant crane motion
giving the motion the required speed.
The hydraulic system has a separate circulation pump that ensures full filtration and cooling capacity, even
when crane is operated at creep speeds for extended periods. This is necessary since the main pumps are of
variable displacement type and will de-stroke and circulate oil only as needed by the crane operation. Cooling is
provided by forced-air oil coolers located on a platform at the rear of the crane. This ensures constant filtration
and cooling under all crane operating modes.
The pressure-compensated control valve system enables execution of multiple crane manoeuvres simultaneously
regardless of variations in actual crane loads.
Hydraulic oil level, oil temperature, filter status and operation pressures are all general operating parameters
displayed on the LCD control screen in the operator cabin. Any abnormal values will trigger audio/ visual
alarms in the cabin as well as appropriate responses by the control system.
A separate CJC offline filter loop is incorporated into the hydraulic system to maintain hydraulic oil quality
even when the crane is not in use.
A more detailed technical description of the hydraulic system is provided in Annex A - "Technical
Description of the Hydraulic System".
4. Electrical System Design

4.1. Electric Slip-Ring Unit
The slip-ring unit transfers power and communication signals to and from the rotating part of the crane. Its
rotating part (top end) is contained in an enclosed unit mounted on a bracket attached to the underside of the
king bottom-plate and extending down inside the pedestal. Its stationary part (bottom end) is also a closed unit,
mounted on a fixed framework attached to the pedestal. Individual rings carry separate power circuits supplying
each main HPU motor, the crane utilities, the control system UPS and aircraft warning lights as well as a
number of signal and communications circuits. A heating element inside the slip-ring unit prevents moisture
build-up during prolonged periods of inactivity.
4.2. Main Electric Motors

Electric power cables (one for each HPU motor) are laid
from the slip-ring assembly (rotating side) to the starter
cabinets inside the king machine room and thence to the
motors mounted beneath the bottom-plate. All electric
motors are fitted with heating elements to prevent
moisture build-up during extended periods of inactivity.
5. Control System Design

The control system is based on an industrial-grade PLC that communicates with other system components on
the winches, in the HPU, king and other parts of the crane. Crane motions are controlled by means of joysticks
mounted on consoles on the operator’s seat in the cabin. Joystick movements send signals to the PLC, which
processes them and sends the appropriate control signals to system components. Safety functions such as MOPS
and emergency stops are hardwired into the electrical circuitry with dual/parallel contacts.
The PLC is connected to a computer (industrial-grade PC) to provide an intuitive, easily-accessible graphic
HMI (Human Machine Interface) via a 17” high-definition LCD touch screen for control and monitoring of all
crane functions. The operator’s screen is backlit to ensure readability under all conditions. The HMI application
displays alarms, system status and parameters. The touch screen also provides a means for operator feedback
and command input. Load information is displayed in analogue bar graphs, and payout lengths and sensor
information are displayed in digital form. The PLC and the PC are both located in control cabinet CC-100 in the
rear wall of the cabin.
Full system information is available in real time, and all relevant parameters are logged to provide history for
documentation of normal operation and abnormal events. Redundancy is built into many points in the system
through the use of dual sensors.
The control system receives a important information from the following heavy-duty marine-grade field sensors:
• Knuckle (2x) and main jib (2x) position encoders

• Slew position (1 rotational encoder)
• Main winch payout (1 rotational encoder)
• Whip winch payout (1 rotational encoder)
• Main winch mechanical hook stop (dual switches)
• Whip winch mechanical hook stop (dual switches)
• Main (1x) and whip winch (1x) wire load sensor (dual signals)
• Hydraulic oil temperature (dual sensors/switches)
• Hydraulic oil level (dual sensors/switches)
• Oil filter DPI sensors
• Temperature in electric motors
• MRU (Motion Reference Unit)
Remote access: A dedicated router in CC-100 is programmed with predefined IP addresses for remote access to
the control system. A standard router has 16 preset addresses – 10 for use by system components, 3 for DHCP
provision for mobile computers and similar devices and 3 for the router itself. The customer’s network must
have Internet access to IP-address 80.239.94.33 (Cargotec Norway AS).
To be able to connect, the customer’s firewall must have the following ports available:
• UDP 500
• UDP 4500
• ESP
• AHP
This document and all information and data herein or herewith is the confidential and proprietary property of Cargotec
Norway and is not to be used, reproduced or disclosed in whole or in part by or to anyone without the written
confirmation from Cargotec Norway AS.
© Cargotec Norway AS
Equipment:
OFFSHORE CRANE
Type HMC 3990
2 Issued for Information 12.12.13 CCU HZH

1 Issued for DC 11.11.13 HZH CCU
Rev. Reason for issue: Date Auth. Check. App.
Technical Description of the Hydraulic System
Customer: Project name.:
HM project no.: P.O. No.:
SP2552-1 NA
HM doc. no.: Customer doc. no.: No.of attachments: No. of pages:

SP2552-1-L-MB-001 NA 0 14
Title: Technical Description of the Hydraulic System
Project No. SP2552-1
Document No. SP2552-1-L-MB-001 System Description
INDEX
SYSTEM DESCRIPTION .......................................................................................................................................... 3
1 HPU (HYDRAULIC POWER UNIT) ................................................................................................................ 3
1.1 RESERVOIR WITH ACCESSORIES ................................................................................................................ 3
1.2 OIL COOLERS .............................................................................................................................................. 4
1.3 FILTRATION UNIT ASSEMBLY....................................................................................................................... 4
1.4 CIRCULATION MOTOR/PUMP ASSEMBLY ...................................................................................................... 4
1.5 MAIN MOTOR/PUMP ASSEMBLY .................................................................................................................. 4
1.6 MAIN SYSTEM, LOAD SENSE LS CONTROL ................................................................................................. 5
1.7 EMERGENCY MOTOR/PUMP ASSEMBLY ..................................................................................................... 5
1.8 HIGH PRESSURE FILTERS ........................................................................................................................... 5
1.9 MAIN CONTROL VALVE................................................................................................................................ 5
2 JIB SYSTEM ...................................................................................................................................................... 6
2.1 MAIN JIB ...................................................................................................................................................... 6
2.2 KNUCKLE JIB................................................................................................................................................ 7
3 SLEW SYSTEM ................................................................................................................................................. 7
3.1 SLEW GEARS ............................................................................................................................................... 7
3.2 HYDRAULIC MOTOR INCLUDING VALVES ..................................................................................................... 7
3.3 HYDRAULIC VALVES AND VALVE BLOCK ..................................................................................................... 8
4 MAIN WINCH SYSTEM.................................................................................................................................... 8
4.1 GEARBOX..................................................................................................................................................... 8
4.2 HYDRAULIC MOTORS................................................................................................................................... 8
4.3 W INCH MOTOR VALVE BLOCK .................................................................................................................... 8
4.4 HYDRAULIC VALVES .................................................................................................................................... 9
4.5 MANUAL OVERLOAD PROTECTION SYSTEM (MOPS) ................................................................................ 9
4.6 AUTOMATIC OVERLOAD PROTECTION SYSTEM (AOPS) ......................................................................... 11
5 WHIP WINCH SYSTEM ................................................................................................................................. 11
5.1 GEARBOX................................................................................................................................................... 11
5.2 HYDRAULIC MOTORS................................................................................................................................. 11
5.3 W INCH MOTOR VALVE BLOCK .................................................................................................................. 11
5.4 HYDRAULIC VALVES .................................................................................................................................. 12
5.5 MANUAL OVERLOAD PROTECTION SYSTEM (MOPS) .............................................................................. 12
5.6 AUTOMATIC OVERLOAD PROTECTION SYSTEM (AOPS) ......................................................................... 14
Page 2 of 14
System Description
1 HPU (Hydraulic Power Unit)

The HPU on this crane is located in the rotating Crane King. The main components of the HPU
are described below:
1.1 Reservoir with Accessories

The reservoir or tank is integrated in the rotating crane king structure and it is divided into two
main chambers. The chambers are connected together via holes near the bottom of the
reservoir. One chamber is where the oil enters the tank from the filters and the other chamber is
where the suction ports for the pumps are located. This allows the oil to settle before entering
the self-suction pumps and reduces the threat of cavitation.
The reservoirs are equipped with the following accessories:
• Suction Valves (Butterfly valves or ball valves)

• Drain Valves
• Visual thermometer
• Electric temperature sensors
• Pressure transmitter for level control
• Visual level gauges
• Temperature/Level switch(low level and low low level)
• Return filters
• Drain filters
• Air Breather Filters
• Hatch for entering the reservoir
The Suction Valves (butterfly valves) are mounted on the tank wall by flanges. There is one for
each suction line and they are used to hydraulically isolate the pumps for maintenance. Two ball
valves are located underneath the reservoir for draining the hydraulic oil in the tank. The suction
valve for the Filtration Unit is located underneath the tank.
On the tank wall in the King there is a visual level gauge and a thermometer. In addition, there
is a pressure transmitter for continuous monitoring of the oil level. The electrical signal from the
transmitter is connected to the control system where the signal is converted in the PLC. The
level is indicated on the operators screen by means of a bar graph.
There is a temperature/level switch located on top of the tank. The level indication is achieved
by means of two floating elements sliding on a rod inside the tank. The highest floating switch
indicates the Low level and will give an alarm on the operators screen if this level is reached.
The lowest floating switch indicates the Low Low level, which if activated will automatically shut
down the pumps as well as sending an alarm to the operators screen. The biggest variations in
oil level changes are when the crane’s jib is operated. The switch also includes two temperature
sensors which are used to indicate High oil temperature and High High oil temperature. In both
cases an alarm will be given on the operator screen if activated.
The electric temperature sensor that is mounted on the tank wall is also connected to the
control system and the signal is used to show the continuous oil temperature on the operator
screen in the crane cabin.
Page 3 of 14
There are two return filter units installed outside of the oil reservoir. These are in-line filter units,
and equipped with both visual and electrical clogging indicators, which sends an alarm to the
operator’s screen via the control system if the level of contamination becomes too high. The
well-dimensioned return filters ensure good quality oil.
There are two drain line filters also situated on the top of the tank, one is for the drain lines from
main winch motors, whip winch motors and slew motors, and the other one is for the Main
Pumps drain lines. One common drain manifold gathers all other drain oil from the system and
returns this back to the tank.
Air Breather Filters are installed on top of the tank to stop the build-up of gases and fumes as
well as insuring that atmospheric pressure is kept in the tank regardless of oil volume variations.
The breathers also have a filter to ensure contaminated air does not enter the tank.
The reservoir can be accessed for inspection or maintenance by means of a hatch on top of the
tank.
1.2 Oil Coolers

The oil coolers (4 off) are located on the platform outside of the rotating crane king. They consist
of a cooling element, a fan and an electric motor. The coolers are hydraulically connected by
means of flexible hoses. The coolers have a check valve to ensure a certain oil flow (pressure
drop). They can easily be opened for inspection and cleaning.
1.3 Filtration Unit Assembly

A filtration unit is mounted in the pedestal attached to the crane king bottom plate. It consists of
an electric motor, a fixed displacement pump and a filtration package. The unit has a special
filter element for absorbing water and removing particles in the oil. Both visual and electrical
clogging indicators are included to monitor the overall condition of the filter.
1.4 Circulation motor/pump assembly

The circulation motor/pump assembly is vertically mounted on the tank wall inside the rotating
crane king, outside the oil reservoir. It consists of a fixed displacement pump, adapter flange,
flexible coupling and el. Motor. The electric motor is equipped with heating element and
thermistor. Since the pump is a fixed displacement screw pump the flow from the pump is
constant. This pump is delivering oil into the return system through the oil coolers and through
filters before entering the oil reservoir. This system is therefore important for conditioning of the
oil in the reservoir both with respect to the temperature and the cleanliness level of the oil.
1.5 Main Motor/Pump assembly

The three main motor/pump assemblies (3 single pumps) are mounted vertically inside the King.
The electric motor and the adapter flange are bolted upright underneath a thick plate at the
bottom of the king. The pump is mounted on top of the adapter flange, which has a flexible
rubber flange. Between the shafts on the motor and the pump there is a flexible coupling which
reduces torsion vibrations, as well as compensating for axial, radial and any angular shaft
misalignments.
The hydraulic pumps are axial piston pumps with a variable swash plate design for adjusting the
displacement/delivery volume from the pumps. The pumps deliver a flow proportional to the
swash plate angle and are designed for use in open loop circuits. Each pump is equipped with a
pressure compensated load sense (LS) regulator. A common LS system controlled by the PLC,
adjusts the compensating pressure depending on the maximum load/pressure reading in the
Page 4 of 14
system. Maximum operating pressure for this main pump system is 330 bar.
The electric motors, all equipped with heating element and thermistor, operate at a constant
speed.
1.6 Main system, Load Sense LS control

To control the main pumps an electric operated proportional control valve is used. This valve is
tuned in the control system so that when the joystick is moved out of centre the pumps will
automatically increase from an idle pressure of approximately 40 bars to a pressure level of
approx 150 bars.
When a crane function is used the LS pressure is read by two pressure transmitters mounted in
parallel. The control system will then automatically set the required pump pressure by regulating
the electric operated proportional control valve to a calculated pressure.
1.7 Emergency Motor/Pump Assembly

The emergency motor/pump assembly is mounted vertically inside the crane king. It consists of
a variable displacement axial piston pump, an electric motor (equipped with heating element
and thermistor), an adapter flange and a flexible coupling. The hydraulic pump is isolated from
the main system by manually operated shut off valves. The pump is equipped with an LS
regulator and is hydraulically controlled by the load/pressure in the main control valve. A
separate pressure relief valve is installed on the pump outlet to prevent high pressure in this
system
1.8 High Pressure Filters

The high pressure filters are mounted on the front wall of the tank inside the rotating crane king.
Each main pump outlet is connected to a high pressure filter, and each filter has a by-pass
valve and both a visual and electric clogging indicator. An alarm signal is given on the operator
screen if any clogging indicator is activated. Pressure relief valves are located on every pump
outlet (before filter) to limit the pressure in the system.
1.9 Main Control Valve

The main control valve located in the rotating crane king consists of several standard modules
that are bolted together. The modules are as follows:
• One inlet section

• One module for the Main Winch Up/Down function.
• One module for the Main Jib up/down function.
• One module for the Knuckle Jib out/in function
• One module for the Slew clock-wise/counter clockwise function.
• Mid-section with additional P & T ports
• One module for the Whip Winch
• End cover with inlet connection plate
The inlet section houses two different pressure control valves of cartridge type, which are
inserted into cavities. The largest one is a direct operated pressure relief valve. The upstream
side of this valve is connected to the common oil supply line and the downstream side is
connected to the common return line. This limits the pressure in the system if an unintentional
pressure built up should occur.
Page 5 of 14
The smallest valve in the inlet section is a direct operated pressure reducing valve. The
upstream side of the valve is connected to the common oil supply line. The valve reduces the
pressure down to 45bar (as long as the oil supply pressure is above 45 bar) and is used to feed
oil to the pilot valves via the external port “PP”.
Each working module contains the same type of main components.
Pilot pressure relief valves are fitted for limiting the pressure in the two outlet ports, A and B,
that are connected to the actuator e.g. winch, cylinder etc. The pressure setting is set
individually for the A and B ports on each module.
The main spool inside each working module directs the oil from the oil supply line to the actual
working port and from the actual working port to the return line. The position of the spool is
controlled by hydraulic pressure acting on the cross sectional area at the end of the spool. The
opposite side of the spool is then connected to drain. The spool is spring centred, which means
that when the pressures on both sides of the spool are zero, the spool is centred by means of
two springs, one at each end of the spool. In this position the oil supply port is closed.
Two pilot valves are used to control the position of the main spools in the main control valve.
The pilot valve is a proportional electric operated pressure-reducing valve. All pilot valves for the
crane functions such as slew, main jib, knuckle jib and winch are controlled via the control
system, connected to the joystick located on the operator chair in the crane cabin. When one of
the joysticks is taken out of neutral position a pilot pressure is applied to one side of the spool
and the other side is connected to drain by means of the actual pilot valve.
Each working module also has a pressure compensator fitted mounted in the oil supply line
upstream of the main spool. The purpose of this valve is to always keep a constant pressure
drop across the main spool ensuring that the oil flow to an individual function is independent of
the load pressure of this function and that the oil flow to one function is independent of the load
pressure of other functions.
2 Jib System
The Jib System is used to handle the load hanging from the hook from minimum to maximum
working radius and mainly consists of two main jib hydraulic cylinders and two knuckle jib
hydraulic cylinders.
2.1 Main Jib

The Jib is connected to the rotating crane king structure by two main bearings at the top of the
crane king and to the rod bearing of the two hydraulic cylinders at the lower end of the Jib
structure. The two hydraulic Main Jib cylinders are equipped with spherical bearings at both
ends and are built especially for use in a marine environment, with chrome plated piston rods in
order to obtain good protection against corrosion.
A valve block including a load control valve (over centre valve/counter balance valve) is flanged
to the hydraulic connection on the piston side of the cylinder. Since the cylinders are always
exposed to external forces in one direction (compression forces), there are only load control
valves on the piston side of the cylinders which have the following functions:
Page 6 of 14
• Locking of the flow from the piston side of the cylinders in case of a hose or pipe rupture
or if the pumps are stopped during operation.
• Cavitation free load lowering controlled by the lowering pressure i.e. the rod pressure
supplied via the main spool in the main control valve. This prevents the cylinders from
accelerating downwards.
• Free flow through the check valve function for lifting of the load.
The two cylinder rod sides are also hydraulically connected together inside the crane king and
have a pressure relief valve to limit the pressure on the rod side of the cylinders. The
downstream side (return line) of the valve is connected to a common return line that is routed to
the oil reservoir.
2.2 Knuckle Jib

The two hydraulic knuckle jib cylinders are equipped with spherical bearings at both ends which
support them to the outer end of the main jib and the lower end of the knuckle jib structure. The
cylinders are built especially for use in marine environment with chrome plated piston rods in
order to obtain good protection against corrosion.
The knuckle jib cylinders are exposed to external forces in both directions (compression and
tension forces), so it is necessary to have a load control valve (over centre valve/counter
balance valve) flanged to the hydraulic connection at both ends of the cylinders. The load
control valves on the knuckle jib cylinders have the same functions as for the main jib cylinders.
Additionally, the rod side of the cylinder also contains a pressure relief valve which limits the
pressure on the rod side of the cylinder. The downstream side (return) of the valve is connected
to a common return line that is routed to the oil reservoir.
3 Slew System
The slew system consists mainly of slew gears, hydraulic motors and hydraulic valves.
3.1 Slew Gears

A slew bearing equipped with an internal gear ring sits between the rotating crane king and the
top of the foundation. The slew torque is transferred to the gear ring from the output pinions of
the gearboxes which are located inside the rotating crane king and mounted with the pinion at
the lower end of the gearbox. The seven slew gears are hydraulically driven with a built in fail-
safe dynamic multidisc brake, which are disengaged by means of a hydraulic pressure taken
from the common A- or B lines of the hydraulic motors. In the case of a hose or pipe rupture the
brake locks the slew function immediately. The brakes are dimensioned to take the full load at
the maximum trim list, plus any additional dynamic force acting on the slew gears.
3.2 Hydraulic Motor including valves

Each of the seven slew gear is equipped with a fixed displacement hydraulic motor with axial
piston rotary group of bent axis design. All motors are controlled by means of a working section
in the main control valve. On the main ports, A and B there is a load control valve which closes
the return or downstream flow when the spool in the main control valve is in neutral position or
when the pumps are stopped during operation. The valves also ensure cavitation free
Page 7 of 14
movement when the crane is slewing “downwards”.
3.3 Hydraulic Valves and Valve Block

In addition to what is mentioned above, the Slew system also consists of the following hydraulic
components:
• A main control valve (see chapter 1.8)
• A 3/2 way electric operated directional valve (slew motor by-pass function)
• A ball valve
• A accumulator
• Accumulator valve block
A 3/2 way electric operated directional valve is used to enable the slew motor by-pass function
when the slew function is not in use.
The accumulator stores sufficient oil to keep the motors topped up with hydraulic oil. Oil from
the bladder accumulator will flow through a pressure reducing valve inserted in the valve block
(20 bars) to each hydraulic slew motor.
The ball valve is used to isolate the valve block during maintenance.
4 Main Winch System

The crane is equipped with a Main Winch (20T SWL) which is mounted on top of the crane
King. It contains a steel drum with two side plates and two gear-boxes. The main components of
the Winch are listed below.
4.1 Gearbox
There are two horizontally mounted gear boxes, one each side of the winch drum, equipped
with a fail-safe multi-disc brake and a sprag clutch. A fail-safe brake means that if no hydraulic
pressure is applied the brake is engaged, a result of this is the brakes will lock immediately if a
hose or pipe rupture should occur. The brake is dimensioned to take the full load plus any
additional dynamic forces acting on the winch. Since the gear box houses a sprag clutch there
is no need to apply a hydraulic pressure to the brakes when the winch is used for hoisting.
Torque is transferred via a rotating flange on the gearbox.
4.2 Hydraulic Motors

Since the gear box is hydraulically driven a hydraulic motor is located on each gear box. The
motor is a fixed displacement motor with axial piston rotary group of bent axis design. The motor
is hydraulically controlled by means of a working section in the main control valve inside the
crane king.
4.3 Winch Motor Valve Block

Both hydraulic motors on the winch are equipped with a valve block, flanged directly to the main
A and B ports on the motor. The valve block contains a pilot operated pressure relief valve and
a load control valve as well as cartridge valves which relate to Emergency Lowering. These
cartridge valves are inserted into cavities in the valve block.
The function of the pilot operated pressure relief valve is to limit the pressure drop or maximum
output torque across the hydraulic motor.
Page 8 of 14
The load control valve is mounted between the “Winch UP” port on the motor and the A-port on
the working section in the main control valve. The functions of this valve are:
• Locking of the downstream flow or return flow if the pumps are stopped.
• Cavitation free load lowering controlled by means of the pilot pressure that is supplied in
the “Winch Down” line via the spools in the main control valve. This prevents the load
from accelerating downwards.
• Free upstream flow for load hoisting through the built-in check valve.
4.4 Hydraulic Valves

In addition to what is mentioned above, the Winch system consists of the following main
hydraulic components:

• Two 3/2 way electric operated directional valves (CT on/off and MOPS selection)
• A proportional pressure relief valve (CT adjust valve)
• A pressure relief valve (MOPS adjust valve)
• A pressure reducing valve with a check valve
• A pressure reducing valve
• A sequence valve
• A shuttle valve
The first 3/2 way el. operated valve is used to enable Constant Tension (CT). When the
operator selects CT on the screen, this valve is energised and in turn opens the 2/2 valve in
each motor valve block. This enables the pilot pressure setting for the pilot operated pressure
relief valve in the motor block to be controlled by the proportional pressure relief valve in the
king via the MX port on the motor valve block.
The second 3/2 way el. operated valve and pressure relief valve are used in MOPS mode. For a
more detailed description of the MOPS function see chapter 4.5.
A pressure reducing valve with a check valve is housed in a cabinet along with the sequence
valve and a pressure transmitter. The sequence valve ensures that 30 bar is present before the
brakes are released.
An additional pressure reducing valve supplies a flow to each hydraulic winch motor to keep the
motors topped up with hydraulic oil.
4.5 Manual Overload Protection System (MOPS)

The main winch is fitted with an emergency release system or MOPS (Manual Overload
Protection System). The purpose of this system is to reduce the risk of any structural damage to
the crane if the winch is hooked onto another vessel or an object on the seabed. The system
must also work if a power failure should occur on board the vessel and it is for this reason that a
UPS is installed to provide emergency power. The system is activated by pushing the MOPS
button located near the operator’s chair. The system includes the following main components:
• Two Accumulators
• A MOPS/Emergency Pay Out Block
Page 9 of 14
• A Pressure Relief Valve
Since the emergency release system must work even if a power loss should occur, the hydraulic
energy is taken from two bladder accumulators mounted close to the MOPS /Emergency Pay
Out Block. The nominal volume of each accumulator is 50 litres and they are connected to the
ACC1, ACC2 ports on the block.
The MOPS/Emergency Pay Out Block contains different valves which are connected by internal
drillings in the block. The main components included in the valve block are listed below:
• A 3/2 way electrically operated pilot valve

• A 2/2 way hydraulic operated directional valve
• One 3/2 way hydraulic operated pilot valve
• A pressure Relief Valve
• A pressure reducing/relief valve
• Four check valves
• A shuttle valve
The 3/2 way electrically operated pilot valve is a directional poppet valve. The “P” port is
connected to the bladder accumulators mentioned above and the “T” port is routed to the
external drain port “CTD”. The “A” port is connected to the pilot valve on the 2/2 way pilot
operated directional valve and also the 4/2 hydraulic operated pilot valve.
The 2/2 way hydraulic operated directional valve is a cartridge valve and it consists of a main
stage including a valve cone, a bushing and a valve cover. On top of the cover there is a
hydraulic operated 3/2 way pilot spool valve with NG6 mounting pattern. The 2/2 way directional
valve is mounted in the same line as from the B ports on the winch motor block to the B port on
the on the main control valve inside the rotating crane king. The 2/2 way hydraulic operated
directional valve is used to close the connection between the “Lowering” port on the hydraulic
motor and the working section in the main control valve when the Emergency release system is
activated. In this mode the valve prevents oil to flow to the reservoir via the spool in the main
control valve (The A- and B ports are connected to the T port when the spool is in neutral
position). The 2/2 way valve is normally open i.e. when there is no pilot pressure available the
main cone is open.
When the MOPS button in the crane cabin is activated, the 3/2 way electric operated pilot valve
is activated and opened. The emergency release functions will now activate in the following
manner:
Oil from the two bladder accumulators will flow through a pressure reducing valve (40 bars) to
the 2/2 way hydraulic operated directional valve and it will close as described above. The
accumulators will also ensure sufficient oil flow to disengage the brakes on the winch and avoid
cavitation on the winch motor when the load is lowered.
In addition to this the 4/2 hydraulic operated pilot valve, also of NG6 design, will pressurize the
Pil2 ports on the motor valve blocks on the winch and “dump” the pressure setting of the pilot
operated pressure relief valve mounted between the “Winch Up” port on the motor and the load
control valve in the motor valve block, The pressure setting of this valve is then overridden by
Page 10 of 14
the pressure setting of a remote pressure relief valve via the pilot port, MX. The pressure setting
of remote pressure relief valve is a predefined value. If the load pressure is higher than this
predefined pressure setting, the load will be lowered.
4.6 Automatic Overload Protection System (AOPS)

The AOPS function shall automatically activated both when the load registered by the load cell
exceeds a certain value which is predefined according to the AOPS load chart in the control
system and when the hook is within a defined sector outside the shipside. The Winch Down
electrically operated proportional valve –XYVL202 is energized in the main control valve (100%
activation) which lowers the load at maximum speed and stops when the load is below the rated
lift capacity.
5 Whip Winch System

The crane is equipped with a Whip Winch (10T SWL) which is mounted on top of the Jib close
to the crane king. It contains a steel drum with two side plates and two gear-boxes. The main
components of the Winch are listed below.
5.1 Gearbox
There are two horizontally mounted gear boxes, one each side of the winch drum, equipped
with a fail-safe multi-disc brake and a sprag clutch. A fail-safe brake means that if no hydraulic
pressure is applied the brake is engaged, a result of this is the brakes will lock immediately if a
hose or pipe rupture should occur. The brake is dimensioned to take the full load plus any
additional dynamic forces acting on the winch and one brake is dimensioned to take full load
during personnel lift. Torque is transferred via a rotating flange on the gearbox
5.2 Hydraulic Motors

Since the gear box is hydraulically driven a hydraulic motor is located on each gear box. The
motor is a fixed displacement motor with axial piston rotary group of bent axis design. The motor
is hydraulically controlled by means of a working section in the main control valve inside the
crane king.
5.3 Winch Motor Valve Block

Both hydraulic motors on the winch are equipped with a valve block, flanged directly to the main
A and B ports on the motor. The valve block contains a pilot operated pressure relief valve and
a load control valve as well as cartridge valves which relate to Emergency Lowering. These
cartridge valves are inserted into cavities in the valve block.
The function of the pilot operated pressure relief valve is to limit the pressure drop or maximum
output torque across the hydraulic motor.
The load control valve is mounted between the “Winch UP” port on the motor and the A-port on
the working section in the main control valve. The functions of this valve are:
• Locking of the downstream flow or return flow if the pumps are stopped.
• Cavitation free load lowering controlled by means of the pilot pressure that is supplied in
the “Winch Down” line via the spools in the main control valve. This prevents the load
from accelerating downwards.
Page 11 of 14
• Free upstream flow for load hoisting through the built-in check valve.
5.4 Hydraulic Valves

In addition to what is mentioned previously, the Winch system consists of the following main
hydraulic components:

• Two 3/2 way electric operated directional valves (CT on/off and MOPS selection)
• A proportional pressure relief valve (CT adjust valve)
• Two 4/2 way electric operated directional valves
• A pressure relief valve
• A pressure reducing valve with a check valve
• A pressure reducing valve
• A sequence valve
• Two shuttle valves
The first 3/2 way el. operated valve is used to enable Constant Tension (CT). When the
operator selects CT on the screen, this valve is energised and in turn opens the 2/2 valve in
each motor valve block. This enables the pilot pressure setting for the pilot operated pressure
relief valve in the motor block to be controlled by the proportional pressure relief valve in the
king via the MX port on the motor valve block.
The second 3/2 way el. operated valve and a pressure relief valve are used in MOPS mode.
For a more detailed description of the MOPS function see chapter 5.5.
The two 4/2 way electrically operated hydraulic pilot valves are housed in a cabinet along with
the sequence valve, a pressure transmitter, a shuttle valve and a pressure reducing valve with a
check valve. The two 4/2 way valves separate the braking circuit when Personnel lift is selected
by the operator. One brake is dimensioned to take the full load when handling personnel. The
sequence valve ensures that 30 bar is present before the brakes are released.
A pressure reducing valve supplies a flow to each hydraulic winch motor to keep the motors
topped up with hydraulic oil.
5.5 Manual Overload Protection System (MOPS)

The whip winch is fitted with an emergency release system or MOPS (Manual Overload
Protection System). The purpose of this system is to reduce the risk of any structural damage to
the crane if the winch is hooked onto another vessel or an object on the seabed. The system
must also work if a power failure should occur on board the vessel and it is for this reason that a
UPS is installed to provide emergency power. The system is activated by pushing the MOPS
button located near the operator’s chair. The system includes the following main components:
• Two Accumulators
• A MOPS/Emergency Pay Out Block
• A Pressure Relief Valve
Since the emergency release system must work even if a power loss should occur, the hydraulic
Page 12 of 14
energy is taken from two bladder accumulators mounted close to the MOPS /Emergency Pay
Out Block. The nominal volume of each accumulator is 50 litres and they are connected to the
ACC1, ACC2 ports on the block.
The MOPS/Emergency Pay Out Block contains different valves which are connected by internal
drillings in the block. The main components included in the valve block are listed below:
• A 3/2 way electrically operated pilot valve
• A 2/2 way hydraulic operated directional valve
• A pressure Relief Valve
• A pressure reducing/relief valve
• Four check valves
• A shuttle valve
The 3/2 way electrically operated pilot valve is a directional poppet valve. The “P” port is
connected to the bladder accumulators mentioned above and the “T” port is routed to the
external drain port “CTD”. The “A” port is connected to the pilot valve on the 2/2 way pilot
operated directional valve and also the 4/2 hydraulic operated pilot valve.
The 2/2 way hydraulic operated directional valve is a cartridge valve and it consists of a main
stage including a valve cone, a bushing and a valve cover. On top of the cover there is a
hydraulic operated 3/2 way pilot spool valve with NG6 mounting pattern. The 2/2 way directional
valve is mounted in the same line as from the B ports on the winch motor block to the B port on
the on the main control valve inside the rotating crane king. The 2/2 way hydraulic operated
directional valve is used to close the connection between the “Lowering” port on the hydraulic
motor and the working section in the main control valve when the Emergency release system is
activated. In this mode the valve prevents oil to flow to the reservoir via the spool in the main
control valve (The A- and B ports are connected to the T port when the spool is in neutral
position). The 2/2 way valve is normally open i.e. when there is no pilot pressure available the
main cone is open.
When the MOPS button in the crane cabin is activated, the 3/2 way electric operated pilot valve
is activated and opened. The emergency release functions will now activate in the following
manner:
Oil from the two bladder accumulators will flow through a pressure reducing valve (40 bars) to
the 2/2 way hydraulic operated directional valve and it will close as described above. The
accumulators will also ensure sufficient oil flow to disengage the brakes on the winch and avoid
cavitation on the winch motor when the load is lowered.
In addition to this the 4/2 hydraulic operated pilot valve, also of NG6 design, will pressurize the
Pil2 ports on the motor valve blocks on the winch and “dump” the pressure setting of the pilot
operated pressure relief valve mounted between the “Winch Up” port on the motor and the load
control valve in the motor valve block, The pressure setting of this valve is then overridden by
the pressure setting of a remote pressure relief valve via the pilot port, MX. The pressure setting
of remote pressure relief valve is a predefined value. If the load pressure is higher than this
predefined pressure setting, the load will be lowered.
Page 13 of 14
5.6 Automatic Overload Protection System (AOPS)

The AOPS function shall automatically activated both when the load registered by the load cell
exceeds a certain value which is predefined according to the AOPS load chart in the control
system and when the hook is within a defined sector outside the shipside. The Winch Down
electrically operated proportional valve –XYVL205 is energized in the main control valve (100%
activation) which lowers the load at maximum speed and stops when the load is below the rated
lift capacity.
Page 14 of 14
4 Handling, Preservation & Installation

Table of Contents
1. Introduction ......................................................................................................................................1
2. Unloading and Handling ...................................................................................................................1
3. Crane Preservation ..........................................................................................................................1
4. Installation of Crane Unit ..................................................................................................................1
4.1. Crane installation .......................................................................................................................1
5. Initial Start-up ...................................................................................................................................1
6. Function and Load Tests..................................................................................................................2
7. Wire Handling Recommendation ......................................................................................................2
T0011 – Handling, Preservation & Storage Procedures .......................................................................3

MACGREGOR NORWAY AS
Blank page.

MACGREGOR NORWAY AS
1. Introduction
The purpose of this procedure is to:
1. Ensure that all components are handled / lifted in a safe and correct way to avoid any injury or damage
to personnel or equipment.
2. Ensure up to 2 years’ storage with no deterioration in function and/or quality that could reduce the
working performance or service life of the unit.
3. Ensure that installation and initial start up are performed in a safe and correct way.
2. Unloading and Handling

Crane components are provided with lifting lugs for safe lifting. See separate document: T0011 – Handling,
Preservation & Storage Procedures page 3.
3. Crane Preservation
See separate document: T0011 – Handling, Preservation & Storage Procedures page 3.
4. Installation of Crane Unit

Check the following:
• Deck structure must be free from cracks, rust, oil and other elements that could inhibit bolting/welding
of the pedestal to the sub-foundation.
• The crane is delivered as agreed.
• Be sure that no dust or other contaminants enter the hydraulic system.
• Be sure that the vessel’s foundation sub-structure is dimensioned to bear the weight of the specific
crane and the forces it will exert.
4.1. Crane installation

Crane delivered Ex Works, installed under Cargotec Norway AS supervision.
5. Initial Start-up
It is important to check that valves and controls are in the correct position before attempting to start the crane.
As a final check before starting, check the rotation of the electric motors. Motors must rotate in a clockwise
direction as seen from the motor’s fan end. If a motor rotates in the wrong direction, swap two phases and check
again for clockwise rotation.
The main HPU motors are bolted just below the slew bearing on the underside of the king bottom plate. Access
is through a door in the pedestal.
A hydraulic pump must not be allowed to run in the wrong direction for any length of time, as this will
reduce the service life of the pump.

Upon completion of the initial test run, check the oil level in the oil tank, and top up if necessary.
The first time the system is started there may be air in the system. Run the power pack for a couple of minutes at
low pressure. The winch and the slew will automatically vent air from the system when operated.
See Chapter 5 for details on crane start and operation.
6. Function and Load Tests

Do not put the crane into normal service until the Harbour Acceptance Test (HAT) and the Sea Acceptance Test
(SAT) have been performed.
7. Wire Handling Recommendation

Steel wire on a drum is a complex component in a winch system, and “training” a new wire will contribute to
optimum spooling
This is done by lowering and raising the full length of wire a minimum of three times while maintaining a
tension equivalent to 10%-20% SWL.
T0011 – Handling, Preservation & Storage Procedures

(following pages)

Blank page.
PROJECT DOCUMENT
This document and all information and data herein or herewith is the confidential and proprietary property of
MacGregor Norway AS and is not to be used, reproduced or disclosed in whole or in part by or to anyone without
the written confirmation from MacGregor Norway AS.
© MacGregor Norway AS
www.macgregor-group.com
Equipment:
Offshore Products
00 Issued for Approval 13.03.09 SVB

Rev. Reason for issue: Date Auth. Check.
Title:
T0011 Handling Preservation & Storage Procedure
Customer: Project name.:
- -
HM project no.: Supplier:
- MacGregor Norway AS
Andøyfaret 15, N-4623 Kristiansand
NORWAY
HM doc. no.: Customer doc. no.: No.of attachments: No. of pages:

T0011 31
Title: Handling Preservation & Storage Procedure
Proj.No.:
Doc.No.: T0011
1 GENERAL ............................................................................................................. 3
1.1 References ...................................................................................................................................3
2 PRECEDING ACTIVITIES ..................................................................................... 3

2.1 Preparation ...................................................................................................................................3
2.1.1 Offshore products ......................................................................................................................3
3 LIFTING ................................................................................................................. 3
3.1 Safety Note ...................................................................................................................................3
3.2 Lifting Performance .....................................................................................................................4
4 TRANSPORT ........................................................................................................ 4
4.1 Packing .........................................................................................................................................4
4.2 Unpacking ....................................................................................................................................4
4.3 Transport Performance. ..............................................................................................................4
5 STORAGE ............................................................................................................. 5
5.1 Preparation ...................................................................................................................................5
5.2 Storing ..........................................................................................................................................5
6 PRESERVATION .................................................................................................. 6
6.1 Inspection of equipment on Receipt .........................................................................................6
6.2 Preservation of MacGregor Hydramarine Equipment .............................................................6

6.2.1 Preservation Check Record Mechanic Hydraulic, Electric, and Instrument. .............................8
6.3 De – Preservation ..................................................................................................................... 24
6.4 Preservation Label ................................................................................................................... 25
6.5 Topped Gearbox ....................................................................................................................... 26
6.6 Table of Preservatives. ............................................................................................................ 27
6.7 Project cycle for preservation at delivery .............................................................................. 30
6.8 Project cycle for preservation after use ................................................................................. 31

Proj.No.:
Doc.No.: T0011
1 GENERAL
The purpose of this procedure is to ensure proper storage, safe lifting and transport of
MacGregor Norway Offshore Products
1.1 References
HM Doc. No. Doc. Title
SPxxx-XXXX-GXX [300T Main….]
SPxxx-XXXX-…. [Spooling….]
SPxxx- XXX-…… [Control…..]
2 PRECEDING ACTIVITIES
2.1 Preparation
The following actions shall be done prior to lifting and transport operations of MacGregor
Norway products. A “Tilt Watch” may be placed on the items to check if the transport and
lifting has been done in a proper way.
2.1.1 Offshore products

Reference is made to relevant transport drawing showing the equipment, lifting
arrangement and transport cradle etc.
• Wire rope to be fully spooled onto the drum with tension. The free end to be
fastened properly.
• Wooden pads (4 off) are to be fitted underneath the feet of the foundations on
small parts without transport cradle.
• Ensure that all movable parts are properly fastened to prevent them from any
uncontrolled movements.
• Ensure that end of interface electric cables and hydraulic hoses are disconnected
and their loose end are fastened and protected properly. Make sure that all ends
are marked properly to avoid any problems during reconnection of the
equipment.
• The opened hydraulic connections to be protected against impurity with caps.
• Lifting and handling of the equipment to be prepared according to relevant lifting
drawing.
• Length and capacity of loose lifting gear to be in accordance to relevant lifting
drawing.
• Loose lifting gear to be inspected for defects.
• Loose lifting gear certificates to be present.
3 LIFTING
3.1 Safety Note

This procedure must be subjected to a pre-operation Tool Box Talk with all relevant
personnel involved. The Safety Hazard to be identified and the required Safety Measures
explained. The operation shall not start until all Safety Measure are in place.
Proj.No.:
Doc.No.: T0011
• Always make sure that proper lifting equipment is used

• Always make sure that the shackles are properly fastened with shackle safety
pins, and no twist on the lifting wire before lifting.
• Always make sure that only certified lifting gear, as described in this procedure is
being used.
3.2 Lifting Performance

The product is equipped with lifting lugs of required capacity and dimensioned for
belonging shackles. The relevant lifting drawing contains information about lifting lug
locations and capacity. Total weight of the unit together with weight in each sling is also
specified. COG is indicated on the drawings and if correct lengths of the lifting slings are
used the lifted object should be in balance.
4 TRANSPORT
The equipment may be transported by ship or truck to final destination.
For more detailed information about overall dimension weights and COG locations
individually for each unit, refer to section 3 in this document and/or corresponding GA
drawing, transport drawing, and or relevant packing list.
4.1 Packing
Belonging equipment to the product may be packed in standard 20` container and on
deck of transport vessel. Preparations described in 2.1 shall be performed. Make sure
there remains no loose component in the container. All the modules shall be properly
strapped to container.
Smaller items may be packed in VCI bags for transport
4.2 Unpacking
The unpacking shall be done short time prior to installation. If unpacking is done earlier,
follow instruction given in section 5.
Check that equipment has not moved inside container, and there are no damages or
elements missing before unloading. If any damages are found, take pictures when
equipment still is inside container, or on transport vessel. Carefully loosen the securing of
each element.
Unpacking from open top container is done by using lifting sets/sling mounting on the
equipment. Follow lifting instructions given in section 3. Fork truck is used for unpacking
equipment without lifting sets.
4.3 Transport Performance.

Common recognized standard for stowing should be applied. The equipment can be
transported on an open platform/deck.
For loading/unloading process follow instruction given in section 3 and use the lifting aids
mentioned there.
Proj.No.:
Doc.No.: T0011
5 STORAGE
5.1 Preparation
• Prepare sufficient area for storing: The equipment shall be stored in areas free of
contamination from welding, grinding or other activity containing hot metal
particles.
• It is recommended to choose sheltered place, if storing the equipment outdoors.
• All the disconnected interface electrical and hydraulic joints are to be protected, no
loose items left.
• Carbon steel surfaces which are not painted to be preserved as described in
attached tables of preservative
• Touch up painting if paint has been damaged.
• If the equipment is contaminated by salt, dirt or particles which may damage the
equipment, the equipment shall be washed with fresh water prior to storage.
5.2 Storage
The product and loose components should be stored in their natural position. They should
rest on wooden pads to isolate the equipment from the ground. Unpainted/exposed steel
shall rest on a rubber layer with wooden pads below. The equipment cannot be stacked
up on top of each other. The equipment is to be protected during storing, and also after
installation onboard against dust, damages, humidity, painting etc. (see chapter 6)
NOTE:
If the equipment is stored for more than three months, the standard periodic maintenance
activities (lubrication) are to be done to the equipment according to the maintenance
schedule. For details refer to corresponding documents. Re-preservation is solely the
responsibility of the buyer or the buyers appointed as described in chapter 6.7 Project
Cycle for Preservation.
Proj.No.:
Doc.No.: T0011
6 PRESERVATION
Preservation work in all stages of the project may involve usage of solvent that may be
harmful to human. Personal performing this type of work, should be wearing personal
protection equipment.
When purchasing preservatives, data sheet must be required as a part of the delivery.
These sheets must be received and correct action taken according to listing on data sheet
before preservation can be carried out.
6.1 Inspection of equipment on Receipt

All equipment is initially preserved by MacGregor Norway. Upon receipt, and prior to
storage, the equipment shall be inspected. Areas where preservation has been damaged,
teared or fret, shall be repaired If found necessary. Use the check record as a guide.
6.2 Preservation of MacGregor Norway Equipment

The hydraulic piping system on the equipment is flushed and sealed off by MacGregor
Norway. All open-end nozzles shall remain plugged or capped to avoid ingress of material
that can contaminate the piping and fluid in the piping. Non metallic plugs shall not be
used. All hydraulic components are filled with proper hydraulic oil during storage and
transport.
All yellowcromated materials, as well as valve spindles are covered with Densotape to
avoid corrosion.
Shafts on rotating equipments, which are not locked, shall be rotated 1 ¼ turn in the
rotation direction to avoid brinelling of the bearing. Make sure that new shaft positions
vary from one turn to the other.
Connect heaters to all motors that are specified in the check record to be heated. Check
the heaters to be effective after power hook up by using an Ampere meter, or hand feel
the temperature outside the motor.
HM has topped up all gearboxes with gear oil. Vertical gear box with the pinion facing
down, are topped when they are in operation as well as during storage. These gearboxes
are filled with oil and can go right into operation provided that the storage time is limited.
Horizontal gearboxes are also topped with oil. Horizontal gearboxes must be drained to
correct level prior to use of the boxes. However, heavy-duty gearboxes have been
drained for gear oil, and the gear oil is replaced with preservation oil to specified
level. See check record for correct oil and level. Gear boxes topped with oil shall be
marked with labels as shown in chapter 6.6.
All air bottles or accumulators are put under pressure using dried Nitrogen. The pressure
is normally between 2 and 3 bars. Inspect air bottles or accumulators for positive Nitrogen
pressure. If the pressure is below 1.5 bars, re-pressurize with Nitrogen of dew point –
30deg.
All exposed valve spindles are protected with densotape.
All electrical and electric boxes or cabinets exposed to humidity shall be protected with
desiccants inside. Place a sticker on the outside of the cabinet showing the date when the
desiccant was put in.
Proj.No.:
Doc.No.: T0011
Shafts on electrical motors and the mechanical seal at the front bearing shall be protected
with grease of type described in preservation record.
All non terminated cable ends shall be fitted with shrinking shroud.
All space heaters on motors, generators, panels etc. shall be energized for storage.
Preservation shall be checked periodically. Any anomaly shall be rectified. The

preservation period is described in the check record.
If the storage area location results in salt spray, the equipment should be washed down
with freshwater periodically to reduce corrosion risk.
Proj.No.:
Doc.No.: T0011
6.2.1 Preservation Check Record Mechanic, Hydraulic, Electric, and Instrument.

Title.: Handling Preservation & Storage Procedure
Proj.No.: SPXXXX
Doc.No.: SP…………
PRESERVATION SPECIFICATION & RECORD – Crane Pedestal, MECHANICAL

Record No.: Tag No.: Description Record page:
Intervals Initial Date/Sign Date/Sign Date/Sign Date/Sign

Activity no Description of Preservation Activity Preservative
(Months) Preservation Preserved2 Preserved3 Preserved4 Preserved5
Tectyl 122
1 3 All unpainted carbon steel flanges to be coated with preservatives
Decordyn 350
2 1 Check that protection structure is undamaged
Paint system in
3 3 All painting to be undamaged. If not, repair painting
HM…….
Tectyl506/
4 3 Chain linkages which can be exposed to rust to be protected
CortecVpCI369
Tectyl506
5 3 Stainless steel sign to be protected
Decordyn 350
HDG Bolt or
6 3 Open holes unused treaded opening in carbon steel to be sealed of
plastic plug
Texaco
7 3 Door / Hatch hinges to be greased
Multifak EP2
8 3 Gasket in door and hatches to be greased if dry Vaseline
10 3 Ventilation hatches to be closed
Comments:
Performad by Accepted by Specified Requirements:

Date/Signature: Date/Signature: Norsok Standard Z-006.
Proj.No.: SPXXXX
PRESERVATION SPECIFICATION & RECORD – Crane Pedestal, HYDRAULICAL


Open end nozzles plugged or capped properly. Nozzle face coated with Tectyl 506
1 3
preservatives. Flange protected with flange protectors. Decordyn 350
Shafts on rotating equipment, which are not locked, shall be rotated 1 ¼ turn in
2 3 rotating direction. New shafts pos. from one turn to another. Bearings with
lub.oil, check oil level before turning.
Comments:

Proj.No.: SPXXXX
PRESERVATION SPECIFICATION & RECORD – Crane Pedestal, ELECTRICAL


1 3 All sensitive instrumentation exposed to damage to be protected.
All cabinets, panels and boxes exposed to humidity to be protected with

2 3
desiccant. Replace desiccant if necessary.
Inspect internals for corrosion and moisture – if so, dry up and repair, add
3 3
desiccant and ensure tight sealing’s
All spare cable entrances in panels and boxes plugged. If not vertical installed
4 3
with drain plug down – seal drain plug.
5 3 Open nipples and glands in panels and junction boxes to be sealed off.
6 3 All non-terminated cable end fitted with shrinking Shroud
7 3 Check for physical damages to cable trays etc.
Gasket in panels or junction box to be protected with preservatives, if stored

8 3 Vaseline
outdoors.
9 3 Stainless steel – remove black steel welding/grinding spatter.
Comments:

Proj.No.: SPXXXX
PRESERVATION SPECIFICATION & RECORD – Crane King MECHANICAL


Tectyl 122
Decordyn 350
Paint system in
HM…….
Tectyl506/
Cotec369
Tectyl506
Decordyn 350
HDG Bolt or plastic

plug
Texaco
7 3 Door / hatch hinges to be greased
Multifak EP2
8 3 Gasket in door and hatches to be greased Vaseline
Tectyl506 on bolt
9 3 Bondura Bolts, for assembly use Kluberpaste 46 MR 401 ends and creviced
area.
10 3 Ventilation hatches to be closed
Lubrication system to be started and operated for a complete sequence.

11 3 Check that the lub. tanks are filled up with adequate type of grease. Only to
be done if the crane is assembled
Proj.No.: SPXXXX
PRESERVATION SPECIFICATION & RECORD – Crane King, HYDRAULIC


Rando oil
1 3 Hydraulic system initially filled up with specified oil.
HD46
Check air bottles or accumulators for Nitrogen pressure. Pressure between 1,5
2 3
to3 barg or VCI protection. See list of preservatives
3 3 Gear box topped up with specified gear oil according to list of preservative.
4 3 Valve spindles densotaped. Densotape undamaged Densotape
5 3
Densotape
6 3 Extended cylinder rods coated with preservative an protected with wood
Wood
7 3 All loose items/removed parts preserved, stored and marked
Shafts on rotating equipment, wich are not locked, shall be rotated 1 ¼ turn in
8 3 rotating direction. New shafts pos. from one turn to another. Bearings with
lub.oil, check oil level before turning.
9 3 Yellow chromated steel Denso taped. Denso taping undamaged Densotape
10 3 Heavy Duty gearboxes filled to correct level according to list of preservatives.
Comments:

Proj.No.: SPXXXX
PRESERVATION SPECIFICATION & RECORD – Crane King, ELECTRICAL AND INSTRUMENT


2 3 All sensitive instrumentation exposed to damage are protected.
All cabinets, panels and boxes exposed to humidity protected with desiccant.
3 3
Replace desiccant if necessary.
4 3
5 3

9 3 Vaseline
outdoors.
Comments:

Proj.No.: SPXXXX
PRESERVATION SPECIFICATION & RECORD – Crane King, ELECTRICAL AND INSTRUMENT


11 3 Shafts on motors and mech. seals protected with grease/tape
Inspect the space heater is effective using an ampere meter or handfeel the
12 1
unit. Ensure that indication light on temp heating distribution panel is working
For space heaters that are not temporarily energized, measure insulation
13 3 resistance phase to phase and phase to earth. Attached form EP 02 to be filled
in.
14 3 Batteries for PLC and CPU fully charged and isolated from consumer.
15 3 Emergency light batteries and HPU batteries – See supplier instruction.
Opening in hydrae./pneumatic tubing protected with steel caps or plugs of

16 3
material equal to component being plugged. Non metallic plugs shall be used.
17 3 Cabin to be heated.
18
3 Cabin AC Unit to be protected by a tarpaulin
Comments:

Proj.No.: SPXXXX
PRESERVATION SPECIFICATION & RECORD – Crane Jibs MECHANICAL


Tectyl 506
Decordyn 350
Paint system in
HM…….
Tectyl506/
Cotec369
Tectyl506
Decordyn 350
HDG Bolt or
plastic plug
Tectyl506 on
7 3 Bondura Bolts, For assembly use Kluberpaste46 MR401 bolt ends and
creviced area.
Rando oil
8 1 Cylinders shall be full of hydraulic oil
HD46
Texaco
10 3 Nylatron sliding pads (crane booms)
Multifak EP2
Texaco
11 3 Wire sheaves to be turned 1 ¼ turn and greased ( central lub. system )
Multifak EP2
Comments:

Proj.No.: SPXXXX
PRESERVATION SPECIFICATION & RECORD – Crane Jibs, HYDRAULIC

1 3
3 3
Densotape
Wood
Comments:

Proj.No.: SPXXXX
PRESERVATION SPECIFICATION & RECORD – Crane Jibs, ELECTRICAL AND INSTRUMENT


3 3
4 3
5 3

9 3 Vaseline
outdoors.
Comments:

Proj.No.: SPXXXX
PRESERVATION SPECIFICATION & RECORD – Crane Jibs, ELECTRICAL AND INSTRUMENT


11 3
in.
Comments:

Proj.No.: SPXXXX
PRESERVATION SPECIFICATION & RECORD – Crane Winches, MECHANICAL


Tectyl 122
Decordyn 350
Paint system in
HM…….
Tectyl506/
Cotec369
Tectyl506
Decordyn 350
HDG Bolt or plastic

plug
Tectyl506 on dry
7 3 Preservation of wire wire
Bridon, Brilube 70
Comments:

Proj.No.: SPXXXX
PRESERVATION SPECIFICATION & RECORD – Crane Winches, HYDRAULIC


1 3
3 3
Densotape
Wood
Comments:

Proj.No.: SPXXXX
PRESERVATION SPECIFICATION & RECORD – Crane Winches, ELECTRICAL AND INSTRUMENT


3 3
4 3
5 3

9 3 Vaseline
outdoors.
Comments:

Proj.No.: SPXXXX
PRESERVATION SPECIFICATION & RECORD – Crane Winches, ELECTRICAL AND INSTRUMENT


11 3
in.
Comments:

Title.:
Proj.No.:
Doc.No.:
6.3 De – Preservation
Effort has been made to minimize the need of de-preservation. Preservatives may be left
on the products when going into operation provided that these will contribute to extended
life of the product and not harmful to the product in any way.
A certain extent of de-preservation is required. Technical data sheets for each

preservative provides information regarding which type of solvent , de-greaser or washing
agent needed for removal of preservatives. Product data sheets for de-greaser and
preservative should be reviewed prior to removal of preservatives.
De-preservation must be done before prior to commissioning start-up. The

commissioning activities comprise preparation checking, functional activities and
operational activities.
The preparation checking and functional activities must be performed in the same phase,
but the operational activities may be performed in a later phase than the functional
activities depending on installation completion.
If commissioning is performed during multiples phases, the equipment shall be preserved
when functional activities are completed. Subsequently, de-preservation must be
performed prior to commissioning operational activities.
Normally, handover to operation or client is accomplished short after commissioning

completion. Preservation is normally not repeated in this phase.
Following activities shall be performed to achieve de-preservation (equipment specific):
• Remove all protection structure and protective cloths.

• Extended cylinder rods to be washed dissolving agent to remove preservation.
• Remove preservative from unpainted steel surfaces and flanges.
• Drain gear oil in gearboxes to correct level (See chapter 6.2)
• Drain preservative oil completely from heavy duty gearboxes. Refill small amounts
of correct gear oil to cover the bottom, and drain once more. Fill specified gear oil
to correct level.
• Remove densotape on all valve spindles if necessary.
• Remove densotape on el. motor shafts if necessary.
• Connect PLC and CPU batteries.
• If re-preservation shall not be performed after functional activities, remove all
desiccants inside cabinets, panels and boxes.
• Remove plugs or caps for all open-end nozzles which shall be available during
operation.
• Connect space heaters to permanent power source.
• Drain air bottles and accumulators for nitrogen pressure.
• Sealed drain plugs in panels or boxes to be unsealed if correct installed vertical
down.
Title.:
Proj.No.:
Doc.No.:
6.4 Preservation Label
REAR OF LABEL FRONT OF LABEL
MAINTENANCE
Signature Date
PRESERVATION
CARRIED OUT
HM PROJECTNO.: _____________
SERIAL NO.:__________________
INTERVALS:__________________
DATE_________ SIGN_________
Title.:
Proj.No.:
Doc.No.:
6.5 Topped Gearbox
WARNING THIS GEARBOX

HAS BEEN
OVERFILLED WITH
PRESERVATION OIL
THE OIL MUST BE DRAINED OUT

FILL NEW OIL TO CORRECT
LEVEL IN ACCORDANCE TO THE
ACTUAL LUBRICATION CHART
Date________ Sign._________
Title.:
Proj.No.:
Doc.No.:
6.6 Table of Preservatives.
PART RECOMMENDED PRESERVATIVES
Wheels 1. Decordyn 350

2. Tectyl 122 .
3. Densotape on roller surface if needed
4. Tectyl 506 in creviced areas
1. Decordyn 350
Bondura bolts 2. Tectyl 122A with overlap towards
Clevis Pins painted surfaces
3. Tectyl 506 in creviced areas
Other accepted products:

Cortec VpCI 368 and Cortec VpCI 368HB
1. Decordyn 350
Exposed/Machined carbon steel 2. Tectyl 122A with overlap towards
painted surfaces
Cortec VpCI 368HB
1. Bridon Brilube 70
Wire 2. Cortec VpCI368 on dry wire
3. Wire grease outside
Wires are pre-greased.
Wire sheave 1. Decordyn 350

2. Tectyl 122A
3. Tectyl 506 in creviced areas and inside
wire cone.
Cortec VpCI368 and Cortec VpCI 368HB
Drive Rack Equipment 1. Decordyn 350

2. Tectyl 122A with overlap towards
paintedsurfaces
Cotec VpCI368HB
Pinion Equipment 1. Decordyn 350

2. Tectyl 122A
Other acceptable products:
Cortec VpCI368HB
Slew pinion teeth on cranes. 1. Kluber Grafslocon Ca 902 (first layer)

Open gear on slew pinion rack and pinion 2. Kluber Grafslocon A G1 (second layer)
drive.
Dry and clean pinion can be preserved by
means of :
Tectyl 122A or 121B, Cortec VpCI368HB
Title.:
Proj.No.:
Doc.No.:
Yellow chromed fittings

1. Densotape
2. Decordyn 350
3. Tectyl 506
4. Cortec VpCI368
Chains 1. CRC SP400

Alternate preservative for chains are:
Cortec VpCI368 or Cortec VpCI368HB
Stainless steel signs 1. Cortec VpCI369 with overlap towards

painted surfaces.
It is not a part of the standard to preserve sign

but recommended for long time storage.
Open holes 1. To be plugged with plastic or metallic

plug.
Pneumatic cylinders 1. Cortec VpCI369 on exposed cylinder

rods.
It is not a part of standard to preserve
pneumatic cylinders, but recommended for
long time storage
Hydraulic cylinders 1. Apply densotape on exposed rod.
Preservation of JB and Cabinets 1. Insert Cortec VpCI emitter

dimensioned for cabinet size (Lifetime
2 years)
2. Spray cabinet with Cortec VpCI238,
when inspection and close.
If there is open cable glands in the cabinet,

plug with plastic plug and change emitter in
cabinet.
Preservation of electrical interface 1. Spray with Cortec VpCI238

contacts
Title.:
Proj.No.:
Doc.No.:
Cabin AC unit Protect outside unit from rain and dust with a
tarpaulin.
Hooks and blocks 1. Bearings to be greased with Texaco

EP 2
2. Texaco Novatex Heacy EP2
Telescopic Jib with Nylatron sliding pads Texaco Multifak EP2

(Sliding surface only)
Motor shaft, spline sleeve Kluber Kluberpaste 46MR401
Treads on pipe and hose fittings Parker Hanifin

Niromont-Flussig
Lubrication for assembly and corrosion Kluber Kluberpaste 46MR401

protection of pins, bearing surface and Texaco Multifak EP2 (if grease nipple)
sph. bearings
Valve lever housing, Spring housing, Kluber Kluberpaste 46MR401

Internally.
Pins/bolts in shackles Kluber Kluberpaste46MR401
Threads on Bolt, studs Kluber Staburags NBU30K
Dead weight on wire rope incl. timble Kluber Kluberpaste 46MR401
Spherical bearings in Knuckle jib, Kluber Staburags NBU 12K

bearing/cylinder. Jib bearing hydr.
Cylinder Texaco Novatec Heavy EP2
Title.:
Proj.No.:
Doc.No.:
6.7 Project cycle for preservation at delivery
Production with Transport Inspection by receipt

Preservation
Maintenance Storage inside/outside Periodic preservation

Preservation/repair Maintenance preserve.
preservation By 3 months interval
Assembly and Periodic preservation De-preservation where

Installation Maintenance preserve. Required in Procedure
By 3 months interval
Title.:
Proj.No.:
Doc.No.:
6.8 Project cycle for preservation after use
Preservation/repair Storage Periodic preservation

preservation Maintenance preserve.
By 3 months interval
De-preservation where
Required in Procedure
5 Operation
Table of Contents
1. Safety ..............................................................................................................................................1
1.1. Safety features ..........................................................................................................................1
1.2. Safety Instructions .....................................................................................................................3
1.3. General Handling Considerations ..............................................................................................4
1.3.1. Weather and Sea State .......................................................................................................4
1.3.2. Derating ..............................................................................................................................4
1.3.3. Parking................................................................................................................................4
1.3.4. Tugger Winch Parking .....................................................................................................4
1.3.5. Welding ...............................................................................................................................4
2. Modes of Operation .........................................................................................................................5
2.1. Normal.......................................................................................................................................5
2.2. Constant Tension (CT) ..............................................................................................................5
2.3. Personnel Lift...........................................................................................................................5
3. Crane Controls Overview .................................................................................................................6
3.1. General .....................................................................................................................................6
3.2. Cabin Equipment .......................................................................................................................7
3.2.1. Operating Panel OP-105 .....................................................................................................7
3.2.2. Operator Panel OP-103 (Chair Left Armrest).......................................................................8
3.2.3. Operator Panel OP-104 (Chair Right Armrest) ....................................................................8
3.2.4. Control Cabinet CC-100 ....................................................................................................10
3.2.5. Control Screen ..................................................................................................................10
4. Crane System Start and Stop.........................................................................................................18
4.1. Pre-Start Preparations .............................................................................................................18
4.1.1. Planning ............................................................................................................................18
4.1.2. Equipment Check ..............................................................................................................18
4.1.3. Control System On / Off Switch .........................................................................................18
4.1.4. System Checks (In / From Cabin) .....................................................................................19
4.1.5. Check HPU Status ............................................................................................................19
4.2. Normal Start ............................................................................................................................20
4.2.1. Motor Start-Up ..................................................................................................................20
4.2.2. Cold Weather ....................................................................................................................20
4.2.3. After Start..........................................................................................................................20
4.3. Normal Shutdown ....................................................................................................................21
4.4. HPU Control ............................................................................................................................21
5 Operation
MACGREGOR NORWAY AS
4.4.1. General ............................................................................................................................ 21

4.4.2. Local / Remote Pump Control ........................................................................................... 21
4.4.3. Sensors ............................................................................................................................ 21
4.4.4. HPU Operator Screens ..................................................................................................... 22
4.4.5. Reservoir Surveillance ...................................................................................................... 23
5. Normal Crane Operations (Normal Mode) ..................................................................................... 26
5.1. General ................................................................................................................................... 26
5.2. Load Parameters .................................................................................................................... 27
5.3. Crane Ratings ......................................................................................................................... 29
5.4. Main Winch ............................................................................................................................. 30
5.5. Whip Winch ............................................................................................................................. 33
5.5.1. WW Control Screens ........................................................................................................ 33
5.5.2. Whip Winch Constant Tension.......................................................................................... 34
5.5.3. Personnel Lift ................................................................................................................ 36
5.6. Slew ........................................................................................................................................ 37
5.7. Main Jib .................................................................................................................................. 37
5.8. Knuckle Jib ............................................................................................................................. 38
6. Derating ......................................................................................................................................... 39
6.1. Derating overview ................................................................................................................... 39
6.2. Derating / Load Radius Diagrams / Work Area ........................................................................ 40
7. Emergency Procedures ................................................................................................................. 44
7.1. Emergency Stop ..................................................................................................................... 44
7.1.1. Restart After an Emergency Stop ..................................................................................... 44
7.2. Emergency Release Functions ............................................................................................... 44
7.2.1. Automatic Overload Protection System (AOPS) ............................................................... 44
7.2.2. Manual Overload Protection System (MOPS) ................................................................... 44
7.3. Emergency HPU Operation ..................................................................................................... 45
7.3.1. Emergency Operation Procedures .................................................................................... 45
8. Alarms ........................................................................................................................................... 46
8.1. Responsibility of the User ....................................................................................................... 46
8.2. Alarm Philosophy .................................................................................................................... 46
8.3. Operator Interface ................................................................................................................... 47
8.3.1. Status Banner................................................................................................................... 47
8.3.2. Alarm Banner ................................................................................................................... 47
8.3.3. General ............................................................................................................................ 47
8.3.4. Alarm Colours................................................................................................................... 49
8.3.5. Alarm Acknowledgement .................................................................................................. 50
8.3.6. Alarm Query ..................................................................................................................... 50
5 Operation
MACGREGOR NORWAY AS
8.3.7. Alarm List ..........................................................................................................................51

9. Trend Display Screen.....................................................................................................................62
10. Misc Screen .................................................................................................................................64
11. Network Status Screen ................................................................................................................65
12. Setup Screen ...............................................................................................................................66
13. Joystick Setup Screen..................................................................................................................68
14. Troubleshooting ...........................................................................................................................69
15. Control System Setup ..................................................................................................................70
15.1. General .................................................................................................................................70
15.2. Crane Slew Initialisation ........................................................................................................70
15.3. Winch Initialisation .................................................................................................................70
15.4. Main Jib Angle Sensor Initialisation / Replacement................................................................71
15.5. Knuckle Jib Angle Sensor Initialisation / Replacement ...........................................................71
16. PLC LEDs and Troubleshooting – SIMATIC S7 300.....................................................................72
16.1. General .................................................................................................................................72
16.2. PLC System LEDs .................................................................................................................72
16.3. Power Supply Module LEDs ..................................................................................................72
16.4. S7 300 CPU LEDs .................................................................................................................72
16.5. DP interface LEDs .................................................................................................................73
16.6. Ethernet (PN) interface LEDs ................................................................................................74
16.7. Interface module IM 360 LED ................................................................................................75
16.8. Interface module IM 361 LEDs ..............................................................................................75
16.9. Digital Input / Output Modules................................................................................................75
16.10. Analogue Input / Output Modules ........................................................................................76
17. Replacing Siemens S7 Components ............................................................................................77
17.1. General .................................................................................................................................77
17.2. PLC Modules .........................................................................................................................77
17.3. Power supply .........................................................................................................................77
17.4. PLCs .....................................................................................................................................78
17.4.1. Digital or Analogue Modules ...........................................................................................79
18. End Notes ....................................................................................................................................80
Annex A: Emergency Operation Procedures ..................................................................................... A1
5 Operation
1. Safety
1.1. Safety features
General The equipment delivered by MacGregor Norway AS under this contract has been
designed in accordance with current HSE regulations and standards.
In order to operate safely, prevent injuries to personnel and avoid damage to

equipment it is of utmost importance that both the owner and the user of the
equipment thoroughly study the contents of this manual before operating the machine
or any device controlled by equipment delivered by MacGregor Norway AS.
Emergency stop An emergency stop button is located on the right-hand operating panel on the
operator’s seat inside the cabin. Pressing this button cuts off the crane’s hydraulic
pressure. At least one emergency stop button is also located inside the king.
Spring-centred control All control levers, both two-way and joystick type, are spring-centred. When released,
levers they all return to centre, and whatever motion is active stops.
Overload protection All crane motions are protected against overload by hydraulic relief valves and by the
control system. If a particular motion is attempted which exceeds the crane’s design
capabilities, the relevant relief valve for the particular motion will feed the hydraulic
oil back into the hydraulic oil tank, preventing the motion.
Hook stop systems There are two hook stop systems. The software hook stop is based on wire payout
information from rotational encoders on the winch drums and implemented by the
PLC software. The hardware hook stop is based on a switching device suspended
from the tip of the knuckle jib. When the hook touches this device, twin switches send
a double signal to the control system, which stops the winch before the hook is pulled
into the sheave.
Luffing cylinder The jib luffing cylinders are fitted with mechanical stroke limiters which allow luffing
limitation to take place at full speed.
Load holding valves The main jib luffing cylinders are fitted with pilot-operated load-holding valves.
These valves are connected directly to the cylinder ports and have a dual function:
• Maintaining constant luffing speed independent of the load.

• Blocking cylinder motion in case of hydraulic pressure loss. This will
immobilise the cylinders in case of hose or pipe failure.
5 Operation
Failsafe brakes The winch and slew gearboxes all have failsafe, oil-bath, multidisc hydraulic brakes. In
case of hydraulic pressure loss due to hose/pipe failure, the brake actuates automatically
and halts further motion.
Aircraft warning Red aircraft warning lights are mounted atop the main winch and the main jib outer end
lights to mark the crane during conditions of darkness.
Emergency If the main system power should fail, the winch and other crane functions may be
power supplied by the emergency power system which provides a direct connection to the
ship’s power supply. The AHC system will not be available for operation in emergency
mode, however.
Load / Radius A jib angle sensor system provides data to the control system for calculating the
control system working radius. Load cells in sheave hubs on the knuckle jib register the actual load
suspended from the crane. When a lift is close to the allowable radius/capacity, a
warning is displayed on the operator screen. When the maximum permissible radius is
exceeded, the control system halts jib out movement. The only manoeuvre then allowed
by the control system is movement towards a shorter radius.
Tugger The crane operator must ensure that ANY and ALL operations in which a tugger winch
Winches physically holds the main hook away from the whip winch working area are under
precise control. The tugger winch must always be in constant tension mode. This will
allow the tugger winch to pay out wire if the load on the main hook increases. This may
be due to movement of the crane or accidental movement of the main winch. If there is
a power failure or the crane has been switched off, the tugger winch must be reset to
constant tension mode. MacGregor Norway AS also recommends the use of a “weak-
link” connecting sling equivalent to the tugger winch SWL with an extra safety sling
instead of connecting the tugger hook directly to the main hook.
Emergency Automatic Overload Protection System (AOPS)

release systems
The Automatic Overload Protection System protects the crane against the effect of a
gross overload during operation by releasing the wire in a controlled payout before the
crane sustains significant damage. When the system is activated the winch will
automatically pay out wire. As long as AOPS is activated, the winch will maintain a
retaining force corresponding to the relevant SWL.
AOPS is inaccessible when the jib tip is over deck, and is automatically made accessible
when the jib tip is over water.
Manual Overload Protection System (MOPS)
If the wire is caught on another vessel or the seabed and the crane and/or vessel is
disabled, there is a risk of exposing the crane to higher loads than it is designed for as
the vessel drifts. Should this occur, the operator can activate the MOPS by pressing the
yellow button for the appropriate winch on operating panel OP-104 (next to right
joystick). The system will then pay out wire while maintaining a retaining force of
approx. 10-20% of maximum rated winch capacity.
Both emergency release functions are inaccessible to winches operating in personnel-lift

mode.
5 Operation
1.2. Safety Instructions

Never handle loads The jib system is able to lift heavier loads at reduced radius. When lifting heavy loads,
heavier than the always check that the winch are able to lift the load before any further operation.
winch can lift
Risk of collision Pay attention to the risk of collision with the superstructure when slewing and jibbing.
Auto Tension with Never activate Auto Tension Mode while a load is hanging from the hook. This can put
load in the hook the load into free fall and cause major damage to vessel or other structure.
Lifting gear Never use lifting gear with cracks deformations etc. that can reduce the original
strength. All lifting gear must also have the required lifting capacity for the actual load.
Always pay Respect the alarms and information given on the screen.
attention to the
crane control system
Override Mode Do not operate the crane in override mode unless the situation requires this. Override
mode supersedes all interlocks of crane
Operator To operate the crane, the operator must be familiar with the crane and crane user
manual. The crane operator must also fulfil the requirements given by the vessels flag
authorities.
Single wire parts The crane must never be operated if the information on the screen is not correct
compared to actual block in use.
Wire tension – Operational restriction on main winch, please refer to Annex B - "Safety Bulletin 2010-
retrieval operations SB03".
5 Operation
1.3. General Handling Considerations

1.3.1. Weather and Sea State
A ship and crane’s surroundings have a significant impact on what a crane can do and how; thus, wind and sea
must always be taken into account when planning and performing a lifting operation. The situation must be
reassessed if conditions change appreciably in the course of an operation.
A crane can operate under a wide range of conditions, but a few key parameters are critical to operational
planning. These include wind speed and direction, heave (wave height and period), list and trim conditions,
offlead angles and the type of lift (i.e. internal, external or ship-to-ship – also treated as an environmental
factor).
Obviously, where relative movements are concerned (external and ship-to-ship lifts), sea state and weather are
important factors that must be taken into account in all planning and operations.
1.3.2. Derating
Operators and users of MacGregor HMC offshore cranes need to understand the basics of crane load limitations
under the different operating modes to avoid putting too much strain on the crane under varying conditions.
Incorrect crane operation can lead to dangerous situations, damage to equipment or to the vessel, and serious
personal injury or worse.
A crane always has its own individual ratings, which describe exactly what capacity the crane can lift at a given
radius under given conditions. As the radius increases or as conditions deteriorate, the allowed rating decreases;
this is referred to as derating. Load diagrams apply to internal, subsea (external) and ship-to-ship lifting
situations.
1.3.3. Parking
The crane must be properly parked after use: knuckle jib folded in, main jib down, slew angle at park and both
knuckle jib and hook(s) in their cradles, if present. This achieves three important purposes:
1. With the cylinder rods fully retracted, their bare metal surfaces are protected from the corrosive marine
environment.
2. Releasing system pressure eliminates strain on system components and extends the life of seals on
cylinders, valves and connections.
3. Securing idle equipment is an important safety measure on board a ship.
1.3.4. Tugger Winch Parking

When the crane is parked, the tugger winches should also be parked – i.e. both tugger winch cylinders should be
retracted completely to protect the cylinders and minimize cylinder rod corrosion.
1.3.5. Welding
Sensitive electronic components are easily damaged by the stray electrical charges that welding currents can
produce. Therefore, if any electric welding is to be done on the crane, the control system must first be isolated
by turning off the main control system circuit-breaker, F15, located in ES400 in the king.
5 Operation
2. Modes of Operation
2.1. Normal
Normal crane operation allows the crane operator to carry out most lifting operations with the crane such as
slewing, luffing, ordinary lifting and lowering with any winch, and parking.
2.2. Constant Tension (CT)

In this mode, the control system keeps wire tension at a constant, adjustable value based on load deviations
registered by the load cell. For reasons of safety, it is impossible to switch between main winch and whip winch
while constant tension is enabled, meaning that these buttons are inhibited.
2.3. Personnel Lift

Main or whip winches can be equipped with a personnel lift mode which imposes added restrictions to ensure a
very high margin of safety. The emergency release systems (MOPS/AOPS) are disabled in this mode.
On this crane, this mode is available only on the whip winch, so it is covered in the whip winch section.
5 Operation
3. Crane Controls Overview

3.1. General
Equipment located in the cabin is briefly presented in this section, and operation is described in subsequent
sections.
The following are located in the operator’s cabin:
• One operator’s chair with control panels on either side

• One control panel located on the wall to the left of the operator chair, with switches for window
wipers/washers and heating
• One HMI touch-screen panel
• Two camera monitor for winches
• Radio/CD player
• UHF / VHF radios
• Microphone for UHF/VHF radio
• Cabin air conditioning unit w/controls
• One fold-down chair
5 Operation
3.2. Cabin Equipment

Window wiper and The left, right, front (central) and rooftop windows are fitted with a wiper/washer
washer system. The rooftop window is, however, not included in the washer system. The
window wipers are each activated by a three position switch. Centre – off, left – high
speed, right – slow speed. The “Pump 1” pushbutton activates washing of the front
(central) window, while the “Pump 2” pushbutton activates washing of the two side
windows.
Cabin ventilation The operator cabin is equipped with two heaters and an air conditioner. The heaters
are located under the operator chair and are controlled by an on/off switch located
on the control panel on the left wall. Temperature is thermostat-controlled.
The air conditioning unit is located on the rear wall of the cabin and has individual
controls for cooling and fan speed on the front of the unit.
Radio w/ CD player The operator cabin is equipped with an RDS radio/CD player and a set of speakers
mounted on the side walls on either side of the operator.
VHF/UHF radio The operator cabin is equipped with a VHF radio and a UHF radio mounted on the
wall panel. The top switch on the right joystick is used for push to talk (PTT), and a
switch below the radios is used to select which radio to operate.
3.2.1. Operating Panel OP-105

General OP-105 is mounted on the cabin wall at the operators left side, and consists of these
controls:
• Window wiper and washer switches

• Cabin heater/defroster controls
• Radio/CD player
• UHF radio
• VHF radio
Window wiper and The left, right, front (central) and rooftop windows are fitted with a wiper/washer
washer system. The window wiper and washer switches are located on the wall mounted
utility panel at the operators left side.
Window wipers and The front top window, front bottom window, roof window and both side windows of
washers the cabin are all equipped with wipers and washers.
Cabin heater These switches control the cabin heating and defrosting.
Radio/CD player Stereo system with speakers on left and right walls
UHF/VHF radios For communications
5 Operation
3.2.2. Operator Panel OP-103 (Chair Left Armrest)

OP-103 is located in the operator chair left console, and includes:
• A four-way joystick with several top and front switches

• MOPS buttons for main and whip winches
• Tugger winch controls
Four-way joystick The spring-centred four-way joystick with thumb wheel and front switches controls
the crane slew and main jib luffing functions.
FUNCTION COMMENTS
Joystick X- • Crane slew Clock Wise (CW)
positive
Joystick X- • Crane slew Counter Clock Wise
negative (CCW).
Joystick Y- • Main jib down
positive
Joystick Y- • Main jib up
negative
Front switch • Alarm Acknowledge
Front switch • Front washer
Front switch • Front wiper
Thumb wheel • Tugger 1 in/out, tension +/-
MOPS Main winch The MOPS Main winch button has a cover to protect it from being pressed
accidentally. Lift cover to operate. Push once to activate MOPS mode, and once more
(Manual Overload to deactivate. More information in the Main Winch section.
protection system)
MOPS Whip winch The MOPS Whip winch button has a cover to protect it from being pressed
accidentally. Lift cover to operate. Push once to activate MOPS mode, and once more
(Manual Overload to deactivate. More information in the Whip Winch section.
protection system)
3.2.3. Operator Panel OP-104 (Chair Right Armrest)

OP-104 is located in the operator chair right console, and includes:
• A four-way joystick with several top and front switches

• A switch to activate/deactivate the joysticks
• An Emergency Stop (ES) button
• A Button to activate/deactivate CT
• A key switch to activate personnel lift mode
• A personnel lift mode indicator lamp
5 Operation
Four-way joystick The four-way spring-centred joystick with thumb wheel and front switches controls
the main/whip winches and knuckle jib functions.
FUNCTION COMMENTS
Joystick X-positive • Crane knuckle jib out
Joystick X-negative • Crane knuckle jib in
Joystick Y-positive • Winch down
Joystick Y-negative • Winch up
Front switch • Signal horn
Front switch • Main/whip winch selection
Front switch • PTT (UHF/VHF)
Thumb wheel • Tugger 1 in/out, tension +/-
Control enable on/off Turning this switch On enables the joysticks.
Note: To prevent accidents, always set in ‘Off’ position when leaving the operator
chair or when the crane is not being operated!
Emergency stop The ES button locks in stop position when activated. To release turn the button CCW.
button
Personnel lifti This key switch is used for activating personnel lift mode on the Whip Winch. The
enable/disable key can only be removed in normal mode. More info in the whip winch section.
Personnel lift This lamp lights when personnel lift mode is activated
indicator lamp
CT On/Off This button activate/deactivate constant tension mode.
5 Operation
3.2.4. Control Cabinet CC-100

CC-100 is located behind the operator’s chair and contains the PLC, the computer (PC) and other
electric/electronic components presented in Chapter 3. The on/off key-switch for the entire control system are
also located here.
When this switch is turned Off, the emergency stop loop is de-energized, meaning that no pumps or crane
functions can be activated. This switch is always turned off to ensure that the crane cannot be operated while
service is being performed. System off is also indicated by an alarm on the control screen. This switch may be
locked in the Off position.
Note: This switch will stop the crane in any mode.
3.2.5. Control Screen

Control screen HB001 is a 17” LCD touch screen with a graphic HMI (Human Machine Interface) used for
operating and monitoring crane functions. The HMI application runs on a Windows 7 Professional 64-bit ® PC,
also in the CC-100 cabinet, with an Ethernet connection to the control system PLC
5 Operation
General screen elements and layout

The control interface on the operator’s screen is designed to display the most vital data in an intuitive
presentation.
Main functions
1. Alarm Banner (always on top) displays the last incoming alarm. This alarm is acknowledged on the
alarm screen or by pressing the yellow top switch on the left joystick. Described in further detail in the
alarm section.
2. Alarm Status Banner (always on top) displays the alarm status for different groups. Described in further
detail in alarm section.
3. Equipment and Functions Status Banner (always on top) displays the status of equipment and functions
by using different colours. Described in more detail below.
4. Field displaying the name of the active screen
5. Time and date field
6. Buttons for selecting either the Main- or Whip Winch (illus. next page).
7. Load indicator:
o Green area: Load range for the selected crane derating. This range can change according to
mode, wave-height and dynamic factor.
o Yellow area: Dynamic forces are acceptable. This range can change according to mode, wave-
height and dynamic factor.
o Red area: Load exceeds 100% of maximum SWL for Internal Hs=0 in current mode
8. Menu button (menu presented next page).
9. Relative Knuckle Jib Angle Information. Press Rel. Knuckle Jib button for pop-up dialog box (ill. Next
page).
1
5
4
2 3
5 Operation
Bringing up displays
The following screens are defined and can be selected by touching the MENU button at the
bottom and selecting the desired screen from the menu (shown at right):
• Previous
• Setup
• Alarm
• Misc
• MW Lineup
• HPU
• Trend
• Main
The menu also has a Previous button at the top which will return the previous screen.
Choosing an item in this menu will not start any process.
Relative Knuckle Jib

Angle dialog (pop-up (9)
5 Operation
Equipment / function status indication
The items in the equipment and function status banner are presented here.
Status Line text State Function

Main AOPS Grey: AOPS disabled
Green: AOPS is enabled but not active
Flashing red: AOPS activated
Main MOPS Grey: MOPS disabled
Green: MOPS enabled but not active
Flashing red: MOPS activated
Whip AOPS Grey: AOPS not enabled
Green: AOPS enabled but not active
Flashing red: AOPS activated
Whip MOPS Grey: MOPS disabled
Green: MOPS enabled but not active
Flashing red: MOPS activated
Personnel lift Grey: Whip Winch Personnel lift disabled
Blue: Whip Winch Personnel lift enabeld
IntLock Override Grey: Interlocks are active
Orange: Operator has activated interlock override
Note: When interlock override is active, all safety features in the crane control system are
deactivated. We recommend that a report is filled out with the reason for activating this function
each time it is used
Crane Ctrl Grey: Joysticks and foot pedals are disabled
Enabled Blue: Joysticks and foot pedals are enabled
5 Operation
General screen objects

Screen objects are basically objects with a certain functionality attached to them.
Examples of screen objects are ‘bar graphs’. All bar graphs in the front screen application have the same design
and share the same basic functionality. Other examples are numeric output fields etc.
Common functionality improves recognition, accelerates the learning curve and simplifies the application. It is
very important that the user is familiar with the different properties of the screen objects.
General buttons
Buttons in the HMI screen application are activated by touching them on the touch screen. Some buttons, when
touched, will produce a pop-up dialogue that prompts the user for input. The various pop-up dialogues will now
be presented in brief.
Button State Function

Grey Background The function is not activated
Yellow Background The function is activated
Grey Text on Button The button is inhibited – cannot be operated
Background is The associated function is active (the Main Winch mode-selection buttons are typical
Blinking examples). After pressing Confirm, but before AHC is ready, the button blinks.
S and R (Set/Reset) buttons

In some displays have an S or R button. These are places where specific
settings are entered In all cases touching the button brings up a dialogue
to enter a new value or confirm a new setting.
5 Operation
Bar Graphs
Bar graphs are a vital part of the front screen application. These are used to show system
parameters both in analogue and numeric format.
The bar graphs used in the HMI screen application have a set of features associated with
them.
Bar graph scaling enables the operator to adjust the scale to suit the values expected in the
coming operation, or to zoom in to specific signal ranges. Touch the bar graph that is to be
adjusted. A pop-up dialogue with several options is displayed on the screen. Use the
selections to set a new maximum or minimum, for example, and then close the pop-up.
The bar graph will now show the new settings.
A max/min marker function is included to help visualise the range of a signal. When this
function is active, two light blue lines are used to continuously show the lowest and
highest value shown by the bar graph. For example, if this mode is active and the highest
value ever shown is 7.0, the “high” marker is next to the 7.0 point on the scale. If the bar
graph value exceeds this value, for example to 8.0, the “high” marker is pushed up to the
8.0 point. Note that the low/high markers for all bar graphs can be reset by touching the
Set Markers button on the bar graph pop-up that appears when the bar graph is touched.
A reference marker function is included as a help to the user. When this function is active,
a yellow line is “frozen” on the screen to display a reference that the user can adjust as
needed. This feature is useful for observing variations.
Numeric output fields
Numeric output fields are used to display any real time value. The
output field states the name of the signal and the unit of measure.
All output fields have a light grey background and black numbers.
Touch the unit of measure to change the unit of the signal
Input fields
Numeric input fields are used to enter new values. The input field consists of the name of the signal, and the unit
of measure, if relevant.
All input fields have a white background and black text/numbers. After touching the white area, a pop-up
dialogue appears in which the user enters the appropriate input.
Status indicators
Status indicators display the state of a signal or a system. The lamps

are grey by default, and go red or green depending on the value of
the signal.
5 Operation
Radio buttons
Radio buttons are used to choose among different choices.
Click inside the circle beside the item to be selected. If the selection is approved by
the control system, a black dot is showed inside the circle indicating that the selection
has been carried out.
Valve objects
Two types of valves are used in the HMI screen application: valves which the operator can open/close directly,
and valves which the operator cannot open/close (operated by the control system).
When the operator touches a valve object with direct control capabilities, a pop-up dialogue will appear
prompting to confirm a start or stop command.
The colour coding below is used to show the various modes of operation for all valve objects with direct control
functionality.
Symbol Object Function

Steady grey fill No feedback and no command signals are attached to the object
Steady white fill The valve has been closed by the PLC
Flashing white and green Flashes while the valve is closing or opening
Steady green fill The valve has been opened by the PLC
5 Operation
Pump objects
The pumps are presented with colour codes indicating pump status.
Symbol Object Description
Grey frame: pump is in remote mode,

Grey frame, white fill colour
white fill: pump is ready
Yellow frame: pump is in local mode,

Yellow frame, white fill colour
white fill: pump is ready to be started
Grey fill colour Pump is not ready
Green fill colour Pump is running
Red fill colour Pump has tripped
Pump is not available, for instance when an emergency

Red cross over pump
button is activated.
Filter objects
The various filters are presented on the front screen with colour coding indicating filter status.
Symbol Object Description

Grey fill colour filter is ok.
Red fill colour

filter is clogged, and must be checked.
5 Operation
4. Crane System Start and Stop

4.1. Pre-Start Preparations
4.1.1. Planning
All operating factors must be considered by the operator before the crane is started. The following conditions
must be checked but are not limited to:
• Weight, COG and shape / added mass of the load(s) to be lifted

• Weather / environmental conditions
• An assessment of the actual lift job is to be performed on the basis of the first two items. Lift mode and
derating to be determined, limits identified, lifting gear selected.
• A plan must be made for safe execution of the lifting operation. Deck area for pick-up and landing of
loads and the routing between are to be visually checked for obstructions, clear view and maximum
loading imposed on deck.
4.1.2. Equipment Check

The operator must first check the crane and all its systems and equipment:
• Check that lifting gear / loose gear is in good order and approved for the purpose by a visual inspection
of equipment and certificates.
• Visually inspect crane, wires, wire sheaves, machine room with pumps, hoses, oil tank level and valves
(visible leaks/defects).
• Check that emergency stop buttons in king are not activated.
• Check that the crane is fit for the operation and rigged for the job in question: winch selection, reeving,
hook height above deck, working radius etc.
• Communication with bridge
4.1.3. Control System On / Off Switch

Check that the Control System on/off switch (also called the service mode switch) located in control cabinet
(CC-100), is ON (1).
Warning: If the key is in OFF position, always check whether any service operations are being performed
on the crane before switching ON and starting up.
5 Operation
4.1.4. System Checks (In / From Cabin)

• Check that the emergency stop button in the cabin is not activated. If one or more emergency buttons
are activated an alarm will be displayed on the alarm screen and it will not be possible to start any
pumps.
• Review alarm status to get an overview of the situation. Use the Alarm Status Banner buttons to check
unacknowledged alarms.
Check all active alarms and take the whatever steps are necessary to prepare for crane operation.
4.1.5. Check HPU Status

Choose the HPU screen from the menu. Check that the tank oil levels are acceptable and that the temperature in
the oil reservoir is ok.
Check that the Ctrl Enable switch on OP-104 (right operating panel) is Off.
5 Operation
4.2. Normal Start

4.2.1. Motor Start-Up
(The HPU screen is still open from the HPU status check):
1. Starts each main

pump by
touching its
motor symbol.
2. If the circulation
motor is set to
“Auto”, the
circulation pump
will
automatically
start when a main
pump is started.
In “Manual”
mode, the
operator must
start/stop the
circulation pump
separately.
3. The CJC pump
must be started
manually, but it
should normally
be running, even
when the crane is
not in use.
4.2.2. Cold Weather

If the oil temperature is under 0°C, close the shutoff valve downstream from the circulation/cooling pump. This
will help the system warm up faster. Open the valve once the oil temperature has reached 0°C.
4.2.3. After Start

Note! Motor symbols will flash until the start-up procedure is completed. Do not operate the controls before
these symbols have a steady green light.
• Check that oil level and temperature are acceptable, that all colour codes on the HPU screen are normal
(green motors, grey filters), and there are no critical alarms on the alarm banner.
• Pay attention to the crane control system and respect the warnings and alarms it gives.
• Is communication with the slinger / banksman satisfactory?
• Is communication with the bridge in order?
Once the HPU has started and system checks are complete, the crane is ready for operation.
5 Operation
The Ctrl Enable switch on OP-103 (left operating panel) remains Off if any mode is to be selected or derating
performed. Always turn this switch off before leaving (or entering) the operator’s seat.
Details on how to operate the crane are described in later chapters.
4.3. Normal Shutdown

Turn off AHC/AT Check that AHC/ AT mode and constant tension (CT) modes are deactivated on
and CT modes whatever winches have them.
Park crane Park crane before initiating shutdown: knuckle jib folded in, main jib down, slew
angle at park and both knuckle jib and hook(s) in their cradles, if present.
Controls on/off Check that the Ctrl On/Off switch on operating panel OP-104 (right) is turned OFF.
Shut down The main pumps can now be stopped by touching the motor symbols on the HPU
screen to select them, and then touching the Stop button in the motor pop-up to stop
them.
The circulation pump will continue to run 5 minutes after the last main pump has
stopped. The circulation pump will stop automatically if it is set in “Auto” mode. The
CJC filter pump is left to run continually, even when the crane is not in use.
4.4. HPU Control

4.4.1. General
The HPU consists of four double main pumps, one circulation pump, one CJC filter pump and seven oil coolers.
4.4.2. Local / Remote Pump Control

For service purposes all pumps can be started and stopped locally at the starter panels. Set local/remote switches
to Local.
To return pump control to the control system, the local/remote switches on the starter panel in the king must be
set to Remote, indicated in the control system by a grey frame around the motor symbols.
4.4.3. Sensors
Level and temperature sensors and switches on the oil reservoir send information to the control system.
Pressure sensor switches on all system filters send signals to the control system when clogged.
Analogue indications are given in the king (thermometer, sight glass, warning lights).
5 Operation
4.4.4. HPU Operator Screens

The HPU screen shown below is opened by choosing HPU in the menu.
8
5
6
2 10
9
The following table below lists the main

functions on this screen.
No. Description
1 Main pump status (1-4)
2 Circulation pump status
3 Filter symbol (red when clogged)
4 Pressure reading main pressure
5 Oil Temperature
6 Oil Tank Level in %
7 High temp alarm lamp
8 High and low level indication lamps and bar graph
9 Buttons for choosing the HPU, main winch or whip winch lineup screens
10 CJC filter pump status
5 Operation
Winch lineup screens
These screens display information about the valves in the hydraulic control system as well as various pressure
readings. They also provide oil cooler fan motor control.
The buttons along the bottom right provide easy access between the three HPU system screens.
4.4.5. Reservoir Surveillance

Feedback to the control system from the tank sensors and switches affects HPU start and stop, generates alarms
on the operator’s terminal and provides operating parameters for oil cooler control.
Analogue Sensors
SENSOR PARAMETER FUNCTION / RESPONSE

Temperature • Temp. reading on HMI display
Oil temperature
sensor • Alarm issued to operator
• HPU stop
Level / Pressure Switches
5 Operation
SWITCH ALARM SYSTEM / RESPONSE

Reservoir Low Reservoir Low level • Alarm indication on HPU screen on HMI display
level switch alarm
Resevoir Reservoir LowLow • All pumps are stopped if they are running.
LowLow level level alarm • Blocks pump start.
switch • Alarm indication on HPU screen on HMI display
Resevoir High Reservoir high level • Alarm indication on HPU screen on HMI display
level alarm
Resevoir Reservoir HighHigh • Alarm indication on HPU screen on HMI display
HighHigh level level alarm
Reservoir High Reservoir High • Alarm indication on HPU screen on HMI display
temperature temperature alarm
switch
Reservoir Reservoir HighHigh • Alarm indication on HPU screen on HMI display
HighHigh temperature alarm
temperature
switch
Filter Status
All hydraulic system filters have built-in pressure switches that signal the PLC when the filter is clogged. When
a pressure switch is activated, an alarm is generated in the control system and displayed on the HMI screen, as
described in earlier chapters.
5 Operation
Oil Cooler Manual / Automatic Operation

The crane is equipped with five forced-air oil coolers that can be set for manual or automatic operation.:
Mode Description
Manual Manual mode is set by touching MAN in the Oil cooler motor operation pop-up. This must be done
for each cooler. Each cooler can then be started and stopped by touching the OFF and ON buttons.
Note: The oil cooler will not start automatically when in manual mode, which may lead to
overheating, especially during AHC operations.
Automatic Automatic mode is set by touching AUTO in the Oil cooler motor operation pop-up. When automatic
(recommended) mode is selected, the coolers start at the following temperatures:
Cooler 1: > 45 degrees C
When automatic mode is selected, the coolers stop at following temperatures:

Cooler 1: < 44 degrees C
5 Operation
5. Normal Crane Operations (Normal Mode)

5.1. General
Normal crane operations consist of the following:
• Starting the pumps

• Rating/derating
• Main winch functions
• Whip winch functions
• Slew functions
• Main jib functions
• Knuckle jib functions
• Tugger winch functions
Starting the pumps
All motor/pump units are started from the operator’s touch-screen in the cabin. Check that the HPU is running at
an idle pressure of approx. 40 bar. Check that the circulation pump has started automatically. Make sure that the
oil coolers are set Auto to maintain proper temperature control during operation.
Note: When planning to operate more than one crane function at a time, ALL pumps must be running.
Loads are always lifted off the deck by using the winch. Any of the main jib, knuckle jib and slew functions
may then be used once the crane is carrying the load.
Sections on Main and Whip winches
During crane operations, relevant information and controls are found in the Main and Whip screens on the
operator’s terminal. All items on these screens will be briefly presented in the sections on the two winches, the
details on pop-ups and so on will be presented in subsequent sections as their functions are presented.
5 Operation
5.2. Load Parameters

Hook position and hook stops
A rotational encoder is installed on the main winch for keeping track of hook position and wire payout. The
encoder registers nothing but the length of wire paid out. Since the hook position follows the jib tip, and the jib
tip’s position varies with the main and knuckle jib angles without affecting wire payout, the control system PLC
must continuously use real-time crane geometry parameters to calculate the hook’s true position.
The main winch has two upper hook stops and one lower hook stop
• Upper hook stop (calculated from encoder signals )

• Upper hook stop (signal from the hook stop proximity switches)
• Lower/end hook stop (calculated from encoder signals)
The upper (software) hook stop is activated by the control system when the calculated hook position is less than
the initialized zero meters. When upper hook stop is reached, the knuckle jib in and main jib down movements
stop.
The lower hook stop (end stop) is activated by the control system when three turns are left on the winch drum.
Payout stops, preventing the entire length of wire from being run out. An alarm is given when the calculated
wire payout is less than 50 metres from the end stop.
Note: Wire stretch may cause inaccuracy in this function.
It is recommended that a verification of this function is included in the crane operator’s daily check list.
Hook Load Sensor
A dual bridge load cell fitted to the upper sheave hub on the knuckle jib measures the main winch load. The
load can be monitored on the HMI display in the cabin. Refer to MacGregor Hydramarine AS load charts for an
overview of crane derating according to radius and sea state.
Maximum Load
The maximum permissible load for the current crane derating and radius is displayed inside the dial on the main
screen.
An alarm is generated on the control screen and the cabin buzzer is activated when 90 % of max load is reached.
At 100 % of maximum load the horn outside the cabin will sound and an alarm will be generated on the operator
display.
When the load reaches 100% of allowed maximum load, the main- and knuckle jib will only be allowed to
move to a smaller radius.
Crane Radius
The radius is the calculated distance from jib tip to centre of crane king. Crane radius is calculated from the
main jib angle and knuckle jib angle registered by the jib angle encoders.
5 Operation
Interlocks
The following states will halt winch up movement in normal mode:
• Upper hook stop

• Hook load > 130% of max load for Hs=0 (Dynamic overload)
• Main winch encoder error
The following will halt winch down movement in normal mode:
• Lower hook stop

• Main winch encoder error
Derating
Derating comprises a range of parameters in specific situations, and is dealt with in the following section.
5 Operation
5.3. Crane Ratings

The current crane rating is displayed in the upper right-hand corner of the current winch screen. Touching the S
button next to the rating field opens one of the Crane Rating pop-ups shown below. The rating set here will
affect the maximum permissible hook load according to mode, sea
state and radius.
Modes
The available modes are (DNV):
• Ship To Ship Lift

• OnBoard / OffBoard
Derating maximum lift
The control system computes the maximum permissible hook load

relative to the crane radius, based on mode selection and Dynamic
Factor or Significant Wave Height input in the Crane Rating dialog
box.
This is the process called derating, which implements a reduction in crane capacity reflecting the higher
dynamic forces acting on the crane and load under certain conditions.
Significant wave heigth
The Significant Wave Height input box is used in Ship To Ship and OnBoard/OffBoard modes for derating
the crane according to the sea state.
5 Operation
5.4. Main Winch

The main winch is selected by touching the MW On button on the menu banner to the left of the main screen.
The winch is controlled by the right joystick y-axis: y-positive (pushing joystick) pays out, and y-negative
(pulling joystick) hauls in the wire.MW Control Screens
When the main winch has been selected on the operator’s control terminal, the Main Winch Screen appears on
the display:
Main Winch screen

4 2 1
3
10
12
11
13
6 7
Screen items 1. Indicator showing currently selected Crane Rating

description 2. Button for opening dialogue for setting Crane Rating
3. Indicator showing currently selected Main Winch mode
4. Button for opening dialogue for selecting Main Winch mode.
5. Indication field showing whether the selected Main Winch mode is activated
or not.
6. Button for resetting the main winch trip meter
7. Button for resetting the whip winch trip meter
8. Fields showing “relative” hook position (trip meter)
9. Fields showing hook position (measured from upper hook stop)
10. Radio buttons for selecting crane load range
11. Button for redefining the current crane load range
12. Button for opening crane systems information pop-up
13. Button for opening pop-up for selecting speed limits
5 Operation
MW mode selection pop-up
For selecting Constant Tension Mode (see section 7.3).
Main winch information pop-up
This pop-up gives the operator information on various

pressure readings and status items relevant to the main winch.
To operate the crane in Double Part or Triple Part mode, is

required by the system that the Part sensor detects the correct
configuration. In case of a sensor malfunction or maintenance,
is possible to select Double or Triple Part without the sensor
information, to do that Interlock must be active.
5 Operation
Crane information pop-up
This pop-up gives the operator information on various pressure measurements and status items relevant to other
crane functions.
5 Operation
5.5. Whip Winch

The whip winch is selected by touching the WW On button on the menu banner to the left of the main screen.
The winch is controlled by the right joystick y-axis: y-positive (pushing joystick) pays out, and y-negative
(pulling joystick) hauls in the wire.
5.5.1. WW Control Screens

When the whip winch has been selected on the operator’s control terminal, the Whip Winch Screen appears on
the display:
WW screen
2 1
4
3
13
11
10
12
Screen items 1. Indicator showing current Crane Rating

description
2. Button for opening Crane Rating dialogue
3. Indicator showing current Whip Winch mode
4. Button for opening dialogue for selecting Whip Winch mode
5. Indicator showing whether the selected Whip Winch mode is
activated or not
6. Button for redefining the current crane load range
7. Radio buttons for selecting crane load range
8. Button for opening crane systems information pop-up
9. Fields showing the hook position, (measured from upper hook stop)
10. Button for resetting the main winch trip meter
11. Button for resetting the whip winch trip meter
12. Fields showing “relative” hook position (trip meter)
13. Button for opening pop-up for selecting speed limits
5 Operation
Whip winch information pop-up
This pop-up gives the operator information on

various pressure readings and status items
relevant to the whip winch.
Crane information pop-up
This pop-up gives the user information on

various pressure readings and status items
relevant to other crane functions, and is the
same screen described on the main winch
control screens.
5.5.2. Whip Winch Constant Tension

The constant tension has to be chosen from the whip winch mode select menu
which is opened by pressing the “S” next to the Whip Winch mode in the upper left
corner in the Whip Winch screen.
5 Operation
Activating constant tension
1. Start main pumps and activate the whip winch by means of the button in the top left side of the screen.
The button feedback is steady yellow.
2. Open whip winch mode select menu and press constant tension mode and confirm.
3. The status field should change from “Off” to “Constant tension”. Note that tension is not activated yet.
4. Set the control enable switch in the right arm rest in enable position, and push the CT button on the right
armrest.
5. The “Active” field will now change to blue background with white text.
Deactivating constant tension
To deactivate CT, the operator must push the CT button on the right armrest.
5 Operation
5.5.3. Personnel Lift

The whip winch is rated for a personnel lift mode. The indicator in the status field shows if personnel lift is
activated. The load indicator on the whip winch screen is automatically scaled to fit the personnel lift load
range. The winch gear brakes engage when the joystick is centred or if an emergency stop or power failure
should occur.
Activating personnel lift mode
This mode is activated by turning on the key switch on the right control panel (OP-104). If the hook load
exceeds 1 ton, the mode is not activated until the load is less than 1 ton. A load increase raising the hook load
above 1 tonne will not deactivate personnel lift mode, however but it will trigger an alarm.
Deactivating personnel lift mode
Turn off the personnel lift key switch on the left control panel (OP-104).
Interlocks
• Crane load is 130 % of max allowed load in personnel lift mode, winch up movement is stopped.
• Whip Winch AOPS is disabled (status field becomes grey)
• Whip Winch MOPS is disabled (status field becomes grey)
Other operating prerequisites (except for emergency operations)
• Mean wind velocity <10 m/s

• Significant wave height <2m
• Visibility Daylight
• The crane operator shall have a means of direct communication with the personnel being lifted or with
a banksman who has a direct view of the personnel being lifted.
• Lifting of personnel shall only be performed using equipment specially designed for the purpose, i.e.
baskets conforming to EN14502-1.
5 Operation
5.6. Slew
The left joystick’s x-axis (left control panel OP-103) controls crane slew. Pushing the joystick left slews the
crane to the left (counter clockwise), and pushing the joystick right slews the crane to the right (clockwise).
Centring the joystick as the crane is slewing will cause the control system to ramp down the slew speed to zero,
bringing crane slew to a smooth, controlled stop.
The displayed slew angle range is from zero to 360 degrees, where zero indicates the crane pointing straight
forward relative to the vessel. Angle value increases in right (clockwise) direction. Crane slew is unlimited in
both directions.
Interlocks
The following will halt slew movement:
• Slew position encoder error
5.7. Main Jib

The left joystick y-axis (operating panel OP-103) controls main jib movement. Pushing the joystick forward
lowers the main jib and pulling the joystick back raises the main jib.
The position of the main jib is measured by an angle sensor, with the angle increasing as the jib moves up. Zero
degrees is when the main jib is at its lower end stop. Main jib angle is displayed on the operator’s terminal.
Jib speed is reduced as it approaches its end-points to provide a smooth stop.
Main jib down movement is stopped if the active winch’s hook stop is reached (indicated by alarms). The active
winch’s wire must then be paid out in order to continue the main jib’s down movement.
Interlocks
The following will stop main jib up movement:
• End stop reached.

• Main jib angle encoder error.
• Main jib moving in wrong direction – alarm
• Main winch Hook load > 100% of max allowed load and increasing radius
The following will stop main jib down movement:
• End stop reached

• Whip winch hook stop
• Main winch hook stop
• Main jib moving in wrong direction - alarm.
• Main jib angle encoder error.
5 Operation
5.8. Knuckle Jib

The right joystick x-axis (operating panel OP-104) controls knuckle jib movement. Pressing the joystick right
swings the knuckle jib out and pressing the joystick left swings the knuckle jib in.
The position of the knuckle jib is measured by an angle sensor, with the angle increasing as the jib swings out.
The angle of the knuckle jib is relative to the main jib. Zero degree is when the knuckle jib is perpendicular to
the main jib. Knuckle jib angle is displayed on the operator’s terminal.
Jib speed is reduced as it approaches its end-points to provide a smooth stop.
Knuckle jib in movement is stopped if the active winch’s hook stop is reached (indicated by alarms). The active
winch’s wire must then be paid out in order to continue the knuckle jib’s in movement.
Knuckle jib out movement is stopped if the maximum hook load is exceeded.
Interlocks
The following will stop knuckle jib out movement:
• Knuckle jib angle encoder error.
The following will stop knuckle jib in movement:

• Whip winch hook stop
• Main winch hook stop
• Knuckle jib angle encoder error
5 Operation
6. Derating
6.1. Derating overview
To prevent peak loads and dynamic forces from exceeding a crane’s design limits, it is necessary to restrict hook
load and operating radius in heavy seas (high significant wave height). A calm sea creates little need for
regulating maximum allowed hook load, and a crane can operate at full rated capacity. But rough seas and a
swaying crane subject the crane to considerable dynamic forces, and capacity must be reduced through a
procedure called derating. Each crane is supplied with its own load/derating curves which roughly indicate load
limits relative to radius in defined operating modes:
• Ship to Ship lift – This applies to a pickup or landing point defined by another vessel which is moving
independently. The derated capacity is based on an increase in the dynamic amplification factor
resulting from the higher relative velocities of the jib tip and the other vessel.
• OnBoard / OffBoard – This applies to a pickup or landing point defined inside the vessel, or to
shallow water always in conditions that heave is less than 0.5m.
The fundamental factors involved in the overall derating challenge are:
• Higher forces acting on the crane as a result of increased crane base motion.
• Very high peak loads caused by high relative motion between the jib tip and the sea surface or the load
at rest.
If derating is required, the operator must open the Crane Rating pop-up and select the appropriate lifting mode
and enter the wave height (or dynamic factor). The control system then imposes reduced load/radius limits
automatically. But the load charts are based on analysis of normal operating practices and relevant standards,
and cannot cover all possible crane manoeuvres. The operator is therefore still responsible for careful
assessment, planning and execution of each lift and for a correct response to unforeseen situations.
See also section 6.3 - "Crane Ratings".
5 Operation
6.2. Derating / Load Radius Diagrams / Work Area

See following pages and/or User Manual Volume 2 Section 1.4 for:
• SP2552-1-N-XX-001 SHIP TO SHIP Load Radius Diagram - Single Fall Mode

• SP2552-1-N-XX-002 SHIP TO SHIP Load Radius Diagram - Double Fall Mode
• SP2552-1-N-XX-003 SHIP TO SHIP Load Radius Diagram - Triple Fall Mode
5 Operation
5 Operation
5 Operation
5 Operation
7. Emergency Procedures
7.1. Emergency Stop
When activated: All HPU pumps will shut down and all crane functions will stop. All valves are de-energized.
Note: An emergency stop will not de-energize all components in the system, and the control system will still be
powered up.
An alarm indication is displayed on the operator’s screen to inform the operator.
7.1.1. Restart After an Emergency Stop

Alarm Activation of the emergency stop will cause an alarm to appear
on the operator’s screen. This alarm must be acknowledged.
Identify cause of Check reason for emergency stop.

emergency stop
Check and correct errors and other potential problems.
Emergency stop buttons Turn emergency stop button counter clockwise to release.
must be reset Check emergency stop buttons in king (2) and in cabin (1).
Execute start procedure Resetting the emergency stop button will not start the system.
from HMI touch-screen
7.2. Emergency Release Functions

7.2.1. Automatic Overload Protection System (AOPS)
The Automatic Overload Protection System automatically releases the wire in a controlled payout if the sensed
load exceeds maximum load including dynamic factor. As long as AOPS is activated, the winch will maintain a
retaining force corresponding to the relevant SWL.
AOPS is inaccessible when the jib tip is over deck, and is automatically made accessible when the jib tip is over
water.
AOPS enabled and/or active is displayed on the control terminal.
7.2.2. Manual Overload Protection System (MOPS)

A MOPS button for each winch is located on OP-103 (next to left joystick) and is fitted with a protective cover
to prevent inadvertent use.
When the MOPS button is pressed, the winch will pay out wire while the system maintains a retaining force of
approximately 10-20% of maximum rated winch capacity. MOPS works independently of the control system
and is powered by batteries.
Both emergency release functions are inaccessible to winches operating in personnel-lift mode.
5 Operation
7.3. Emergency HPU Operation

A 63 kW emergency HPU is mounted inside the king for use in the event of control system (PLC/PC) failure,
HPU failure or power failure. This unit can power the crane for operation at reduced speeds.
When needed, the motor is connected to the ship’s normal or emergency power system by means of a jumper
cable and started from the emergency starter panel on cabinet ES-404 inside the king.
In the event of HPU or power failure, the crane can be operated from the cabin in the normal way using the
control system. If the control system has failed, the crane is operated from the emergency control unit stored
inside the king.
7.3.1. Emergency Operation Procedures

The emergency operation procedures are provided at Annex C - "Emergency Operation Procedures", and consist
of the following:
• Emergency operation procedure, part 1

• Crane emergency operation procedure, part 2
• Winch emergency operation procedure, part 2
5 Operation
8. Alarms
8.1. Responsibility of the User
The alarm system is a vital part of the operator’s ability to understand the overall situation, safety information
and environment at all times. Every effort has been made to implement a safe and simple system that presents
all alarms, but which helps the important ones stand out rather than blend in with the range of other alarm
messages.
The alarm system will only work as intended if the user has set it up to give the expected response.
It is important that the crane operator inform other users whenever alarms are acknowledged but not corrected,
or whenever the alarm buzzer is silenced (for trouble-shooting for example), whenever such actions may present
a safety hazard or affect trouble-shooting.
8.2. Alarm Philosophy

The alarm system is built on the following alarm philosophy:
• A new alarm is always displayed in the alarm banner in the top menu bar and in the alarm list. Alarms
are automatically associated with an alarm group for sorting and grouping
• All defined alarms require operator acknowledgement
• If an alarm is acknowledged and the alarm condition resolved, the alarm message will automatically be
removed from the display
• If an alarm condition is resolved (returned alarm), but the alarm is not acknowledged, the alarm
message will turn green and remain showing until acknowledged by the operator
When an inappropriate condition exists for a preset amount of time, an alarm is generated in the PLC CPU and
stored in temporary memory. The HMI continuously reads the memory, grouping and sorting alarms according
to the crane systems (main winch, whip winch etc.) The HMI time-stamps the alarms and displays any new
alarm in both the alarm banner and in the alarms list (the most recent unacknowledged alarm is always
displayed on the alarm banner).
The alarm display will be continuously updated with new incoming and returned alarms. All alarms are logged
for two weeks within the control system (newer systems).
5 Operation
8.3. Operator Interface

8.3.1. Status Banner
In addition to the alarm banner, the status banner contains shortcut buttons which indicate the status of different
alarm groups.
• A red frame around the shortcut button indicates an active (standing) alarm within the alarm group
• A blinking red frame indicates a new (and not acknowledged) alarm within the alarm group
Clicking on an alarm group shortcut will open the alarms page with the alarms for that group sorted by date and
time.
Note that the Status Banner is further described in other parts of the user manual.
8.3.2. Alarm Banner

The alarm banner always displays the most recent alarm until it is acknowledged. If there is no
unacknowledged alarm, no alarm is shown in the alarm banner.
8.3.3. General
Alarms are sorted by date and time according to when they were read by the operator terminal system. They are
always displayed with the most recent on top. Thus, as alarms are acknowledged, the display goes backward
through the list (newest to oldest).
The user may acknowledge alarms with the dedicated Alarm Acknowledge button in the left joystick, or via the
buttons on the alarms screen.
To list all alarms, the operator can call up a separate alarms screen via the alarm button on the main menu. On
the alarms screen, the alarms list presents alarms according to the alarm query setting. The most recent alarm is
always shown on top. Alarms are displayed in rows with alarm information in columns as follows:
• "Date" is when the alarm was received and stamped by the control system
• "Time" is the time the alarm was received and stamped by the control system
• "Priority" shows alarm priority - however this feature is irrelevant to crane operation
• "Group" defines the alarm group the alarm is associated with. Groups are as follows:
HPU Hydraulic power unit alarms
CR Crane alarms
MW Main winch alarms
WW Whip winch alarms
AHC Active heave compensation alarms
MISC Miscellaneous alarms
• "Name" is the actual name used by the control system for the alarm. This will usually correspond to the
tag name used by the PLC
• "Comment" shows the alarm description
• "Value" shows the status of the alarm when it was received
5 Operation
The alarm status screen shown above is accessed by pressing "Alarm" from the "Menu" button.
The alarm display may appear in two modes:
• Alarm Status: the current alarm situation is displayed. Only non-acknowledged alarms (whether they
are standing or returned) are listed. Alarms are sorted by time
• Alarm History: all alarms (since the last HMI reboot) for the selected group are displayed. The list is
sorted by time
The active display mode is shown in the upper left corner of the alarm display. Alarm status is the default view.
The "New Query" button allows the operator to filter alarms in greater detail. This function is described in
greater detail later in this section.
The operator can acknowledge alarms directly from this screen.
The "Long Term History" button allows access to a list of all alarms from the past 2 weeks (can be filtered by
date/time, but not sorted) as seen in the following image.
5 Operation
This screen shows the alarm history displayed in "Long Term History" mode. Here, the operator is able to
display alarms from the following periods:
• Last 15 minutes
• Last hour
• Last day
• Last week
• Last 2 weeks
8.3.4. Alarm Colours

The following text colours are used in the alarm display:
Red New alarm waiting for operator acknowledgement

Blue Alarm acknowledged, but not returned (condition is not resolved)
Green Alarm returned (condition is resolved), but not acknowledged
5 Operation
8.3.5. Alarm Acknowledgement

Alarms can be acknowledged in two ways, either by pressing the dedicated “Alarm Ackn” button in front of the
left joystick or by using the “Ack Selected” or “Ack All” buttons in the alarm display. Pressing the alarm
acknowledge button will acknowledge the last incoming alarm shown in the alarm banner.
From the alarm display, alarms can be acknowledged individually or by groups. To acknowledge an alarm, click
on the alarm in the display. Press and hold on the touch screen, and repeat to select several alarms. Click “Ack
Selected” to acknowledge the selected alarm/s, or click “Ack ALL” to acknowledge all alarms in the alarm
group.
8.3.6. Alarm Query

Sometimes the user needs to investigate and search for alarms and alarm combinations. The control system
provides comprehensive functions to help the user in such cases via the operator terminal.
The alarm system is divided into simple, intuitive alarm groups. Each of these groups typically pertains to a
part or aspect of the crane. Each alarm group may consist of further subgroups which are available by selecting
and performing a new alarm query. The alarm display shows alarms for selected alarm groups according to the
last alarm query.
There are two ways to do an alarm query:
• Click on the group symbol in the status banner. The alarm status display will appear with an alarm
query for the selected group
• In the alarm status display a new alarm query can be selected with the “New Query” button. A menu for
the query selection will appear
Click on “Alarm Query” to bring up the alarm query popup which will appear over the lower buttons in the
alarm display.
Alarm Query Functions

The alarm query popup dialogue offers the following selection of alarm groups:
• Click on “All Alarms” to see all defined alarm groups.
The following parameters may also be included in the query:
• Status or history display (status is default)

• Select unacknowledged
• Select acknowledged
• Select all (default)
5 Operation
8.3.7. Alarm List

(HM rev 0)
The following list presents the main operational alarms of the system. The alarms are presented with Tag info,
alarm text, alarm group and alarm description.
General system
Item TAG info (HMI) Alarm text (HMI) Group Alarm description
(HMI)
2.0 CR_EmergencySto Emergency Stop CR Any emergency stop activated
p Activated
2.1 CR_EmergencySto Emergency stop CR Emergency stop activated –ES400
p_S0 on/off
2.2 CR_EmergencySto Emergency stop CR Emergency stop activated –ES404
p_S04 on/off
2.3 CR_ServiceMode Emergency Stop - CR Service mode switch activated – crane lock out
Service Mode
2.4 CR_IntLockOverrid Interlock Override CR Interlock button override – all interlocks disabled
e_STA
2.5 CR_JS_Right_X_E Joystick Right - CR Error with joystick directional switch or
RR Switch Error X Axis potentiometer. Calibration needed.
2.6 CR_JS_Right_Y_E Joystick Right - CR Error with joystick directional switch or
RR Switch Error Y Axis potentiometer. Calibration needed.
2.7 CR_JS_Right_ERR Right Joystick error - COM Right Joystick - Profibus communication error
DP19
2.8 CR_JS_Left_X_ER Joystick Left - CR Error with joystick directional switch or
R Switch Error X Axis potentiometer. Calibration needed.
2.9 CR_JS_Left_Y_ER Joystick Left - CR Error with joystick directional switch or

R Switch Error Y Axis potentiometer. Calibration needed.
2.10 CR_JS_Left_ERR Left Joystick error - COM Left Joystick - Profibus communication error
DP18
2.11 TW1_JS_ERR Joystick Tugger CR Error with joystick directional switch or
Winch 1 - Switch potentiometer. Calibration needed.
Error
2.12 TW2_JS_ERR Joystick Tugger CR Error with joystick directional switch or

Winch 2 - Switch potentiometer. Calibration needed.
Error
2.13 CR_JS_Left_OVR_ Joystick Left - CR Directional switches in joystick disabled. Only
STA Override Switches potentiometer used as reference.
2.14 CR_JS_Right_OVR Joystick Right - CR Directional switches in joystick disabled. Only
_STA Override Switches potentiometer used as reference.
2.15 TW_JS_OVR_STA Joystick Tugger CR Directional switches in joystick disabled. Only
Winches - Override potentiometer used as reference.
Switches
2.16 CR_MOPS_ChgBr MOPS Battery CR MOPS battery charging error – Fuse tripped
k_TRP charging breaker -
Tripped
2.17 CR_MOPS_Battery MOPS Battery NOT CR MOPS Battery NOT OK
_Fault1 OK
5 Operation
(HMI)
2.18 CR_MOPS_Battery MOPS Battery NOT CR MOPS Battery NOT ready
_Fault2 ready
2.19 CR_MOPS_Battery MOPS Battery < CR MOPS Battery < 85% charged
_LOW 85% charged
2.20 MISC_RollAngle_ Roll Angle High MISC MRU roll ≥ 6,0 degree.
H
2.21 MISC_MRU_ERR MRU - Signal Error MISC MRU error – analog outputs from MRU not OK.
2.22 IC300_ERR CC-300 - Remote IO COM CC-300 – Profibus communication error
Error - DP3
2.23 IC400_ERR ES-400 - Remote IO COM ES-400 - Profibus communication error
Error - DP4
2.24 Encoder_MW_ERR Main Winch Encoder COM Main Winch Encoder - Profibus communication
IO Error - DP11 error
2.25 Encoder_MJ_A_ER Main Jib Encoder A COM Main Jib Encoder A Profibus communication error
R IO Error - DP13
2.26 Encoder_MJ_B_ER Main Jib Encoder B COM Main Jib Encoder B - Profibus communication error
R IO Error - DP14
2.27 Encoder_WW_ER Whip Winch Encoder COM Whip Winch Encoder - Profibus communication
R IO Error - DP12 error
2.28 Encoder_KJ_A_ER Knuckle Jib Encoder COM Knuckle Jib Encoder - Profibus communication
R A IO Error - DP16 error
2.29 Encoder_KJ_B_ER Knuckle Jib Encoder COM Knuckle Jib Encoder - Profibus communication
R B IO Error - DP17 error
2.30 Encoder_Slew_ER Slew Encoder IO COM Slew Encoder - Profibus communication error
R Error - DP10
2.31 Encoder_WW_Spo Whip Winch COM Whip Winc Spooling Encoder - Profibus
olPos_ERR Spooling Encoder IO communication error
Error - DP15
2.32 CR_OverloadM55 Grease Pump M55 CR Grease Pump M55 for crane functions is overloaded
overloaded and not moving
2.33 CR_GreasePumpM Grease Pump M55 CR Grease pump for crane functions disabled.
55Disabled disabled
2.34 CR_OverloadM56 Grease Pump M56 CR Grease Pump M56 for Main Winch is overloaded
overloaded and not moving
2.35 CR_GreasePumpM Grease Pump M56 CR Grease pump for Main Winch disabled.
56Disabled disabled
2.36 CR_LubeMon1NoF No grease flow - CR No grease flow detected by the lubrication monitor 1
lowM55 Lubrication Monitor on –M55
1 on -M55
2.37 CR_LubeMon2NoF No grease flow - CR No grease flow detected by the lubrication monitor 2
2 on -M55
2.38 CR_LubeMon3NoF No grease flow - CR No grease flow detected by the lubrication monitor3
3 on -M56
2.39 Software_ERR Software error CR Error in PLC software
2.40 Module_ERR I/O-Access error CR PLC I/O access error
5 Operation
Hydraulic Power Unit (HPU)
(HMI)
3.0 HPU_TankLevel_ERR HPU Reservoir Level HPU Cable break or faulty sensor.
- Signal Error
3.1 HPU_Tank1LevelSwitc Oil Tank 1 Level HPU HPU oil level sensor fault. Cable break or faulty
h_ERR Switch - Sensor Fault sensor.
3.2 HPU_TankLevel_L HPU Reservoir Level HPU HPU oil tank level less than 55 %
- Low Alarm
3.3 HPU_TankLevel_LL HPU Reservoir Level HPU HPU oil tank level less than 50 %
- Low Low Alarm
3.4 HPU_TankLevel_H HPU Reservoir Level HPU HPU oil tank level above 95 %
- High Alarm
3.5 HPU_TankLevel_HH HPU Reservoir Level HPU HPU oil tank level above 100 %
- High High Alarm
3.6 HPU_Tank1TempSwitc Oil Tank 1 HPU HPU oil temperature sensor fault. Cable break or
h_ERR Temperature Switch - faulty sensor.
Sensor Fault
3.7 HPU_TankTemp_H HPU Tank HPU HPU reservoir - high temperature
Temperature - High
Alarm
3.8 HPU_TankTemp_HH HPU Tank HPU HPU reservoir - high high temperature
Temperature - High
High Alarm
3.9 HPU_MP1_TRP HPU M1 - Main HPU Motor start/stop tripped
Pump 1 - Tripped
Pump 2 - Tripped
Pump 3 - Tripped
Pump 4 - Tripped
3.13 HPU_CircPump_TRP HPU M10 - Circ HPU Motor start/stop tripped
Pump - Tripped
3.14 HPU_CJCPump_TRP HPU M11 - CJC HPU Motor start/stop tripped
Pump - Tripped
3.15 HPU_Cooler1_TRP HPU M20 - Cooler 1 HPU Motor start/stop tripped
- Tripped
- Tripped
- Tripped
- Tripped
- Tripped
- Tripped
- Tripped
3.22 HPU_EmPump_TRP Emergency Pump HPU Motor start/stop tripped
M31 tripped
3.23 HPU_CoolingFan_TRP HPU M61 - Cooling HPU Motor start/stop tripped
Fan - Tripped
5 Operation
(HMI)
3.24 HPU_MP1_PowerMissi Main Pump 1 - HPU Main motors, power missing. Check supply and
ng Power Missing fuses.
3.28 HPU_Circ_PowerMissi Circulation Pump - HPU Circulation Pump power missing. Check supply
ng Power Missing and fuses.
3.29 HPU_CJC_PowerMissi CJC Pumps - Power HPU CJC Pump power missing. Check supply and
ng Missing fuses.
3.30 HPU_Cooler1_PowerMi Cooler 1 - Power HPU Cooler motor power missing. Check supply and
ssing Missing fuses.
3.37 HPU_DrainFilter Main pump drain HPU Clogged oil filter. Replace filter element.
filter pressure switch
3.38 HPU_WinchDrainFilter Winch motor Drain HPU Clogged oil filter. Replace filter element.
Filter
3.39 HPU_ReturnFilter1 Return filter 1 HPU Clogged oil filter. Replace filter element.
pressure switch
pressure switch
pressure switch
pressure switch
3.43 HPU_CJCFilter CJC Filter pressure HPU Clogged oil filter. Replace filter element.
switch
3.44 HPU_MainFilter1A Main filter 1A HPU Clogged oil filter. Replace filter element.
pressure switch
3.45 HPU_MainFilter1B Main filter 1B HPU Clogged oil filter. Replace filter element.
pressure switch
3.46 HPU_MainFilter2 Main filter 2 pressure HPU Clogged oil filter. Replace filter element.
switch
switch
5 Operation
(HMI)
switch
pressure switch
switch
pressure switch
3.52 HPU_KingDrainFilter Slew / Tugger Drain HPU Clogged oil filter. Replace filter element.
Filter
3.53 HPU_OilRecoveryFilter Oil Recovery Filter HPU Clogged oil filter. Replace filter element.
pressure switch
3.54 HPU_DrainTankLevel_ Level switch oil drain HPU Oil leakage detected in drain tank/king.
H tank
3.55 HPU_MainPress_L Main Pressure - Low HPU Main pressure below 50 bar.
Alarm
3.56 HPU_MainPress_H Main Pressure - High HPU Main pressure above 350 bar.
Alarm
3.57 HPU_EmPump_RUN Emergency Pump HPU Emergency pump running.
M31
3.58 HPU_LS_Press_A_ERR LS pressure A HPU Cable break or faulty sensor.
(PT219A) - Sensor
Fault
3.59 HPU_LS_Press_B_ERR LS pressure B - HPU Cable break or faulty sensor.
Sensor Fault
3.60 HPU_LS_Press_DEV LS pressure - HPU Deviation between sensor A and B.
Deviation Error
3.61 CR_PowerReqM1_Faile Power request for M1 HPU Request sent from crane to ship’s PMS but no
d failed confirmation within 90 seconds.
3.65 HPU_MainPress_ERR Main Pressure - HPU Cable break or faulty sensor.
Signal Error
3.66 HPU_AuxSupEarthFault Aux Supply (230V) - HPU Earth fault detected on 230V supply to control
Earth Fault system.
3.67 HPU_MainSup1EarthFa Main Supply 1 (A) - HPU Earth fault detected on 690V main supply 1.
ult Earth Fault
3.68 HPU_MainSup2EarthFa Main Supply 2 (B) - HPU Earth fault detected on 690V main supply 2.
ult Earth Fault
3.69 HPU_MainSup3EarthFa Main Supply 3 (C) - HPU Earth fault detected on 690V main supply 3.
ult Earth Fault
3.70 HPU_MainSup4EarthFa Main Supply 4 (D) - HPU Earth fault detected on 690V main supply 4.
ult Earth Fault
3.71 HPU_TankTemp_ERR HPU Tank HPU Cable break or faulty temperature sensor.
Temperature - Signal (TT201)
Error
5 Operation
(HMI)
3.72 HPU_TankTemp_L HPU Tank HPU HPU tank temperature below 10 degrees Celsius.
Temperature Too Main pumps start inhibited to prevent damage.
Low To Start Main
Pumps
Slew system
(HMI)
4.0 CR_SlewAccuPress_ Slew accu. pressure - CR Cable break or faulty sensor.
ERR Sensor Fault
4.1 CR_SlewPosDeviatio Slew Position CR Measured slew position deviates from preset slew
n Deviation position
Jib system
(HMI)
5.0 CR_MainJibMoving_ Main Jib Moving CR Main jib moving without joystick command.
ERR Error
5.1 CR_MJ_Enc_DEV Main Jib Encoders - CR Deviation between sensor A and B.
Deviation Error
5.2 CR_KJ_Enc_DEV Knuckle Jib Encoders CR Deviation between sensor A and B.
- Deviation Error
5 Operation
Whip Winch (WW) system
(HMI)
6.0 WW_Load_H Whip Winch Load > WW Whip winch load > 90% of allowed load.
90%
6.1 WW_Load_HH Whip Winch Load > WW Whip winch load > 110% of allowed load.
110%
6.2 WW_Load_HHH Whip Winch Load > WW Whip winch load > 125% of allowed load.
125%
6.3 WW_LoadCell_DEV Whip Winch Load WW Deviation between WW load cell channels.
Cell - Deviation
Error
6.4 WW_AOPS_ERR Whip Winch AOPS - WW AOPS disabled due to deviation between WW load
Disabled Due To cell channels.
Sensor Fault
6.5 WW_AOPS Whip Winch AOPS - WW WW AOPS activated by control system.
Active
6.6 WW_MOPS Whip Winch MOPS - WW WW MOPS activated by operator.
Active
6.7 WW_HookStop Whip Winch Hook WW WW hook stop activated either by mechanical hook
Stop stop sensor or by the hook position measurement.
6.8 WW_MechanicalHoo Whip Winch WW WW hook stop activated by mechanical hook stop
kStop Mechanical Hook sensors.
Stop
6.9 WW_HookPos_H Whip Winch Position WW WW hook position close to lower hook stop (end
High stop).
6.10 WW_LowerHookSto Whip Winch Lower WW WW lower hook stop active (end stop).
p Hook Stop
6.11 WW_MOPS_AccuPr Whipline Winch WW WW MOPS accumulator pressure low.

ess_L MOPS Accumulator
Pressure - Low
Alarm
6.12 WW_PersonnelLift_ Personnel Lift active WW WW personnel lift activated by key switch.
Active
6.13 WW_PersonnelLift_ Load Too High To WW Load too high to activate personnel lift.
NAvail Activate Personnel
Lift
6.14 WW_BrakeOff WW Brake Off - WW Whip winch brake off without joystick command.
Alarm
6.15 WW_MotorDisp_DE WW Motor WW WW Motor displacement pressure deviation mode

V Displacement - alarm
Deviation
6.16 WW_AHC_PosDev_ WW AHC Position AHC Position deviation more than 0.5 meters of hook
H Deviation High relative to the seabed in AHC.
6.17 WW_AHC_PosDev_ WW AHC Position AHC Position deviation more than 1.5 meters of hook
HH Deviation High High relative to the seabed in AHC.
5 Operation
(HMI)
6.18 WW_MOPS_AccuPr Whipline Winch AHC Cable break or faulty sensor.
ess_ERR MOPS Accumulator
Pressure - Signal
Error
6.19 WW_AHC_ControlV WW AHC Control AHC Deviation between commanded and read signal.
alve_DEV Valve Deviation
6.20 WW_AHC_Valve_F WW AHC Ctrl. AHC Cable break or faulty sensor.

BK_ERR Valve - Sensor Fault
6.21 WW_BrakePress_ER WW brake pressure - WW Cable break or faulty sensor.
R Sensor Fault
6.22 WW_DispPress_ER WW disp. pressure - WW Cable break or faulty sensor.

R Sensor Fault
6.23 WW_LoadCell_A_E Whip Winch Load WW Cable break or faulty sensor.

RR Cell A - Signal Error
6.24 WW_LoadCell_B_E Whip Winch Load WW Cable break or faulty sensor.
RR Cell B - Signal Error
6.25 WW_Speed_H WW Speed High - WW WW hook speed higher than specified.
Alarm
6.26 WW_AHC_Stopped AHC stop condition AHC AHC stop conditions:
active on Auxiliary Emergency stop active, NOT WW On selected, no
Winch main pumps running, MOPS/AOPS active, hook
pos < 5 meters, AHC deviation > 1,5 meters, MRU
error or load cell sensor error (only in AT).
AHC/AT has to be enabled to generate this alarm.
6.27 WW_OutsideWorkin Whip Winch outside WW Whip Winch outside working area
gArea working area
6.28 WW_SpoolingDev_ Whip Winch WW Whip Winch Spooling device – difference between
H Spooling Deviation – setpont and actual position >3%
High Alarm (>3%)
6.29 WW_SpoolingDev_ Whip Winch WW Whip Winch Spooling device – difference between
HH Spooling Deviation – setpont and actual position >5%
High High Alarm
(>5%)
5 Operation
Main Winch (MW) system
(HMI)
7.0 MW_Load_H Main Winch Load > MW Main winch load > 90% of allowed load.
90%
7.1 MW_Load_HH Main Winch Load > MW Main winch load > 110% of allowed load.
110%
7.2 MW_Load_HHH Main Winch Load > MW Main winch load > 125% of allowed load.
125%
7.3 MW_LoadCell_DEV Main Winch Load MW Deviation between MW load cell channels.
Cell - Deviation Error
7.4 MW_LoadCell_A_E Main Winch Load MW Cable break or faulty sensor.

RR Cell A - Signal Error
7.5 MW_LoadCell_B_E Main Winch Load MW Cable break or faulty sensor.
RR Cell B - Signal Error
7.6 MW_AOPS_ERR Main Winch AOPS - MW AOPS disabled due to deviation between MW load
Disabled Due To cell channels.
Sensor Fault
7.7 MW_AOPS Main Winch AOPS - MW MW AOPS activated by control system.

Active
7.8 MW_MOPS Main Winch MOPS - MW MW MOPS activated by operator.

Active
7.9 MW_HookStop Main Winch Hook MW MW hook stop activated by the hook position
Stop measurement.
7.10 MW_MechanicalHoo Main Winch MW MW hook stop activated by the mechanical hook
kStop Mechanical Hook stop sensors
Stop
7.11 MW_HookPos_H Main Winch Position MW MW hook position close to lower hook stop (end
High stop).
7.12 MW_LowerHookSto Main Winch Lower MW MW lower hook stop active (end stop).
p Hook Stop
7.13 MW_HookStop_ER Main Winch Hook MW Only signal from one of the proximity switches in
R Stop - Sensor Fault the mechanical hook stop sensor.
7.14 MW_Speed_H Main Winch Speed - MW MW hook speed higher than specified.
High Alarm
7.15 MW_MOPS_AccuPr Main Winch MOPS MW MW MOPS accumulator pressure 1 LOW.

ess1_L Accumulator
Pressure 1 - Low
5 Operation
(HMI)
Alarm
7.16 MW_MOPS_AccuPr Main Winch MOPS MW MW MOPS accumulator pressure 2 LOW.
ess2_L Accumulator
Pressure 2- Low
Alarm
7.17 MW_PersonnelLift_ Personnel Lift active MW MW personnel lift activated by key switch.
Active (Recovery Mode)
7.18 MW_PersonnelLift_ Wrong mode or Load MW Wrong mode or Load too high to activate personnel
NAvail Too High To lift.
Activate Personnel
Lift
7.19 MW_BrakeOff Main Winch Brake MW MW brake off without joystick command.
OFF Alarm
7.20 AHC_WrongMode AHC - Wrong Mode AHC Load too high for AHC/AT High Speed Mode.
According To Load Switch to AHC/AT Normal Mode.
7.21 AHC_HeaveVelocity Heave Velocity > 2,0 AHC True heave velocity in crane tip higher than 2 m/s or
_H m/s (120 m/min) 1m/s in double part.
7.22 AHC_PosDev_H AHC Position AHC AHC position deviation. More than 0,5 meters
Deviation High deviation between hook and set point relative to the
seabed.
7.23 AHC_PosDev_HH AHC Position AHC AHC position deviation. More than 1,5 meters
Deviation High High deviation between hook and set point relative to the
seabed.
7.24 MW_AHC_ControlV Main AHC Control AHC Deviation between commanded and read signal.
alve1_DEV Valve 1 - Deviation
Error
Error
Error
Error
7.28 MW_MOPS_AccuPr Main Winch MOPS AHC Cable break or faulty sensor.
ess1_ERR Accumulator
Pressure 1 - Signal
Error
7.29 MW_MOPS_AccuPr Main Winch MOPS AHC Cable break or faulty sensor.
ess2_ERR Accumulator
Pressure 2 - Signal
5 Operation
(HMI)
Error
7.30 MW_BrakePress1_E Main Winch Brake MW Cable break or faulty sensor.
RR Pressure 1 - Signal
Error
7.31 MW_BrakePress2_E Main Winch Brake MW Cable break or faulty sensor.
RR Pressure 2 - Signal
Error
7.32 MW_DoublePartDet Main Winch Double MW Double part sensor active but mode not selected.
Part Detected (not
selected)
7.33 MW_DoublePartSel Main Winch Double MW Double part selected but not detected by double part
Part Selected (not proximity switch.
detected)
7.34 MW_MotorDisp1_D Main Winch Motor MW Deviation between commanded and read signal.
EV Disp. 1 - Deviation
Error
7.35 MW_MotorDisp2_D Main Winch Motor MW Deviation between commanded and read signal.
EV Disp. 2 - Deviation
Error
7.36 MW_MotorDispPres Main Winch Motor MW Deviation between sensor A and B.
s_DEV Disp. Pressure
Sensors - Deviation
+CC100
7.37 MW_MotorDispPres Main Winch Motor MW Cable break or faulty sensor.
s1_ERR Disp. Pressure 1 -
Signal Error
7.38 MW_MotorDispPres Main Winch Motor MW Cable break or faulty sensor.
s2_ERR Disp. Pressure 2 -
Signal Error
7.39 MW_AHC_Stopped AHC stop condition AHC AHC stop conditions:
active on Main Emergency stop active, NOT MW On selected, no
Winch main pumps running, MOPS/AOPS active, hook
pos < 5 meters, AHC deviation > 1,5 meters, MRU
error or load cell sensor error (only in AT).
AHC/AT has to be enabled to generate this alarm.
7.40 AHC_MW_ModeSpe AHC Main Winch Speed too high for normal AHC/AT mode. Select
ed_H Mode – High Speed High Speed Mode.
7.41 AHC_MainPress_L AHC - Main Pressure MW Main pressure below 220 bar.
Low
7.42 MW_OutsideWorkin Main Winch outside MW Main Winch outside working area
gArea working area
7.43 MW_MOPS_AccuPr Main Winch MOPS MW Deviation between sensor A and B.

ess_DEV Accumulator
Pressure Sensors -
Deviation
5 Operation
9. Trend Display Screen

The Trend Display presents historical data as curves. By nature it may be complex and difficult to work with.
Some special features have therefore been built in to the trend chart to simplify the day-to-day operation.
The Trend display can show both real time and historical data, and can show up to 6 simultaneous plots.
2
1
Display functions
The large trend chart (1) shows historical or real-time trends colour-coded for the various parameters that may
be displayed.
To select a parameter for display, click inside the trend chart. The Historical Trend Setup popup now opens
(next page, bottom), displaying a list of parameters and a range of fields for defining the chart.
The left side of the chart shows the chart’s vertical scale (2) (in either metric or oilfield units), and the top shows
the time scale.
At the bottom of the display, trend-related controls enable the user to set range, zoom and other chart properties.
5 Operation
Mode It is possible to show both real-time data and historical data. The historical data is
stored in the computer for 28 days.
While in real time, the right side of the trend is always ‘now’. In historic mode, the
right side of the trend is not necessarily ‘now’.
Pan time Pan time is only available in Historical Mode. It is used to pan forward or backward in
time to display the desired time period.
Vertical range The vertical scale (2) is actually a bar graph showing the magnitude of the selected
parameter. The colour of the scale lines indicates which parameter it applies to.
Horizontal range The standard horizontal range is 30 minutes, but this can be changed with the “Zoom
Time” buttons.
Zoom Time (Zoom The horizontal scale is adjusted using the “Zoom Time” buttons. This is a real-time
horizontal) trend factor that can be scaled from one second up to approximately 20 hours.
Min Value/ To adjust a specific

Max Value parameter’s vertical scale,
select it by touching the
(Zoom vertical) relevant “pen button” in the
Historical Trend Setup box.
Enter “Min Value” and “Max
Value” in the input fields in
the same way as other
analogue value input fields.
5 Operation
10. Misc Screen

The operator can manage various settings and system surveillance tasks on this screen. The screen items will
first be presented, and then the functions will be described in more detail.
4
1
2 5
3
6
1. Information button to access a screen showing details regarding the Profibus network.
2. Information button to access a screen showing details regarding Digital Inputs and Outputs to the PLC
system.
3. Information button to access a screen showing details regarding Analogue Inputs and Outputs to the
PLC system.
4. Radio buttons used for globally changing the units between Metric and Oilfield. (If implemented – this
may be an option)
5. Button for setting and resetting the Main Interlock override function. When activated, the button turns
yellow, and the IntLock Override icon in the status banner at the top of the screen is activated.
Note: When interlock override is active, all safety features in the crane and control system are
deactivated. We recommend that a report is prepared stating the reason for activating this function each
time it is used.
6. Counter for the Interlock override, increases by one each time the override function is activated.
7. Buttons for turning jib floodlights and other lights on. These buttons turn yellow when the lights are on.
8. Activation button to put the CCTV cameras into automatic mode for the. This ensures that the active
winch is always the one displayed on the winch video monitor.
9. Hour counter
5 Operation
11. Network Status Screen

This screen gives the user an overview of which components are connected to the Profibus network, and
whether or not there are problems with any of the units.
If a node on the network is not communicating with the PLC, this is indicated by a red light. When the node is
“healthy” and connected, the light is green.
5 Operation
12. Setup Screen

The setup screen is for the maintenance personel on board for easier troubleshooting and adjustments of
parameters in the control system.
The menu is password protected, so only authorized personel can enter the menu. Password is 1000.
4
5
2
1. Radio buttons for selecting which of each set of dual sensors is used as system reference. Analogue
information fields to the right display reference and realtime values.
2. Menu buttons to access encoder, joystick calibration, setup and reset screens.
3. Button for shutting down front screen HMI software application.
4. Button for reinitializing I/O values.
5. Button for starting uninitiated I/O conversations.
5 Operation
Resetting the encoders
It is of utmost importance to follow the directions below when resetting encoders or position measuring devices.
Incorrect position settings can cause serious damage or personal injury. The interlock override may be used if
neccesary to reach the required reset position.
With the device in the desired position, press the relevant S button on the encoder reset screen (below) to reset
the device’s “null point”.
Encoder Instructions
Main winch position Place hook in desired upper position (about 1.5 metres from sheaves), knuckle jib
fully in, main jib fully down, when resetting main winch position encoder.
Whip winch position Place hook in desired upper position (about 1.5 meter from sheaves), knuckle jib
fully in, main jib fully down, when resetting whip winch position encoder.
Slew angle The crane must be parked, with the knuckle jib resting in the parking cradle.
Knuckle Jib angle The knuckle jib encoders are to be reset with the knuckle jib folded all the way in.
Main Jib angle The main jib encoders are to be reset with the main jib lowered completely.
Encoder reset screen
5 Operation
13. Joystick Setup Screen

The screen is divided in three parts, Left Joystick, Right Joystick and Tugger winch joysticks. The left and right
parts are nearly identical.
2 3
1. Indicators for whether or not the direction switches for the joystick axes are active.
2. Potentiometer X axis force reading.
3. Potentiometer Y axis force reading.
5 Operation
14. Troubleshooting
Although the Control System is designed for a long and trouble-free service life, problems may occur with the
equipment.
Trouble-shooting then becomes necessary. Technicians must have drawings, descriptions and component data
sheets as their primary aids. These will normally be sufficient for 90% of the problems occurring on systems
that have been operative for some time.
By experience, the PLC system, software and input/output modules are very rarely the cause of failure!
Note that all software changes should be done subsequent to filling out a Software Change Request form
(contact MacGregor service for request form). This is required to ensure that all parties have an updated base of
system features, as well as to ensure that the built-in safety and functions are not jeopardised.
This trouble-shooting section mainly contains PLC system failure procedures.
For detailed information on the components used, refer to the component data sheet section of this manual.
5 Operation
15. Control System Setup

15.1. General
The following procedures comprise the main setup items:
• Crane slew initialisation

• Winch initialisation
• Main jib angle sensor setup
• Knuckle jib angle sensor setup
15.2. Crane Slew Initialisation

When to perform This procedure must be performed after the PLC has been repaired or replaced, or
after an absolute encoder failure.
What to do Select “Setup” from the menu sidebar on the touch screen terminal. The setup menu is
password protected.
Password: 1000.
Park the crane as precisely as possible.
Press S next to Slew Angle sensor, then R (Reset) in the Slew Angle popup.\
Comments The AOPS system will not be operational if the crane slew angle is not initialised.
Troubleshooting the crane slew angle sensor is thus essential.
15.3. Winch Initialisation

When to perform This procedure must be performed if the PLC has been repaired or replaced, or after
an absolute encoder failure.
What to do Select Setup from the menu sidebar on the touch-screen terminal. The Setup menu is
password-protected.
Password: 1000.
Park the crane and run the main winch hook to the correct hook-stop position relative
to the jib tip.
Press S next to Main/Whip Winch Hook Position, then R (Reset) in the popup.
Comments It is not possible to run the hook past the position set when the winch was last
initialised. To set a new “final hook-stop” the PLC has to be restarted.
5 Operation
15.4. Main Jib Angle Sensor Initialisation / Replacement

When to perform This procedure must be performed when the absolute encoder gives a wrong readout
or has been repaired.
Indication Wrong readout on main jib angle.
What to do Select Setup from the menu sidebar on the touch-screen terminal. This menu is
password protected.
Password: 1000.
Lower the Main Jib until it reaches its mechanical end stop.
Press S next to Main Jib Angle, then R (Reset) in the popup.
Comments An incorrect setting on this encoder will affect hook load calculations, winch position
calculations and the AOPS system.
15.5. Knuckle Jib Angle Sensor Initialisation / Replacement

When to perform This procedure must be performed when the absolute encoder gives a wrong readout
or has been repaired.
Indication Wrong readout on knuckle jib angle.
What to do Select Setup from the menu sidebar on the touch-screen terminal. This menu is
password protected.
Password: 1000.
Retract the knuckle jib until it reaches its mechanical end stop.
Press S next to Knuckle Jib Angle, then R (Reset) in the popup.
Comments An incorrect setting on this encoder will affect hook load calculations, winch position
calculations and the AOPS system.
5 Operation
16. PLC LEDs and Troubleshooting – SIMATIC S7 300

16.1. General
This section contains troubleshooting guidelines for standard equipment used on MacGregor HMC cranes.
Therefore, this section may contain descriptions of equipment not installed in the actual delivery.
16.2. PLC System LEDs

The various PLC modules have LEDs that indicate normal operation as well as fault information. This section
describes the LEDs and their functions in the various modules.
16.3. Power Supply Module LEDs

PS 305/307 power supplies have only one LED that indicates 24VDC either present or not present.
16.4. S7 300 CPU LEDs

The table below describes the functions of the SF, 5VDC, FRCE, RUN, STOP LEDs.
LED Meaning
SF DC5V FRCE RUN STOP
D D D D D CPU power supply missing
D L X D L CPU is in STOP mode
Start the CPU
L L X D L CPU is in STOP mode as result of error
X L X D F CPU requesting memory reset
(0,5Hz)
X L X D F CPU executing memory reset
(2Hz)
X L X F L CPU is in startup mode
(2 Hz)
X L X F L CPU was halted by a programmed break point
(0,5Hz
L L X X X Hardware or software error
X X L X X User enabled the force function
X X F X X Node flashing test was activated
(2 Hz)
F F F F F CPU has an internal system error.
Proceed is as follows:
Set mode selector switch to STOP
Perform POWER ON/OFF
Read diagnostics buffer, see STEP 7
Contact your local SIEMENS partner
5 Operation
16.5. DP interface LEDs

The table below describes the functions of the BF, BF1, BF2 LEDs.
LED Meaning
SF 5VDC BF BF1 BF2
L L L/F - - PROFIBUS DP interface error
L L - L/F X Fault at the second PROFIBUS DP interface of CPU 317

or CPU 319-3 PN/DP
L L - X L/F Fault at the second PROFIBUS DP interface of CPU 317

or CPU 319-3 PN/DP
5 Operation
16.6. Ethernet (PN) interface LEDs

The table below describes the functions of the LINK, RX/TX, BF2 or BF3 LEDs.
LED LED status Description of status
Not Flashes Lit

lit
LINK - - X There is no connection between the PROFINET interface of

your PROFINET device and a communication partner in the
Ethernet (a switch, for example).
- X - Only with an i/o device:
User-activated flashing from STEP 7
X - - The Ethernet connection between the PROFINET interface of

the PROFINET device and the communication partner is
down.
RX - - X At the current time, data are being received from a

communication partner on Ethernet via the PROFINET
(flickers) device’s PROFINET interface.
X - - No data are currently received via the PROFINET interface.
TX - - X Data are currently being sent to a communication partner on

Ethernet via the PROFINET device’s PROFINET interface.
(flickers)
X - - No data are currently being transmitted via the PROFINET

interface.
BF2 - - X Error on the PROFINET interface, communication no longer

or possible (for example, with a CPU as i/o controller, when the
BF3 communication is down)
- X - Error on the PROFINET interface (for example, due to station

failure of one or more i/o devices)
X - - No error at the PROFINET interface.
5 Operation
16.7. Interface module IM 360 LED

The table below describes the function of the SF LED.
Display element Meaning Explanation
SF Group error The LED lights up if
- The connection cable is missing

- IM 361 is switched off
16.8. Interface module IM 361 LEDs

The table below describes the function of the SF and 5 VDC LEDs.
Display element Meaning Explanation
SF Group error The LED lights up if
- The connection cable is missing

- IM 361 connected in series is switched off
- The CPU is in POWER OFF state
5 VDC 5 VDC supply for the S7-300 -
backplane bus
16.9. Digital Input / Output Modules

The table below describes the fault status of the digital I/O modules.
Fault Description
SF Some i/o modules have the ability to indicate group-error.
Reason for indication may be loss of power to module or module failure.
Remedy: check fuses and/or replace module (when power is switched off).
5 Operation
16.10. Analogue Input / Output Modules

The table below describes the fault status of the analogue I/O modules
Fault Description
SF Some i/o modules have the ability to indicate group-error.
Reason for indication may be loss of power to module or module failure.
Remedy: check fuses and/or replace module (when power is switched off).
5 Operation
17. Replacing Siemens S7 Components

17.1. General
Several components require special handling when replacing. This may include special precautions in handling,
setting of switches or transfer of software.
17.2. PLC Modules

Care must be taken whenever you are working with PLC modules to prevent unexpected CPU shutdown. Do
not work with PLC modules while the system is in operation.
17.3. Power supply

The module to be replaced is installed and wired up. A new module of the same type is to be fitted. If you have
provided the modules in your system with slot numbering, you must remove the number from the old module
when replacing it and apply the number to the new module. To remove a module, follow the steps outlined
below:
1. Set the PLC mode switch to STOP.

2. Set the Standby switch of the power supply module down (0 V output voltages).
3. Open the PLC supply circuit-breaker. Refer to the loop diagrams for identifying the correct circuit-
breaker.
4. Open the power supply cover.
5. Disconnect the power supply from the power supply module.
6. Loosen the module’s mounting screws.
7. Swivel the module out.
To fit the new module, follow the steps outlined below:
1. Check the voltage selector switch.

2. Hook the new module of the same type on and swivel it downward.
3. Screw the module on.
4. Check that the PLC supply-circuit breaker is open and the Standby switch is down.
5. Connect the power supply to the power supply module.
6. Close the power supply cover.
7. Close the PLC supply circuit-breaker.
8. Set the power supply module’s Standby switch up (output voltages at rated value).
9. Set the PLC mode switch to RUN if applicable.
5 Operation
17.4. PLCs
PLC modules may only be replaced by modules with the exact same part number. The part number is printed on
the lower left corner of the module front. If another PLC module is to be used, it may only be replaced by
qualified MacGregor Marine Service personnel.
Note that all accumulated data is stored in the Micro Memory Card on the PLC module so no data will be lost.
This may include data such as motor run time, wire usage and similar integrated information.
To remove the module, follow the steps outlined below:

2. Set the power supply module’s Standby switch down (0 V output voltages).
3. Open the PLC cover.
4. Disconnect all connectors.
5. Remove the micro memory card.
6. Loosen the module’s mounting screws.
1. Hook the new module of the same type on and swivel it downward.
2. Screw the module on.
3. Connect all connectors.
5. Insert the micro memory card.
6. Set the power supply module’s Standby switch up (output voltages at rated values).
7. Set the PLC mode switch to RUN.
8. Close the cover.
5 Operation
17.4.1. Digital or Analogue Modules

To remove a module, follow the steps outlined below:
1. You cannot replace analogue and digital modules while in RUN mode. Therefore, switch the Standby
switch on the power supply down.
2. Loosen the front connector’s mounting screw and pull it off.
3. Loosen the module mounting screw.
Before fitting the front connector, you must remove (break off) the front part of the coding key, because this
part is already fitted in the wired front connector.
Caution: The module can be damaged.
If, for example, you insert a front connector for a digital module in an analogue module, the module may be
damaged.
Modules are only to be operated with their complete front connector-coding key.
1. For analogue modules make sure that the measurement type-coding key on the side of the new module
matches that of the old module. If in doubt refer to the loop diagrams for further information.
2. Hook the new module of the same type on at the appropriate slot and swivel it downward.
3. Screw the module on with the mounting screw.
4. Fit the front connector.
5. Switch the power supply Standby switch up.
6. After fitting, each programmable module will be reinitialised by the PLC with parameters.
To replace a front connector, follow the steps outlined below:
1. Set the power supply Standby switch down and switch off all load power supplies for the module.
2. Loosen the front connector screw and pull it off.
3. Remove the labels from the front connector and insert them into the new front connector.
4. Wire the new front connector.
5. Insert the front connector in the module.
6. Screw the front connector on.
7. Switch on the load voltage and set the power supply Standby switch up.
5 Operation
18. End Notes

denotes optional equipment that may not be part of the specific crane delivery.
All winches have software hook stops.
Winches with AHC/AT mode, and winches with Constant Tension (CT) mode and >1000
metres of hook travel are also fitted with mechanical hook stops.
5 Operation
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5 Operation
6 Maintenance
Table of Contents
1. General Maintenance Instructions ....................................................................................................1
2. General Inspection Instructions ........................................................................................................3
3. Periodic Maintenance.......................................................................................................................5
4. Interpreting the Periodic Maintenance Program Matrix .....................................................................6
5. MOPS Function Test ......................................................................................................................17
6. Annexes .........................................................................................................................................18
6 Maintenance
MACGREGOR NORWAY AS
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6 Maintenance
MACGREGOR NORWAY AS
1. General Maintenance Instructions

The maintenance program has been developed by MacGregor Norway AS in accordance with our supplier’s
maintenance program for each component. The maintenance program involves the following actions:
Lubrication, Inspection, Overhaul and Replace. These actions are implemented in a Periodic Maintenance
Program. Conforming to this maintenance program will ensure a long, trouble-free service life. The importance
of the operator's continuous attention during operation of the equipment is strongly emphasized. If any
irregularities should occur, immediately shut down the equipment, detect the cause and take the necessary
corrective action.
Lubrication: Lubrication is identified with the following:
• Apply grease to grease nipples.

• Apply lubricant or oil onto surfaces to reduce friction or corrosion.
• Refill or change oil to system or component.
Inspection: Inspection is identified with the following:
• Check component for any damage.

• Check for correct function of each component.
• Check for any unfamiliar noise from each component.
• Check for any abnormal vibration from rotating components.
• Check for correct oil quantity.
• Check condition of paint and other surfaces on all components.
• Check for leaks.
• Check for corrosion.
• Check lifting umbilical for wear.
Overhaul: Overhaul is identified with the following:
• Remove the component from the system.

• Disassemble the component and inspect each part.
• Repair if necessary:
o Bearings.
o O-rings, gaskets and seals.
o Wear of mechanical parts.
o Hydraulic valves fittings and hoses.
o All bolts, nuts and washers.
• Clean all components before reassembling and remounting.
• Replace or repair components as needed, before mounting assembly.
• Repair damaged paint surfaces.
Replace: Replace includes the following:
• Remove original component and replace with a new component.
6 Maintenance
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6 Maintenance
2. General Inspection Instructions

Regular inspection and maintenance will:
• Prevent accidents and maintain safe operation of your MacGregor equipment through inspections and
operator training.
• Avoid unnecessary interruptions in up-time.
• Ensure peak efficiency throughout your crane's long life.
• Address potential problems before they become more costly or inconvenient.
• Reduce overhead costs associated with parts, lubricants and tools.
• Reduce downtime by scheduling when production will not be interrupted.
In addition to the periodic maintenance program, it is recommended to perform daily / pre-start inspections:
• Visual check for hydraulic oil leaks on the crane, both internal and external.
• Visual check of the hydraulic reservoir fluid level.
• Visual check of the oil coolers.
• Visual check of the aircraft warning light as required.
• Visual check of the crane hook latch.
• Visual check of wire sheaves and spooling.
• Visual check of wire rope for evident deterioration and damage or improper reeving.
• Visually check for loose, missing or corroded bolts, pins, keepers or locking wire.
• Visually check loose gear to be used, such as slings, sling hooks and shackles.
• Ensure the correct load-rating chart for the configuration in use is visible to the crane operator.
• Perform a “walk-around” visual examination of the crane structure to ensure that no damage exists.
• Visually check that the crane can rotate freely in its working area.
• Verify mechanical hook function.
• Check control system alarm log.
• Lubricate components and correct deficiencies as required based on the results of these inspections.
Yearly and five yearly safety inspections:
National and recertification requirements by classification societies like: DNV, Lloyds Register of Shipping,
Germanisher Lloyd, Bureau Veritas and American Bureau of Shipping include yearly and five yearly safety
inspections and retesting. These inspections have to be made by the original equipment manufacturer (OEM) or
OEM certified service companies.
Inspections on your advanced MacGregor Active Heave Compensated Offshore Cranes produce neutral reports
on equipment condition and provide recommendations for necessary actions when required. The main purpose
of an inspection is to assess and maintain the condition of the equipment. Our experience and high standards of
design and manufacturing of your advanced crane is the basis for all inspections.
6 Maintenance
A proactive approach can help to avoid catastrophic breakdowns, downtime and off hire situations. MacGregor,
the original equipment manufacturer (OEM), have the resources of personnel that provide the skill and
experience that is necessary to guide a proactive approach, helping you as our customer to focus on and to
predict the most effective maintenance needs.
The inspection of advanced cranes relies on equipment specific inspection programs, where MacGregor
advanced cranes are looked at not only with respect to mandatory standards but also to specified technical and
operational requirements.
The final inspection report is a document that complies with industrial and mandatory requirements. The full
report includes two documents; an ”Inspection summary report” which is a evaluation of the overall equipment
condition in terms of safety and operation, based on what the inspection reveals, and the second document is a”
Service report” in which you will get recommendations for actions and spare parts when needed.
6 Maintenance
3. Periodic Maintenance
Maintenance of the crane is organized in different time intervals. The intervals are specified as follows:
• xx Weeks: xxW
• xx Months: xxM
• xx Years: xxY
• xx Hours: xxH (operating hours)
Examples:
• 3 months interval: 3M
• 2 years interval : 2Y
• 1 Week interval: 1W
• 2 months / 200 hours: 2 M / 200 h
Maintenance log !
During the warranty period, either the enclosed maintenance
log or the vessel’s own maintenance log should be used to
document crane maintenance, as this will be called upon
should a warranty issue occur.
All necessary inspection points are identified in the periodic maintenance program tables.
As a general recommendation all hydraulic motor bearings should be replaced after 15000 operating hours.
To prevent corrosion of the main and knuckle jib cylinder rods, the crane should not be parked with the cylinder
rods left exposed.
In longer periods of inactivity, to avoid shortening of the main and knuckle jib cylinder’s service life, repeatedly
extend and retract the cylinders to maintain internal lubrication and tightness.
6 Maintenance
4. Interpreting the Periodic Maintenance Program Matrix
Maintenance action reference (this is the first maintenance action listed)

Shows which of the crane/winch systems that is involved
Shows which of the crane/winch systems that is affected
Shows the recommended lubrication interval (here; N/A indicates no lubrication necessary)
Shows the recommended Inspection interval (here; every 3 M or 100 hrs)
Shows the recommended Overhaul interval (here; every 5 years)
Indicates component replacement
Short description of the maintenance action
Reference to the full description of the maintenance action
Note: Maintenance actions that are greyed out do NOT apply.
Periodic maintenance program appendices:
Where referred to, please find the applicable annex in section 6.6 – Annexes.
6 Maintenance
PERIODIC MAINTENANCE PROGRAM

No System Equipment / Lubrication Inspection Overhaul Replace Short Description Reference / Procedure
Function Interval Interval Interval
1 Hydraulic Slew motor N/A.
Inspect for abnormal noise, vibration,
3M/500H
leaks, paint condition and corrosion.
-
Overhaul component. Contact
5Y/15000H
Replace if damaged.
2 Hydraulic Slew gearbox 1Y/2500H Change oil in gear and brake.
6M/1000H Change grease, by filling new.
1M/300H Check gear oil level. • User Manual volume 2
3M/500H Inspect for any abnormal noise, vibration. Lubrication charts
Overhaul component. Contact • Annex B: LSS- 03 BRE
5Y
Replace if damaged.
3 Hydraulic Winch motor N/A.
(MW, WW, TW) Inspect for abnormal noise, vibration,
1M/300H
leaks, paint condition and corrosion.
Overhaul component. Contact -
5Y/15000H
Replace if damaged.
4 Hydraulic Winch gearbox 1Y/2500H Change oil in gear and brake.
(MW, WW, TW) 6M/1000H Change grease, by filling new.
1M/300H Check gear oil level. • User Manual volume 2
3M/500H Inspect for any abnormal noise, vibration. Lubrication charts
Overhaul component. Contact • Annex B: LSS- 04 BRE
5Y
Replace if damaged.
5 Hydraulic Tubes, fittings N/A.
and couplings 3M/500H Condition check, leaks, denso tape. -
N/A.
6 Maintenance

Replace if damaged.
6 Hydraulic Oil filters N/A.
N/A.
N/A. • Annex F
1Y/1000
Replace filter elements.
H
7 Hydraulic Manual Valves 1Y Apply grease/Vaseline to the valve levers.
3M/1000H Inspect for any malfunction or damage.
-
N/A.
Replace if damaged.
8 Hydraulic Accumulators N/A.
Inspect general condition, brackets and
6M/1000H
bolts, check pre-charge pressure.
• Annex I
Overhaul or replace if unable to hold the
necessary pre-charge. Contact

9 Hydraulic Jib cylinders Apply grease to the cylinder rod end
6M/1000H
nipples.
6M/1000H Inspect all exposed cylinder rods. -
Overhaul or replace if damaged.
Contact MacGregor Norway AS.
10 Hydraulic System oil 6M/1000H Take oil sample for analysis.
At start-up. Inspect reservoir oil level / quantity. • Annex A: LSS 05
N/A. • Annex G
Replace oil as necessary after analysis.
11 Hydraulic Open Loop N/A.
Variable Pump Inspect for abnormal noise, vibration,
(Main pumps) 3M/500H
corrosion and leaks. -
5Y/15000H Overhaul component.
6 Maintenance

12 Hydraulic Hydraulic hoses N/A
6M/1000H Visual inspection, replace if damaged.
N/A. • Annex E
5Y Replace all outdoor hoses
10Y Replace all indoor hoses
13 Hydraulic Air breather N/A.
filters N/A.
N/A. • Annex F
1Y/1000
Replace filter elements.
H
14 Hydraulic Air/oil cooler N/A.
6M/1000H Visual inspection; leakage & corrosion.
-
N/A.
Replace if damaged.
15 Hydraulic Servo valves N/A.
6M/1000H Visual inspection and functional check
-
N/A.
Replace if damaged.
16 Hydraulic Open Loop N/A.
Variable Pump Inspect for abnormal noise, vibration,
(axial piston 3M/500H corrosion, leaks or damage on attached
pump) components. -
Overhaul component.
5Y/15000H
N/A.
17 Hydraulic Open Loop Fixed N/A.
Displacement Inspect for abnormal noise, vibration,
Pump (screw 3M/500H corrosion, leaks or damage on attached -
pump) components.
5Y Overhaul component.
6 Maintenance

N/A.
18 Hydraulic Emergency Pump N/A.
Inspect for function, abnormal noise,
1Y vibration, corrosion, leaks or damage on
attached components. -
N/A.
N/A.
19 Hydraulic Accumulators NA
(piston) 1Y/2000H Inspect cylinder for damage, leak.
-
Overhaul or replace if damaged.
5Y
20 Mechanical Grease nipples, 1M/300H Apply grease to all grease nipples.
(not part of the N/A • User Manual volume 2
automatic lubr. Lubrication charts
N/A.
System) • Annex A: LSS- 01
Replace if damaged.
21 Mechanical Slew rotation N/A
encoder Inspect for proper function, no damage and
3M/500H
corrosion. • Annex Q
N/A.
Replace if damaged.
22 Mechanical Main and knuckle Apply grease to grease nipples.
jib 1Y
Grease until excess grease is visible.
Check for plate damage/grease nipple • User Manual volume 2
6M/1000H Lubrication charts
condition.
• Annex C
N/A.
Replace if damaged.
23 Mechanical Slewing ring/ gear Apply special grease to drive pinion and • User Manual volume 2
1M/100H
drive pinion slewing ring. Lubrication charts
1Y/500H Check for wear/abnormal tooth clearance. • Annex A: LSS- 08
6 Maintenance

N/A.
Replace if damaged.
24 Mechanical Slewing bearing Part of the Central lubrication system.
Remove blanking bolts for grease • User Manual volume 2
1Y
sampling Lubrication charts
Fresh collar of grease must be visible. • Annex B
6M/1000H
Inspect seal for condition/damage.
6M/1000H Perform slew bearing wear measurement.
25 Mechanical Slewing bearing N/A
and foundation 1M after Initial re-tensioning of all bolts.
bolt connection crane
delivery
25 Mechanical Slewing bearing Inspect all slewing bearing and foundation
1M/500H
and foundation bolts and nuts. (Bolts / nuts in place).
bolt connection 6M/500H Periodic re-tensioning of all bolts.
continued • Annex K
6M/500H Knock – test
• Annex L
1Y Individual bolt removal and examination
N/A
Replace if damaged.
26 Mechanical Wire sheaves Part of the Central lubrication system.
Verify that the sheaves rotate freely.
6M/1000H Verify fresh collar of grease at bearings.
Inspect for corrosion, wear and cracks. • Annex B
Inspect bolts. Initial groove measure. • Annex M
N/A.
Replace if damaged.
27 Mechanical Winch gear drive Part of the Central lubrication system. • User Manual volume 2
pinion & gear Check for wear/damage of the gear wheel. Lubrication charts
wheel rim 6M/500H Verify fresh collar of grease on gear wheel • Annex A: LSS- 08, LSS-20
rim.
6 Maintenance

N/A.
Replace if damaged.
28 Mechanical Bondura bolts N/A
3M/500H
Inspect all Bondura bolts on crane. Check
after first • User Manual volume 2
makeup torque for bolt screws.
year Lubrication charts
Inspect all Bondura bolts on crane. Check • Annex J
6M/1000H
makeup torque for bolt screws.
Replace if damaged.
29 Mechanical Bolts & nuts in N/A.
general Inspect all bolts and nuts on the
6M/500H equipment. Ensure they are not loose or
damaged. • Annex K
N/A.
Replace if damaged.
30 Mechanical Mechanical N/A.
components in Inspect the entire equipment for structural
general 6M/1000H damage. Check for corrosion. Inspect paint
condition. -
N/A.
Replace component if damaged. Contact

31 Mechanical Jib angle encoder N/A.
3M/500H Inspect condition of the arrangement.
• Annex Q
N/A
Replace component if damaged.
32 Mechanical Lift wire Use of a high-pressure lubrication tool is

(MW, WW) recommended.
Inspect for wear, corrosion and general • Annex D
1M/2000H
condition. See reference.
N/A.
6 Maintenance

Replace if damaged. Contact

33 Mechanical Swivels/hooks 1W See reference.
4Y Inspect swivels/hooks.
N/A. • Annex D

34 Mechanical Wire spooling 3M/200H Grease nipples on w. sheave / cylinders
device Inspect for wear, corrosion and general
3M/200H • User Manual volume 2
condition.
N/A. Lubrication charts
• Annex A: LSS-11

35 Mechanical Denso tape N/A
1Y Inspect Denso tape condition
-
N/A
Repair/replace if damaged
36 Mechanical Winch rotation N/A.
encoder Inspect for proper function, no damage or
3M/500H
N/A.
Replace if damaged.
37 Mechanical Spooling encoder N/A.
Inspect for proper function, no damage or
3M/500H
N/A.
Replace if damaged.
38 Mechanical El. Motor/pump N/A.
connection 1Y Inspect for damage. -
N/A.
6 Maintenance

Replace if damaged.
39 Electrical Pressure N/A.
transmitters Recalibration. Contact
2Y
• Annex P
N/A.
40 Electrical Electric motors Apply grease.
Inspect for abnormal noise, vibration,
3M/200H
corrosion and signs of over-heating.
5Y Overhaul motor. • Annex A: LSS-22
41 Electrical MRU. N/A.
(Motion 3M Visually in Trend log.
Reference Unit.) 4Y Recalibration. Contact
• Annex O
42 Electrical Control cabinets N/A
Inspect for loose parts, loose cable
3M
terminations, broken fuse or any water. • Annex N
N/A
Replace if damaged.
43 Electrical Cables N/A
1Y Inspect all cables for mechanical damage.
-
N/A
Replace if damaged.
44 Electrical Cable glands N/A -
6 Maintenance

1Y Check that all cable glands are tight.
N/A
Replace if damaged.
45 Electrical MOPS battery N/A
Load test the 24 VDC backup battery
1Y
package for the MOPS system. -
N/A
Replace if damaged.
46 Electrical Load cells N/A.
Recalibrate Load cells. Contact
1Y
MacGregor Norway AS. -
N/A.
Replace if damaged.
47 Electrical El. Cabinets / N/A.
Junction Boxes 1Y Check Cortec VCI Device due date.
-
N/A.
Replace if due.
48 Electrical Main / whip N/A
winch MOPS 1Y Test MOPS functionality • Section5; MOPS Function
function test
N/A Test
N/A
49 Electrical Hook up N/A.
(mechanical) 6M Visual inspection and functional check.
-
N/A.
Replace if damaged.
6 Maintenance
Blank page.
6 Maintenance
5. MOPS Function Test

At least once a year it is recommended to test the Manual Overload Protection Systems (MOPS). All offshore
winches have separate MOPS system with separate controls and must therefore be tested separately, according
to the description below.
The MOPS test load must be minimum 10-20 % of winch SWL.
The MOPS controls are located in the operator cabin as indicated in the picture to the right (yellow buttons with
safety guard).
Safety measures:
• Verify that the test area is adequately marked.

• Inform the immediate surroundings about the planned
test before running the test.
Winch MOPS functional test:
1. Run the crane/winch in “Normal” mode.

2. Attach the test load to the winch hook.
3. Hoist the load just above the deck or ground
(Approximately 10- 15 cm).
4. Stop the HPU and shut down the crane power (If
possible).
5. Open the protective cover and press the yellow MOPS
push button to activate the MOPS.
Observe:
• Load is lowered to the deck/ground

• Bull horn warning
• MOPS notification on operator’s screen
• With the load resting on deck/ground, the winch is stopped.
• Test duration should be 5 minutes to verify
• MOPS functions and the UPS supply (bull horn sounds for 5 minutes).
6. Open the protective cover and press the yellow

MOPS push button again to de-activate the MOPS
7. Start up the HPU and crane to verify correct behavior of the system.
6 Maintenance
6. Annexes
The following annexes are provided at the end of this chapter:
Annex A Lubrication Standard Specifications (LSS’s)

Annex B Automatic Lubrication System
Annex C Manual Lubrication
Annex D Lift wires and Lifting Hooks
Annex E Hydraulic Hoses
Annex F Replacement of Hydraulic Filters
Annex G Oil Analysis
Annex H Oil Filling and Air Bleed Procedure (Semi-active cranes only)
Annex I Accumulator Pre-Charge Pressures
Annex J Bondura Bolts
Annex K Slew and Foundation Bolts
Annex L Slew Bearing Wear Measurement
Annex M Wire Sheave Wear Measurement
Annex N General Electrical System
Annex O Motion Reference Unit (MRU)
Annex P Pressure Transmitters
Annex Q Encoders
Annex R Hydraulic Pumps
Annex Z Maintenance Log
Annexes that are greyed out, do not apply.
6 Maintenance
Maintenance system for MacGregor products
Doc. ID. : Rev. / date : Page:

LSS-01 nipples (3).doc 02 / 28.04.09 1 of 1
STANDARD LUBRICATING SPECIFICATION
Specification no. :
LSS-01
Lubrication equipment:
GREASE NIPPLES IN GENERAL
General Instruction:
Operate the equipment while applying grease. Use enough

grease so that excess grease can be seen on the bearings.
For location of grease nipples, refer lubrication chart for the
actual product.
General Lubrication Specification:

DIN 51502 KP 2 K 30
ISO 6743-09 ISO-L-XCCEB 2
Suppliers Lubrication Specification:

Hydro Texaco MULTIFAK EP2
Castrol SPHEEROL SX 2/ LMX grease
Comments / notes :

LSS-02 wire (2).doc 03 / 28.04.09 1 of 1
Specification no. :
LSS- 02
WIRE AND SLIDING SURFACES

Apply grease to wire and sliding surfaces according to the
maintenance program
DIN 51502
ISO 6743-09
Hydro Texaco FLOATCOAT/ TEXCLAD 2

Castrol SPHEEROL SX2
Comments / notes :

LSS-03 slew gear BRE (1).doc 03 / 28.04.09 1 of 3
Specification no. :
LSS- 03 BRE
SLEW GEAR BOX (VERTICAL MOUNTING)

Specified in lubricating instruction next pages.

For location of lubricating points, refer lubrication chart for the
actual product.
DIN 51517 / 3 CLP

ISO VG 150
Hydro Texaco MEROPA 150

Castrol ALPHA 150
Comments / notes :
The lubricating specification above is valid for gear unit.

For brake unit, see instructions next page.

Lubricating Instruction:
GEAR LUBRICATING INSTRUCTION
General
- All gears for vertical mounting: completely fill with oil.
Check the table next page for correct plug positions. For vertical mounting an
header oil tank can be supplied.
Continuous working temperature must not exceed 90° C.
OIL CHANGES.
Oil intervals may be modified, depending on actual operating conditions. During
oil change, we recommend that the inside of the gear case is flushed out with
flushing fluid recommended by lubricant manufacturer. Oil should be changed
when hot to prevent build up of sludge deposit. It is advisable to check oil level at
least once per month. If more than 10 % of total oil capacity has to be added,
check for oil leaks. Do not mix oils of different types even of the same make.
Never mix mineral and synthetic oils. Pay attention to oil and gear temperature
during oil change, to avoid the risk of scalding. Be conscious of the pollution
hazard due to the oil.
DISC BRAKES TYPE FL.

For lubrication of the brake plates we recommend to use mineral oils, heat and
aging resistant, having viscosity ISO VG 32. See LSS-05. Hydraulic oil is normally
suitable. The hydraulic fluid in the motor and the brake release is normally
suitable.
The brake and gear units are separately lubricated, and it is essential that
both oil levels are checked independently.
• For brake oil specification see LSS-05
FOR SLEW GEARBOXES “RPR”.
The main bearing (nearest to the output pinion) from the series
065/150/250/400 and 600 is grease lubricated. Take care to fill the bearing
compartment with grease before starting. This is done by pumping grease into the
grease-nipple until the grease comes out of the main bearing which is protected by a
so called “NILOS” ring. Grease should be completely exchanged every 1000
hours or six months, whatever occurs first.
• For grease specification see LSS-01


Brake: Always unscrew the

oil level plug to ensure
escaping of air when filling.
Gear: The expansion tank

must be connected to a top
level plug outlet (ensures no
entrapped air), and the
minimum level mark must be
above top level in gear box.
When filling oil through
expansion tank – always
unscrew an oil level plug to
ensure the oil level and for
escaping of air. When gear
box is full, continue filling to
MIN level on expansion tank.
Normally there is a drain hose
connected, in which also can
be used for filling. The air will
escape trough bleeder plug
on expansion tank. For first
time filling and when change
of oil it can be effective to fill
through the drain plug by
overpressure filling method to ensure evacuation of all
air.

LSS-04 winch gear 02 / 29.04.09 1 of 3
BRE.doc
Specification no. :
LSS- 04 BRE
WINCH GEAR BOX (HORIZONTAL MOUNTING)

Specified in lubrication instruction next pages.

For location of lubrication points, refer lubrication chart for the
actual product.
DIN 51517 / 3 CLP

ISO VG 150
Hydro Texaco MEROPA 150

Castrol ALPHA 150
Comments / notes :
The lubricating specification is valid for gear unit.

For brake unit, see instructions next page.

LSS-04 winch gear 02 / 29.04.09 2 of 3
BRE.doc
General
Check the table next page for correct plug positions. Check oil filling carefully in all cases.
Extension pipes may be installed to facilitate checking of oil level.
OIL CHANGES.
Oil intervals may be modified, depending on actual operating conditions. During oil
change, we recommend that the inside of the gear case is flushed out with flushing fluid
recommended by lubricant manufacturer. Oil should be changed when hot to prevent
build up of sludge deposit. It is advisable to check oil level at least once per month. If
more than 10 % of total oil capacity has to be added, check for oil leaks. Do not mix oils
of different types even of the same make. Never mix mineral and synthetic oils. Pay
attention to oil and gear temperature during oil change, to avoid the risk of scalding. Be
conscious of the pollution hazard due to the oil.

For lubrication of the brake plates we recommend to use mineral oils, heat and aging
resistant, having viscosity ISO VG 32. See LSS-05. Hydraulic oil is normally suitable. The
hydraulic fluid in the motor and the brake release is normally suitable.
The brake and gear units are separately lubricated, and it is essential that both oil
levels are checked independently.
FOR SLEW /WINCH-DRIVE GEARBOXES “RPR”.
The main bearing (nearest to the output pinion) from the series 065/150/250/400 and 600
is grease lubricated. Take care to fill the bearing compartment with grease before
starting. This is done by pumping grease into the grease-nipple until the grease comes
out of the main bearing which is protected by a so called “NILOS” ring. Grease should be
completely exchanged every 1000 hours or six months, whatever occurs first.
• For grease specification see LSS-01


LSS-04 winch gear 02 / 29.04.09 3 of 3
BRE.doc
NOTE:
• The gearbox filling/breather port is fitted with a pressure relief breather valve. Inspect and
replace if necessary before refitting.
• The gear section lower plugs are equipped with magnetic tips. At oil change intervals check
for metal particles. Thoroughly clean plug before refitting.
• Each individual gear housing will be slightly rotated compared to each other due to the
eccentric mounting. Therefore indentify the plug nearest to the gear centreline when checking
oil levels in the chambers.
• After removing centreline plug for oil level checks and no oil is visible through port, make a
simple dipstick from a plastic strip or equal to verify oil level.
Maintenance system for MacGregor products.

LSS-04 winch TNE 5600 0 / 05.02.10 1 of 3
(3).docx
Specification no. :
LSS- 04 TNE 5600

WINCH GEAR BOX

Check the oil level monthly or after 300 operating hours.

Change oil annually or after 2500 operating hours.
Se next pages for oil plug placing and further instructions.
General Lubrication Specification Gear oil: General Lubrication Specification Brake oil:
DIN 51517 / 3 CLP ISO VG 32

ISO VG 150
Gear Oil: Brake Oil:

Texaco MEROPA 150
Castrol ALPHA 150 Texaco HD 32
Comments / notes :
-

LSS-04 winch TNE 5600 0 / 05.02.10 2 of 3
(3).docx
General
Check the next pages for plug positions.
OIL CHANGES.
• Oil intervals may be modified, depending on actual operating conditions. During oil
change, we recommend that the inside of the gear case is flushed out with flushing
fluid recommended by lubricant manufacturer. Oil should be changed when hot to
prevent build up of sludge deposit. It is advisable to check oil level at least once per
month. If more than 10 % of total oil capacity has to be added, check for oil leaks. Do
not mix oils of different types even of the same make. Never mix mineral and synthetic
oils. Pay attention to oil and gear temperature during oil change, to avoid the risk of
scalding. Be conscious of the oil pollution hazard.
• The gear section oil plugs are equipped with magnetic tips. At oil change intervals
check for metal particles. Thoroughly clean plug before refitting.
Rotate winch (Oil level inspection):

• Working with warm oil, rotate winch until 2
off oil plugs are lined up horizontally (oil
plug visible in center of inner access hole).
• Remove the upper and the outer oil plug.
Add oil until excess oil exits the gearbox
through outer oil plug hole.
• Refit oil plugs.
Oil plug
access • Run winch and check for leaks.
holes.
Oil plugs (4), outer

plug in view.

For lubrication of the brake plates we recommend to use mineral oils, heat and aging
resistant, having viscosity ISO VG 32. See LSS-05. Hydraulic oil is normally suitable.
The brake and gear units are separately lubricated, and it is essential that both oil
levels are checked independently.


LSS-04 winch TNE 5600 0 / 05.02.10 3 of 3
(3).docx
Gear box oil quantity (l) 2

Brake oil quantity (l) 0.6

LSS-05 Hydraulic 02 / 26.10.05 1 of 1
oil.doc
STANDARD LUBRICATION SPECIFICATION
Specification no. :
LSS- 05
HYDRAULIC SYSTEM OIL

Oil levels and quantity specified in the maintenance procedure
in the User manual
DIN 51524 / 3 HVLP ISO VG 68 For temp >+35 °C

DIN 51524 / 3 HVLP ISO VG 46 For temp >÷10 °C <+35 °C
DIN 51524 / 3 HVLP ISO VG 32 For temp >÷10 °C <+20 °C
DIN 51524 / 3 HVLP ISO VG 22 For temp <÷10 °C **)

Texaco RANDO OIL HDZ68 For temp >+35 °C
RANDO OIL HDZ46 For temp >÷10 °C<+35 °C
RANDO OIL HDZ32 For temp >÷10 °C<+20 °C
RANDO OIL HDZ22 For temp <÷10 °C
Castrol HYSPIN AWH 68 For temp >+35 °C
HYSPIN AWH 46 For temp >÷10 °C<+35 °C
HYSPIN AWH 32 For temp >÷10 °C<+20 °C
HYSPIN AWH 15 For temp <÷10 °C
Comments / notes :
**) For low temperature operation below ÷20 °C, special arctic oil is
recommended. Please contact relevant supplier for exact specification.
Ex.:
Statoil: HYDRAULIC OIL 131 For temp >÷40 °C < +65 °C

LSS-08 Drive 05 / 30.04.2009 1 of 1
pinion.doc
Specification no. :
LSS-08
DRIVE PINIONS / GEAR RIM
Use a brush to apply grease to all tooth flanks of pinions and gear ring.
Re-lubricate in accordance with the maintenance program.
For location of pinions, refer to the lubrication chart for the product in
question.
Approved Suppliers’ Lubrication Specifications:
Klüber: Klüberplex AG 11-462

* Norsk Industriolje AS: Omega 73
* Hydro Texaco / YX Energy / Chevron: Texclad 2
General Lubrication Specifications:
DIN 51502: MF 2C-10/KF 2C-10

ISO 6743-09: ISO-L-X AAIB2
Typical properties:
Consistency: NLGI 2
Recommended temperatures: –30→
→110 °C (for Kluberplex AG 11-462)
→150 °C (for Omega 73)
→60 °C (for Texclad 2)
Solid lubricants: Solid lubricant content (min 20%)
Comments / notes:
* : Not to be used in automatic grease pump system
The colour of AG 11-462 is white. Omega73 and Texclad 2 is black

LSS-11 Heavy duty 01 / 29.04.2009 1 of 1
grease.doc
Specification no. :
LSS-11
Lubricating equipment:
HEAVY DUTY EQUIPMENT GREASE
If possible, operate the equipment while applying grease.
Initial assembly and manual relubrication: inject grease until excess

grease can be seen on the bearings.
Assembly of roller bearings: fill bearing completely with grease.

For location of grease nipples, refer to the lubrication chart for the
product in question.
Approved Suppliers’ Lubricating Specifications:
Hydro Texaco / Chevron: Novatex Heavy EP 2

Statoil: Statoil Chassis Grease
Greaseway CaH 92
ISO 6743-9: L-XBCIB2 / L-XCCHB2

DIN 51502: KP2K-20 / KP2K-30
Typical properties:
Method
Soap type: Calcium
Consistency: 2 NLGI
Oil type: Mineral
Base oil viscosity at 40 °C: 1300 mm²/s ISO 12058*
Base oil viscosity at 100 °C: 106 mm²/s ISO 12058*
→120 °C
Long polymer (“tacky”) additives: Yes
Extreme pressure (EP) additives: Yes
Solid lubricants: No
*) Base oil viscosity applies to the final mixed oil including long polymer additives.

LSS-20 Winch with gear 03 / 29.04.2009 1 of 2
rim.doc
Specification no. :
LSS-20
MacGREGOR WINCH WITH GEAR RIM
The winch has the following main components which need lubrication:
• A set of gearboxes
• Gear rim(s) and pinions
• Main bearings
• Wire rope
• One or two pulse encoders

(pulse encoder not supplied with all winches)
Note: if the pulse encoder is of a type without grease nipple, it does
not need to be lubricated.
• Additional equipment with grease nipple (if any)
The illustration overleaf shows the location of these components and

references to specific LSS procedures.
Reference is made to the following LSS procedures:

LSS-01, LSS-02, LSS-04, LSS-08, LSS-11
Comments / notes :

LSS-20 Winch with gear 03 / 29.04.2009 2 of 2
rim.doc
Lubrication Instruction:
Other equipment (if any) on winch with grease nipple: LSS-01


LSS-21 HM Winch 01 / 29.11.2006 1 of 2
without gear rim.doc
Specification no. :
LSS-21
HYDRAMARINE WINCH WITHOUT COGWHEEL
The winch has the following main components which need

lubrication:
• One or two gearboxes
• Bearing
(winch with one gearbox only)
• Wire rope
• One or two pulse encoders

(pulse encoder not supplied with all winches)
Note: if the pulse encoder is of a type without grease nipple, it
does not need to be lubricated.
• Additional equipment with grease nipple (if any)
The illustration overleaf shows the location of these components

and references to specific LSS procedures.
Reference is made to the following LSS procedures:

LSS-01, LSS-02, LSS-04, LSS-11
Comments / notes :

LSS-21 HM Winch 01 / 29.11.2006 2 of 2
without gear rim.doc
Lubrication Instruction:
Other equipment (if any) on winch with grease nipple: LSS-01


LSS-22 Electric 1 / 06.02.13 1 of 1
motors.docx
Specification no:
LSS- 22
ELECTRIC MOTORS
50 / 60 Hz
On Lønne motors the bearings should be relubricated every 3 years. This is due to ageing and
irrespective of operation hours. Motors operating under special conditions, such as frequent
operation at maximum speed (n max), heavy vibration, sudden load changes and frequent
reversing operation, the relubrication should be performed at a considerably shorter interval than
at the intervals stated below.
Supplie Manufactu Type Delivery Temp (0C) Mount. Interval Type / Amount Notes Notes
r rer with Ambient / Pos. (h) comp.
grease bearing for vert.
mount.
Lønne Marelli B5M355L Yes 20/50 Vertical 8000 ESSO UNIREX Temperature Information regarding
4 V36 30/60 (V3/V6) 4000 N3 increased by 15 bearing / greasing
45/80 First time greasing deg C, regreasing intervals are noted on a
2000
200 gr. interval halved plate on the motors
55/90 1000
Relubrication 50
gr.
Lønne MEZ 14BG1802 Yes 40 Vertical 4000 ESSO UNIREX Temperature Information regarding
80 V36 50 (V3/V6) 2000 N3 increased by 10K, bearing / greasing
60 regreasing interval intervals are noted on a
1000
Relubrication 20- halved plate on the motors with
40C and in standard
30 gr.
horizontally mounting
Lønne MEZ 14BG315 Yes 40 Vertical 3000 ESSO UNIREX Temperature Information regarding
V36 50 (V3/V6) 1500 N3 increased by 10K, bearing / greasing
60 regreasing interval intervals are noted on a
750
halved plate on the motors with
Relubrication 30 -
40 gr. 40C and in standard
horizontally mounting
ABB ABB M3BP355 Yes 25 Vertical 2000 ESSO UNIREX Temperature Information regarding
V36 40 (V3/V6) 1000 N3 increased by 15 bearing / greasing
Relubrication 70 deg C, regreasing intervals are noted on a
gr. interval halved plate on the motors
Lønne MEZ 7AA/BA Yes 40 Vertical 4000 ESSO UNIREX Temperature
160 V36 50 (V3/V6) 2000 N3 increased by 10K,
60 1000 Relubrication 20- regreasing interval
30 gr. halved
Tp HUALI Y3- Yes 40 Horizo 4000 ESSO UNIREX Temperature Information
nordic 280M2-4 ntal N3 increased by 10- reg.bearing/greasing
15 deg.c, interval are noted on a
Relubrication 30- regreasing interval plate on the motor with
40 gr. halved. 40c and in standard
horiz.mount.
Comments / notes :
• Only relubricate bearings when the motor has a speed of at least n >300 rpm.
• Lubrication intervals are compensated for vertical mounting.
• Smaller electrical motors normally have closed bearings. Relubrication may not
be required.
Annex B - Automatic Lubrication System
1. General
The crane is fitted with an automatic lubrication system .The purpose of lubrication is to promote longer service
life for the equipment. The advantage of a automatic lubrication system is that it releases “a little grease
frequently”, as opposed to “too much grease infrequently”, which is often the case with manual lubrication.
2. System Overview
The system will efficiently provide lubrication for all bearings on king/main jib and knuckle jib. Grease is
stored in two container/pump units, and pumped/distributed out via several distribution blocks to each
individual lubrication point on the jib assembly among others. See picture 2 for typical installation of
container/pump unit.
The system itself is fairly simple and comprises a pump with a lubricant reservoir. The pump has 1-3 outlets,
which lead to progressive distributors (”distribution blocks”). These have one inlet port and several outlet ports.
The grease is distributed from the progressive distributor to the various lubrication points or to a new
distribution block on the crane. These distribution blocks are mechanical blocks that have been designed
according to the desired dosage. See pump unit M55 and M56 in Drawing, Vol. 2: 2.10 Lubrication Charts.
Picture 1: Principle drawing
6 Maintenance - Annex B
MACGREGOR NORWAY AS B1
3. The Lubrication Pump

The pump has a sequence control and up to three adjustable pump-elements. From one element the lubricant is
fed to a two or three distributor system, as shown above in the “principle drawing”. These adjustable pump
elements can easily be adjusted using an Allen key and it is important to adjust these as instructed in the flow
diagram so that the equipment connected to this element receives the correct dose of lubricant. For example; if
the flow diagram says three clicks down, it means that you must screw the element to the fully open position
(default position) and then throttle with three clicks down (clockwise).
In order for the adjustable element to receive the correct dose of lubricant, it is also important to set the pump
sequence. The adjustment screws are located behind a red cap at the front of the pump where the one set screw
is for setting the number of pump revolutions and the other is for setting the frequency of pump actuation. If the
pump setting is 30 revolutions and 30 minutes it means that the pump shall run 30 revolutions every 30 minutes
the pump has current.
The crane automatic lubrication system will also provide lubrication for the main winch bearings and main
winch drive pinions/gear wheel.
Pump M55: Pump M56:

Jib and tugger winch Main winch
Safety valve.
(Do not cover)
Pump elements
Picture 2: Container/pump units mounted near crane cabin
B2 MACGREGOR NORWAY AS
4. Pump Element Adjustment From the Operator Terminal
Picture 3: Typical lubrication setup in the PLC
If the pump has no integrated timer / logics, it is controlled by the crane’s PLC.
Typical setup see picture 3. If the alarm is released frequently and no grease are released through the safety
valve, set Overload Time Before Alarm higher than 7 sec. The alarm can also be released when the Lubrication
monitor are mounted away from the pump unit.
5. The Progressive Distributor MX-F

The progressive piston distributors are devices with a hydraulic sequence control, where only one element port
at a time feeds lubricant to its lubrication point. If one piston - for some reason – is blocked, all distributor ports
are blocked and causing the safety valve to release. There are typically two distributor blocks for the M55 pump
located below the cabin platform and on top of the knuckle jib. For the M56 pump there is typically one
distributor block located on the top of the king near the main winch.
6. Blockage in the System

Some system have no electronic error indicators (delivered as option), but you will clearly see lubricant coming
out of a safety valve on the pump element itself (see picture 2), which indicates a blockage.
This is mainly caused by one of the following three possibilities:
• Blockage in the progressive distributor due to a jammed slide/piston in an element can occur because of
contamination in the lubricant or because the element has been under counter pressure and unused for a
long time.
Action: Disconnect the outlet connections, start the pump and observe if lubricant is released trough the
safety valve. If not: replace the progressive distributor. If lubricant is released: replace the connectors
and check the next distributor or the element.
• High counter pressure due to long tubes/hoses. Install a check valve on the pump element outlet.
• Breakage/damage of a tube/hose. Lubricant leaking on a damaged hose or a pipe can occur without
realising the alarm. In consequence one or more lubricant points are not receiving lubricant. Inspect the
hoses regularly (3M).
7. Lubricant
1. Pump unit 1 M55 (crane): LSS-11

2. Pump unit 2 M56 (gear rim - winch): LSS-08
It is important that the grease is pump-able in the system, even at low temperatures. The system has been
designed to use NLGI class 2 grease.
8. Filling the Pump

A) Standard filling via lubrication nipple with manual or pneumatic grease gun:
filling lubrication nipple
B) Filling via filling socket:

remove lubrication nipple and
replace with filling socket for
grease
filling socket
for grease coupling box
C) Filling via filling press:
filling press
straight filling coupling
Filling the pump units (See Picture 4.) demands a high cleanliness level. Avoid any particles. Even the
slightest dirt can block the piston in the distributor blocks.
9. Service Kit for the Automatic Lubrication System

Item no. Description Quantity
11017148 PUMP ELEMENT PE120V W/CHECKVALVE 6MM 1
11017149 EXTENSION PIECE 21MM 1/8"-M10X1 316 6
11017189 WE 06 LLR 1/8" 316 6

11005436 WE 06 LLR 1/8" 10
11017150 WE 08 LLR 1/8" 3
10003538 GE 06 LLR 1/8" 10
10003539 GE 08 LLR 1/8" 3
11012505 G 06 LL STRAIGHT COUPLING 15
11018922 G 08 LL STRAIGHT COUPLING 10
10003724 M 06 LL NUT 10
10003723 D 06 LL PROFILE RING 10
11005432 THREADED FERRULE 6MM 16

11017158 THREADED FERRULE 8MM 2
11005431 INSERT FOR FERRULE, STRAIGHT 6MM (for 8.3mm hose) 10
11005433 INSERT FOR FERRULE, 90° BEND 6MM 6
11017169 NON-RETURN VALVE MX-F M10X1 3
11017170 NON-RETURN VALVE MX-F 10
11017171 LOCK SCREW MX-F 5
11017173 PIPE BRIDGE 2
Annex C - Manual Lubrication
1. General
The automatic lubrication system (if applicable) delivers lubrication to nearly all critical rotation points.
Most of the manual lubrication points serve preservation purposes and not lubrication of a rotation bolt. Use
LSS-01. See Manual Lubrication Grease Nipples Chart in Vol. 2 of the user manual.
Intervals: Manual lubrication according to the Periodic Maintenance Program
2. Preservation Points
According to the Periodic Maintenance Program (“preservation points”) lubricate the following points:
Lubrication of the bondura bolts:

For preservation, add a small amount of grease on both sides of the
bolt after each re-torque.
Lubrication of the main jib cylinders and knuckle jib cylinders:

For preservation of the scraper ring.
Lubrication non rotation parts:

For preservation. Different constructions on the platform behind the
king.
6 Maintenance - Annex C
MACGREGOR NORWAY AS C1
3. Rotation Points
According to the Periodic Maintenance Program (“rotation points”) lubricate the following points:
Lubrication of pulse encoders

The crane has normally 7 encoders. The angle encoders on the
main winch (each side) and the encoders on the knuckle jib
(each side) needs to be manually lubricated.
Lubrication of the tugger winch (if applicable)

The main bolts on the tugger winch must be lubricated.
However, lubrication of these bolts can be integrated to the
automatic lubrication system. If not, the bolts need manual
lubrication.
Lubrication of hinges
Lubricate door hinges and other non critical lubrication points.
6 Maintenance - Annex C
C2 MACGREGOR NORWAY AS
Annex D - Lift Wires and Lifting Hooks
1. Lift Wires
1.1. General
MacGregor HM offshore cranes uses the following
wire rope type(s):
• Main winch: Fully galvanized, non-rotating

compacted type
• Whip winch (if applicable): Fully
galvanized, non-rotating compacted type
• Tugger winches (if applicable): Fully
galvanized, non-rotating compacted type
Upon delivery, the wire ropes have received offshore

lubrication. This implies that all strands are heavy
lubricated, the core is heavy lubricated during core
closing and the rope is slightly lubricated during final
closing (to avoid water trapping between the outer
strands and the core). This provides the best premise
for a long service life; good protection, low internal
friction and low friction against the wire sheaves.
Compacted strands means high wear resistance, high

transversal stiffness and corrosion resistance.
1.2. Inspection
In order to keep wire ropes in a good working condition, routine inspections and periodic maintenance is
necessary. On wire ropes frequently used in AHC operations, particular attention must be paid at the areas
where they pass over a wire sheave as the wire rope strands have a tendency to open slightly and thus making it
possible for the inspector to get a better view of the wire rope core.
As a minimum, the wire ropes should be inspected monthly. However, lift wires in continuous service should
be observed during normal operation and visually inspected on a weekly basis.
The purpose of the inspection is to reveal dryness, abrasion, internal/external corrosion, core or strand
protrusion/distortion, wire breaks, wear, kinks etc. before the wire rope becomes unsafe to work with (see
illustrations on the following page of unwanted situations).
Note: Any deterioration leading to a suspected loss of original rope strength should be carefully examined and
the Discard criteria provided in ISO 4309 applied in determining whether to remove the rope from service.
6 Maintenance - Annex D
MACGREGOR NORWAY AS D1
Wire protrusion.
External corrosion.
Crown wire breaks. Strand protrusion.
Kinked wire.
Local increase in rope diameter due to core distortion.
Basket deformation (Birdcage).
D2 MACGREGOR NORWAY AS
1.3. Lubrication
Over time, the factory lubrication of the wire ropes will wear off due to the environment and usage. Periodic
maintenance is therefore a necessity.
Manual lubrication with the aid of brushes, rags, gloves, or by other means is costly, risky, and ineffective. The
lubricant forms a film on the surface which water vapour can penetrate, thus becoming trapped. Temperature
changes cause condensation and rust then begins to form from the inside. This will lead to severe corrosion
which promotes premature fatigue failures in the wires and strands.
A high pressure wire lubrication system (e.g. Masto lubrication system) will be able to maintain good
lubrication of the wire rope, penetrating through to its core which is absolutely necessary to keep friction low
and corrosion away.
How often the wire ropes need to be re-lubricated depends on the environment in which the wire ropes operate
along with the usage and the result of the routine inspections. Generally, if the wire rope show signs of dryness,
lubrication should be initiated, ideally before. As a minimum, check every 3 month if the wire rope show signs
of lubrication deterioration.
2. Lifting Hooks
2.1. Inspection
Every 4 years, the hook and hook nut are to be dismantled, inspected and retested (proof loaded). Particular
attention to be paid to the following:
• Wear in hook, centre pin, becket and threads in hook and nut.
• Play in sheave bushes or bearings.
• Spacer bolts, nuts and lynch pins.
• Check for cracks in welds.
• Condition of safety catch and grease nipples.
• Wear to holes in side plates and becket.
2.2. Lubrication
Lubrication of the hooks is normally to be done once a week (each week for frequently used hooks/blocks,
monthly for infrequently used equipment or each time it is used). Refer to the periodic maintenance table.
Please refer to User Manual volume 2 for lubrication charts.
2.2.1. Single Part

Single part hook arrangements have a grease nipple located in the lower part of
the hook weight (drawing at right). It provides a lubrication point for the hook
bearing which is located in the centre of the hook weight. The bearing chamber is
connected to the nipple and a secondary, plugged hole (higher up) by means of a
channel. When lubricating, any old or superfluous grease and air will be pressed
out of the upper hole when the plug is removed.
D4 MACGREGOR NORWAY AS
2.2.2. Double Part

Double part blocks have two or three lubrication points; one on the lower
bearing, one for the swivel (for the largest blocks) and one for the wire sheave.
As with single part hook arrangements, a plugged hole is fitted where any old
or superfluous grease and air will be pressed out.
3. Tools & Tool Safety

• Gloves and safety glasses
• Standard spanner
• Grease gun
4. Hazards
• Avoid skin contact with hydraulic oils by use of gloves.
• Be wary of any cuts that may be caused by running a hand carelessly across damaged wire. Use gloves.
• Ensure winch has been stopped before inspecting wire.
• When laying down the double part block on its side for lubrication, ensure the block is completely
secure as there can be a risk of it falling over.
Annex E - Hydraulic Hoses
1. General
Inspection and replacement intervals should be done according to chapter 6.2 Periodic Maintenance.
Hydraulic hose manufacturers estimate that 80% of hose failures are attributable to external physical damage
through pulling, kinking, crushing or abrasion of the hose.
Hydraulic hose can and will age whether it is in normal service conditions or unused in storage. Hose failure is
not an indication of poor product performance, but rather natural degradation. After a while a hydraulic hose
will show sign of wear that include cracking, blisters and bubbles.
The operating conditions that a correctly installed hydraulic hose is subjected to will ultimately determine its
service life. Extremes in temperature, e.g. high daytime operating temperatures and very cold conditions when
the machine is standing at night, accelerates aging of the hose's rubber tube and cover.
External factors are:
• Environmental conditions.
• Ultraviolet light.
• Salt water.
• Air pollutants.
• Extreme temperatures.
• Ozone.
• Chemicals.
• Electricity.
• Abrasion damage.
6 Maintenance - Annex E
MACGREGOR NORWAY AS E1
Typical examples of abrasion damage:
Abrasion caused by hoses rubbing against each other or surrounding surfaces is the most common type of
damage. Replace the hoses and avoid new abrasion and external damage, ensure all clamps are kept secure, pay
careful attention to routing whenever a replacement hose is installed and if necessary, apply inexpensive
polyethylene spiral wrap, zip tie, sleeves and guards to protect hydraulic hoses from abrasion (see photo below).
E2 MACGREGOR NORWAY AS
Typical examples of ozone and bending damages:
Increased ozone, caused by

pollution, attacks bonds in
certain rubber compounds.
Tiny cracks occur primarily
where the hose is stressed; at
curves, bends and clamping
locations. These cracks allow
airborne contaminants to
invade and weaken the hose.
External heat damage can

result in hardened and
cracked hose covers. Replace
the hoses, check possible
external harmful heat sources.
2. Replacement
MacGregor recommend to replace hoses at the following intervals:
1. All externally fitted hydraulic hose should be replaced every 5 years.

2. All internally fitted hydraulic hose should be replaced every 10 years.
Replacement of denso tape on hose connections after reinstallation is recommended to avoid corrosion.
Installation of a replaced hose at less than the minimum recommended bend radius may significantly reduce the
lifetime of the hose (see illustrations below). Particular attention must be given to prevent sharp bends at the
hose connection to the fitting (photo above).
Proper physical installation of the hose assembly requires a correctly installed port connection ensuring that no
twist or torque is transferred to the hose when the fittings are being tightened.
Bending a hydraulic hose in more than one plane results in twisting of its wire reinforcement. A twist of five
degrees can reduce the service life of a high-pressure hydraulic hose by as much as 70% and a seven degree
twist can result in a 90% reduction in service life.
Ordering of hoses must be done according to the Hose List in chapter 7.
MACGREGOR NORWAY AS E3

• Standard wrench or spanner of appropriate size
• Gloves
• Safety glasses
4. Hazards
• Ensure both the system and the specific damaged hose are devoid of pressure before attempting any
replacement. Removing hoses or tampering with damaged hoses while the system is under pressure can
result in a high pressure release of hydraulic oil.
• Clean the maintenance area before and after maintenance to avoid slippery surfaces and any
contamination.
• Remember to dispose of any damaged or unusable components in the correct manner, by taking them to
a recycling center that deals with the components in question.
E4 MACGREGOR NORWAY AS
Annex F - Replacement of Hydraulic Filters
1. General
1.1. Before Disassembly
Prior to replacement of the hydraulic filters (for action intervals,
see section 6.2 - "Periodic Maintenance Program"), it is important
to make sure that the oil level in the tank is below the return filters
mounted on the tank top. These filters have contamination
retainers which might contain some particles. Lower the level in
the tank by lifting the main jib and the knuckle jib. This action
must be taken to reduce the risk of mixing unfiltered “dirty” oil
with the clean oil in the tank.
Then, shut down the HPU for at least 15 minutes. This will release
the pressure and drain oil to the tank. When applicable, press the
emergency (local) stop button.
Make sure you have the correct filters and sealings. MacGregor Return filter with
recommends to replace the O-rings each time the filters are replaced. contamination retainer(circled)
Keep tools, working area and equipment clean.
Most of the filters are located on the HPU (inside the king). However, they can also be placed outside on the
king platform or mounted on the winches. Normally, all filters (apart from the air breathers and emergency
supply filter) have clogged filter indicators (lights) and an alarm indication in the crane control system.
1.2. After Disassembly

• When draining the filters, collect all fluid in a suitable container and dispose it in accordance with
environmental regulations.
• After disassembly, clean all parts, check for damage or wear and replace parts if necessary.
• When changing a filter element a high level of cleanliness must be maintained.
• The operational safety and life expectancy of the filter, and whether it is ready for use, depends to a
high degree on regular and careful maintenance.
• Normally there is no need for venting the filters after the replacement (except for the replenishment
filters).
6 Maintenance - Annex F
MACGREGOR NORWAY AS F1
Typical crane king modules with HPU and oil filters
F2 MACGREGOR NORWAY AS
2. Breather Filters
Breather filters prevent contamination from the surroundings from entering
the system in connection with fluctuations of the oil level in the tank (tank
breathing).
Some filters are delivered as one unit but most commend are filters with
separate elements.
Removing the element:
1. Remove nut and washer

2. Lift off cap
3. Remove element
Fitting the element:
1. Fit new element

2. Replace cap
3. Replace washer
4. Replace nut and tighten
2.1. Access Point

Access the breather filter via crane king door, for best access use the platform inside the crane king. See 1.2
Filter Locations.
2.2. Tools & Tool Safety

• Wrench or spanner of appropriate size.
• Safety glasses
2.3. Hazards
• Clean area before and after to avoid slippery surfaces or contamination.
• After maintenance, dispose of old filter by taking it to the appropriate recycling center.
3. Offline Filter
Offline oil filtration systems with integrated circulating pumps are
ideal for controlling oil contamination levels for particles, water
and degradation products (oxidation resin/sludge, varnish). The
filters are normally mounted at the bottom of the tank and
circulates the oil in the tank.
The lifetime of the filter element depends on the operating

conditions. It is advisable, though, to replace the element once a
year. When the pressure gauge (illustration beside) indicates a
pressure drop of 2 bar across this filter, an alarm is generated on
the operator terminal indicating that the filter element is due for
replacement.
The Offline filter is normally 3 micron nominal.
3.1. Offline Filter Replacement
Stop the CJC filter Close valve on the oil Close valve on the oil Automatic air vent: No Open oil drain valve.
pump inlet filter outlet action Drain according to
Air vent screw: Open environmental
screw precautions
When the filter housing Lift off the filter housing Unscrew the spring nut Remove the spring and Remove the used filter
is drained, unscrew the the spring guide inserts. Depose of
top nut according to regulations
Clean the filter bottom Put the new CJC filter Insert type B, BLA or Mount the spring guide Tighten the spring nut Replace both O-rings Replace O-ring for the Tighten the top nut with Automatic air vent: No Be aware that oil
inserts in place BLAT, use insert guide carefully - make sure by hand until contact top nut a torque of 90Nm action. spillage is a serious
between the filter there is no contact with spring guide. Then Air vent screw: Replace safety risk - keep clean!
elements between the O-ring and tighten the spring nut 4 usit ring for air vent
the thread turns per filter insert screw, and tighten with
torque of 10 Nm
Blank page.
4. Return Filters
These filters are normally low pressure filters.
The location are typically at the top of the
tank, but they can also be mounted as in-line
filters outside on the king platform or on the
winch itself.
Replacement of return filters as in-line filters:
1. Close inlet and outlet ball valves (if

present)
2. Open the air bleed plug on the top of
the filter to make it easier to drain he
oil.
3. Open the drain valves and drain the
filters completely.
1. Switch off the hydraulic system and release filter pressure.

2. Undo vent screw(s), remove the oil drain plug(s) and drain fluid into a container.
3. Unscrew the cover plate.
4. Remove the filter element(s) from the element spigot. Examine the element surface for dirt residues and
larger particles, these can indicate damage to the components.
5. Remove the contamination retainer by turning anti-clockwise (bayonet fitting) and clean (only type
1.0).
6. Replace or clean the filter element (only W/HC and V elements can be cleaned).
7. Clean the cover plate and housing; pay particular attention to the threads.
8. Examine the filter, especially sealing surfaces and thread for mechanical damage.
9. Check the O-rings and seals and replace if necessary.
1. Moisten the sealing surfaces and thread on the cover plate and housing, as well as the O-ring on the
cover plate and element, with clean operating fluid.
2. When fitting a new element, check that the designation corresponds to that of the old element.
3. Fit the contamination retainer onto the new or cleaned filter element by turning clockwise (only for type
1.0).
4. Place the filter element(s) carefully onto the element location spigot.
5. Screw on the cover plate fully. Then unscrew by one quarter-turn.
6. Screw in the oil drain screw(s); tighten the vent screw(s).
7. Switch on the hydraulic system and vent filter at an appropriate point in the system.
8. Check the filter for leakage.
Typical return filter

mounted separately from
the tank (in-line filter)
Inlet and outlet

ball valves
Drain valve
4.1. Access Point

Access the return filter through the crane king door, by standing on the platform inside the king. See 1.2
Filter Locations.

• Standard wrench or spanner of appropriate size.
• Gloves
• Safety glasses
4.3. Hazards
• Avoid skin exposure to hydraulic oil.
• Clean area before and after maintenance to
avoid slippery surfaces or contamination.
• Dispose of old filter appropriately by taking it to a recycling centre.
5. Pressure Filters
High-pressure filters are installed after the pumps and other prime movers to protect critical hydraulic
components such as cylinders, motors and valves.
1. Close the inlet and the outlet valve (if present). Ref. Hydraulic flow diagram.
2. Remove oil drain plug at the bottom of the bowl, collect oil in a container.
3. Unscrew bowl. (Collect fluid in a suitable container and dispose of it in accordance with environmental
regulations).
4. Remove filter element from element location spigot (examine surface of element for dirt residue and
larger particles; these can indicate damage to the components).
5. Clean bowl by using white sprite or similar.
6. Examine filter, especially sealing surfaces and threads, for mechanical damage.
7. Replace O–rings.
1. Moisten thread and sealing surfaces on the filter bowl and head, as well as the O–ring on the bowl and
element if necessary, with clean operating fluid.
2. When fitting a new element, check that the designation corresponds to that of the old element.
3. Place filter element carefully onto the element location spigot.
4. Screw in filter bowl fully.
5. Screw in oil drain plug.
6. Unscrew filter bowl by one quarter–turn.
7. IMPORTANT: Open Inlet and outlet valve
8. Clean/dry the outside of the filter bowl. After start-up of the hydraulic system again, check for any
leaks.
5.1. Access Point

Access the pressure filters though the crane king door, by standing on the platform inside the king. See section
1.2 Filter Locations.

• Standard wrench
• Spill tray
5.3. Hazards
• Clean area before and after maintenance to avoid slippery surfaces or contamination.
• Ensure valves are closed and system depressurised before performing any maintenance. If valves are
opened while the system is pressurised, high pressure hydraulic oil will be released.

6. Drain Filters
The drain filters are normally located at the top of the tank, but can also be mounted outside on the platform or
on the winches. Three different drain filter types can occur:
Type 1 (In-line) Type 2 (Tank mounted) Type 3 (In-line)

For replacement procedure, see For replacement procedure, For replacement procedure,
section 5 - "Pressure Filters" see section 6 - "Drain see section 4 - "Return
Filters" (see below) Filters"
Typical drain filters
Removing the element: Fitting the element:
1. Loosen cover plate bolts, turn and 1. Moisten sealing surfaces and thread on
remove the cover plate. the cover plate and housing, as well as
2. Remove filter element carefully from the O-rings on the cover plate and
element spigot. Examine element element, with clean hydraulic fluid.
surface for dirt residue and larger 2. When fitting a new element, check that
particles; these can indicate damage to the designation corresponds to that of the
the system components. old element.
3. Remove contamination retainer (if 3. Fit the contamination retainer (if present)
present) by turning anti-clockwise onto the new filter element by turning it
(bayonet fitting). clockwise.
4. Clean cover plate, housing and 4. Place filter element(s) carefully onto the
contamination retainer; pay particular element location spigot.
attention to the threads. 5. Re-fit cover plate and tighten cover plate
5. Examine filter, especially sealing bolts.
surfaces and thread, for mechanical 6. Switch on hydraulic system and Check
damage. filter for leakage.
6. Replace O-rings.
6.1. Access Point

Access the pressure filters though the crane king door, by standing on the platform inside the king. See section
1.2 Filter Locations.

• Gloves
• Safety glasses
6.3. Hazards
• Avoid skin exposure to hydraulic oil.
• Clean area before and after maintenance to
avoid slippery surfaces or contamination.
• Dispose of old filter appropriately by taking it to a recycling centre.

7. Replenishment Filters (Semi-Active Cranes)
Removing the element: Fitting the element:
1. Verify that the HPU is not running. 1. Use clean hydraulic fluid to moisten
2. Close the inlet valves to the sealing surfaces and threads on the cover
replenishment pumps, normally located plate and housing, as well as the O-rings
on the tank wall. on the cover plate and element.
3. Close the outlet valve (if present). 2. When fitting a new element, check that
the designation corresponds to that of the
4. Open the air bleed plug on the top of the old element.
filter to make it easier to drain the oil.
3. Place filters element(s) carefully onto the
5. Drain the replenishment pump filters element location spigot.
with the valves at the bottom of the filter
houses. 4. Screw on cover plate fully and then
unscrew by one quarter-turn.
6. Unscrew top covers.
5. Close the drain valve and air bleed plug.
7. Remove filter element(s) from element
spigot. Examine element surface for dirt 6. IMPORTANT: Open the inlet and outlet
residue and larger particles; these can valves.
indicate damage to system components.
8. Clean cover plate and housing; pay Vent the filters:
particular attention to the threads.
1. Start the HPU and let the replenishment
9. Examine filter, especially sealing pump run for one minute.
surfaces and threads, for mechanical
2. Stop the HPU
damage.
3. Release carefully air bleed plug on top of
10. Replace O-rings and check seals.
the replenishment filter and bleed of all
air.
4. Close the air plug when the oil is floating
and no more air is bleeding.
5. Clean up, start HPU and check filters for
leakages
Replenishment filters
Blank page.

Annex G - Oil Analysis
1. General
According to section 6.2 - "Periodic
Maintenance", the health of the hydraulic oil
in the system needs to be tested at a regular
basis. This is to be done by taking an oil
sample from the reservoir.
For cranes with the reservoir inside the king,

the oil sample is normally taken at a drain
valve located under the reservoir in the crane
foundation (photo at right).
Note: It is important for the trending of the

fluid condition that the same sample location
is used each time.
Typical drain valve for oil sample
2. Bottle Cleanliness
Because of the extreme oil cleanliness levels, even the slightest dirt originating in a sample bottle can have an
adverse effect on the precision of the particle count. It is common to represent bottle contamination levels as the
number of particles greater than ten microns per millilitre (0.01 mm).
6 Maintenance - Annex G
MACGREGOR NORWAY AS G1
3. How to Sample
1. The system should have normal operating temperature and flow conditions when taking an oil sample.
MacGregor recommends to operate the system for at least 30 minutes with actuators cycling prior to
talking samples. (If not possible to sample when the equipment is operating, sample as soon as safely
possible after shutdown to prevent the settling of contaminants).
2. Open the sampling valve and let at least one litre pass the ball valve tube. Collect the flushed fluid in a
container.
3. Use a 100 % clean standard analysis bottle (typical 500 ml) provided by a bottle supplier. Open the
sample bottle cap, taking care not to contaminate. Hold the cap in hand or place on a clean surface, face
down.
4. Fill the sample bottle about halfway, cap and shake well to flush the internal surface. Discard the fluid.
5. Fill the sample bottle again until the fluid level is about 1 cm (½”) from the top.
6. Cap the bottle immediately and then close the sampling valve.
7. Label the sample bottle with sample details, fill out the sample form and enclose both in the supplied
plastic container for transport.
4. Visual Analysis
Looking and smelling at hydraulic fluid is the simplest way to determine the fluid's condition. Clean fluid is
amber in color. A milky, dark, or otherwise abnormal color may indicate the presence of one or more
contaminants. A milky appearance implies contamination by water. If the fluid looks milky, take immediate
action to avoid severe damage to your hydraulic system.
A marked change in the smell of the hydraulic fluid can indicate a chemical breakdown. If a distinct change in
the smell of hydraulic fluid is detected, have it chemically analyzed by a commercial lab.
5. Type of Analysis
A minimum recommendation from MacGregor is to perform a particle and water analysis every 6 months,
whether you are conducting onsite particle counting, or relying on a commercial lab. A full oil analysis are
recommending to be done once a year. The analysis may include particle counter, water content, viscosity,
oxidation, iron, silicon and copper content.
The data from the analysis must be logged.
G2 MACGREGOR NORWAY AS

• Gloves
• Safety glasses
7. Hazards
• Avoid skin exposure to hydraulic oil. If exposed wash area with water and soap.
• Clean area before and after sample to avoid slippery surfaces or contamination of sample.
• Ensure bottle top of sample is secure.
MACGREGOR NORWAY AS G3
Blank Page.
G4 MACGREGOR NORWAY AS
Annex I - Accumulator Pre-Charge Pressures
1. General
Instructions for pre-charging of both bladder and piston accumulators via an accumulator test and filling kit is
provided in this section. When checking or re-charging accumulator pressure, the test and filling kit provided by
MacGregor Norway AS must be used.
Note: When the accumulator is installed in a system, reduce the system pressure to 0.
Pre-charge pressure table:
Acc. Pos. (qty) Dwg. ref Precharge pressure:
Main Winch
WH-05, 12, 13, 14 SP2479-1-L-XA-010 50 bar
WH- 06.1, 07.1, 08.1, 09.1, 10.1 SP2479-1-L-XA-010 40 bar
WH-06.2, 07.2, 08.2, 09.2, 10.2 SP2479-1-L-XA-010 40 bar
Whip Winch
UH-06.1, 09.1, 10.1, 12.1 SP2479-1-L-XA-009 150 bar
UH-06.2, 09.2, 10.2, 12.2 SP2479-1-L-XA-009 150 bar
UH-06.3, 09.3, 10.3, 12.3 SP2479-1-L-XA-009 150 bar
Slew System
SH-06, 07 SP2479-1-L-XA-004 6 bar
6 Maintenance - Annex I
MACGREGOR NORWAY AS I1
2. Charging Procedures
2.1. Bladder Accumulator
• Attach the hexagonal connector (1) to the nitrogen bottle.
• Remove the gas valve protective caps from the accumulator. Secure the swivel connector (2) on the gas
valve and tighten sufficiently to prevent gas leakage. (Use adapter (5) on the accumulator for
installation of swivel connector on gas valve). Screw the bar handle (3) in a clockwise direction to open
the accumulator gas valve.
2 1
• Slowly open the nitrogen bottle valve until the expanding bladder closes the poppet valve. Check this
closure prior to charging to desired pressure.
• Close the nitrogen bottle valve. Wait for 5 minutes, before checking the pre-charge pressure. To lower
the pressure, open the air bleed valve (4).
• The Pre-charge pressure will drop slightly when the compressed gas cools off. Therefore, pre-charge to
20% above required pressure.
• Screw the bar handle (3) in a counter clockwise direction to close the gas valve. Use the air bleed valve
(4) to expel all gas from the pre-charging assembly. Remove the swivel connector (2) . (Remove the
adapter (5) if this has been used). Carefully test the gas connections for leakage by applying soapy
water or using leak detector in and around the gas valve area when the pre-charging is complete.
• Fit the gas valve protective caps.
• Remove the hexagonal connector (1) from the nitrogen bottle.
• Check the pre-charge after one, two and three weeks to ensure that no leakage has occurred. Further
pre-charge checks should be made every six months.
I2 MACGREGOR NORWAY AS
2.2. Piston Accumulator

• Attach the hexagon connector (1) to the nitrogen bottle.
• Remove the gas valve protective U-bolt and the protective cap from the accumulator. Secure the swivel
connector (2) on the gas valve and tighten sufficiently to prevent gas leakage. Screw the top hexagonal
nut on the accumulator gas valve in a counter clockwise direction until bottoming to open gas valve.
• Slowly open the nitrogen bottle valve to allow the piston to bottom the accumulator.
• Close the nitrogen bottle valve. Wait for five minutes, before checking the pre-charge pressure. To
lower the pressure, open the air bleed valve (4).
• The pre-charge pressure will drop slightly when the compressed gas cools off. Therefore, pre-charge to
20% above desired pressure.
• Screw the top hexagonal nut in a clockwise direction to close the gas valve. Use the air bleed valve (4)
to expel all gas from the pre-charging assembly. Remove the swivel connector (2) . Carefully test the
gas connections for leakage by applying soapy water or using leak detector in and around the gas valve
area when pre-charge is complete.
• Fit the gas valve protective cap and the protective U-bolt.
• Remove the hexagonal connector (1) from the nitrogen bottle.
Note: Use nitrogen only! Compressed air and oxygen involve risk of explosion!
MACGREGOR NORWAY AS I3

• Safety glasses
• Spanner or wrench of appropriate size
• Gloves
2.4. Hazards
• Filling accumulators involves dealing with pressurised nitrogen which if handled incorrectly can result
in explosion. Experience personnel recommended.
• Check for damaged hoses, as working with damaged hoses can lead to release of pressurised gas.
• Ensure hose connections are secure.
I4 MACGREGOR NORWAY AS
Annex K - Slew and Foundation Bolts
1. General
• Bolt inspection critical areas: Elongation, threads, cracks and tension.
• Inspect all slew ring bolts / nuts (bolts / nuts in place): 1 M / 500 H
• Perform “knock-test” of all slew ring bolts: 6 M / 500 H
• Initial re-tensioning of all bolts: 1 M after crane delivery
• Periodic re-tensioning of all bolts: 6 M / 500 H
• Removal and examination of individual bolts: 20 % of bolts annually*
* 20% of the bolts shall be removed and examined. The first 20% shall be taken in the most loaded sector of the
crane. If any significant defects are found during this examination another 20% are drawn. If any of this second
set is found to be defective then all bolts shall be drawn. If the first 20% are found to be acceptable the bolts can
be re-used and the next 20 % can be drawn the following year.
Manual torque wrench
When refitting, all bolts shall be tensioned according to: HM doc. No: T0001.
1.1. Knock-Test
It is recommended to use a ball peen hammer and do a “knock test” on each bolt. In the event that a nut should
have become loose, the lack of tension in the bolt will generate a different sound during the knock test as
compared to the fully tensioned bolts. Loose nuts indicate that bolt must be re-tensioned according to HM doc.
no: T0001.
Note: At the 6’th month interval, the knock-test and re-tensioning can be performed every other time.
T0001 – Tightening Torques & Bolt Tensioning Forces: See the following pages.
6 Maintenance - Annex K
MACGREGOR NORWAY AS K1

• Manual torque wrench
• Gloves, glasses and hard hat
• Ball peen hammer
3. Hazards
• A safety harness is recommended if a ladder or lift is being used for re-tensioning.
K2 MACGREGOR NORWAY AS
Annex K - Slew and Foundation Bolts
1. General
• Bolt inspection critical areas: Elongation, threads, cracks and tension.
• Inspect all slew ring bolts / nuts (bolts / nuts in place): 1 M / 500 H
• Perform “knock-test” of all slew ring bolts: 6 M / 500 H
• Initial re-tensioning of all bolts: 1 M after crane delivery
• Periodic re-tensioning of all bolts: 6 M / 500 H
• Removal and examination of individual bolts: 20 % of bolts annually*
* 20% of the bolts shall be removed and examined. The first 20% shall be taken in the most loaded sector of the
crane. If any significant defects are found during this examination another 20% are drawn. If any of this second
set is found to be defective then all bolts shall be drawn. If the first 20% are found to be acceptable the bolts can
be re-used and the next 20 % can be drawn the following year.
Manual torque wrench
When refitting, all bolts shall be tensioned according to: HM doc. No: T0001.
1.1. Knock-Test
It is recommended to use a ball peen hammer and do a “knock test” on each bolt. In the event that a nut should
have become loose, the lack of tension in the bolt will generate a different sound during the knock test as
compared to the fully tensioned bolts. Loose nuts indicate that bolt must be re-tensioned according to HM doc.
no: T0001.
Note: At the 6’th month interval, the knock-test and re-tensioning can be performed every other time.
T0001 – Tightening Torques & Bolt Tensioning Forces: See the following pages.
MACGREGOR NORWAY AS K1

• Manual torque wrench
• Gloves, glasses and hard hat
• Ball peen hammer
3. Hazards
• A safety harness is recommended if a ladder or lift is being used for re-tensioning.
K2 MACGREGOR NORWAY AS
TECHNICAL REQUIREMENTS
This document and all information and data herein or herewith is the confidential and proprietary property of
MacGregor Norway AS and is not to be used, reproduced or disclosed in whole or in part by or to anyone without
the written confirmation from MacGregor Norway AS.
© MacGregor Norway AS
3 Included bolt selection 24.05.2011 SVB OHA

2 Corrected error in section 2 (“M33 or larger” was “M30…”) 02.02.2006 LHE
1 Added information regarding tensioning forces 01.02.2006 SVB LHE
0 Issued for production 22.12.2005 LHE
A Issued for IDC 21.12.2005 LHE MOS
Rev. Reason for issue Date Author Checked
Title:
BOLT SELECTION / TIGHTENING TORQUES / BOLT TENSIONING FORCES
HM doc. no.: No.of attachments: No. of pages:
T0001 - 5
T:\Technical Requirements\
Title: BOLT SELECTION / TIGHTENING TORQUES / BOLT TENSIONING FORCES
Doc. No.: T0001
1 Applicability
1.1 Use of bolt selection, tightening torque and hydraulic tensioning

This document applies when referenced by drawing, technical specification or other document
associated with a delivery.
The bolt selection in this document refers to how to select bolts and bolt quality in general
applications (e.g. winch assembly, gearbox assembly, etc.) and special applications (e.g. slew
ring bolts and nuts)
The tightening torques in this document applies to critical bolts specifically identified by the
drawing, technical specification/requirement or other document. See section 3.
The bolt tensioning forces (hydraulic tensioning) apply to all crane slewing ring bolts with
thread diameter M33 or larger. See section 4.
Other bolts may be tightened according to mechanic’s judgment.

Bolts tightened according to mechanic’s judgment shall be firm, but avoid overtightening. This implies that
tightening torque according to mechanic’s judgment will be much less than tightening torque by torque
wrench, in order to avoid the risk of overtightening.
1.2 Engineering notes (for MacGregor use)

Typical applications of this document are most MacGregor HM assemblies with bolts to be tightened with
a torque wrench / pneumatic wrench or with a hydraulic tensioning device.
The tightening torques (section 3) are valid for standard, full-section, uncoated carbon steel (not
stainless) fasteners lubricated with anti-seize compound, such as Loctite 8009. These tightening torques
are also generally used for hot dip zinc coated fasteners, although such fasteners would require a
somewhat higher torque to achieve maximum clamping force. Source: Tingstad table T-18, lower left-
hand section.
Bolt tensioning forces (section 4): Source: Rothe Erde.
2 Bolt/nut Selection
Selection of bolts/nuts for different assemblies and applications is normally done according to
material specification list on the relevant assembly drawing. Here the bolt size, type and quality
and number are specified. In addition to this, all bolts shall conform with and be tested in
accordance with a recognised standard e.g. pertinent part of ISO 898.
In general bolts are to be delivered according to DNV “Standard for certification of lifting
appliances Oct 2008, Ch. 2, Sec. 2, D400
Bolt connections are normally divided into three different groups; secondary, primary and
essential.
1. Secondary bolts are bolts in platforms, stairs, ladders, railings, installation of cabins and
cabinets etc. Bolts in this category are to be delivered with 2.2 works certificate and it is
T:\Technical Requirements\ Page 2 of 5
Doc. No.: T0001
no requirement to charpy tests. Bolts smaller than M12 to be stainless steel A4 quality.
Bolts from M12 and up to be hot dip galvanised 8.8 quality.
2. Primary bolts are transferring structural loads and are elements in the primary load
carrying structure. Bolts in this category are to be delivered with 2.2 works certificates
and there it is no requirements to charpy tests. Bolts smaller than M12 to be stainless
steel A4 quality. Bolts from M12 and up to be hot dip galvanised 8.8 quality. If the
structural calculations show that an increased strength is required, 10.9 qualities may be
used.
3. Essential bolts are part of a non-redundant load path and a breakage may result in a
collapse or a serious mal-function. Bolts used in slew bearings are also considered as
essential. Bolts in this category are to be delivered with 3.1 certificates. If installed in a
slew bearing for offshore cranes, 3.2 certificates is required. Normally 8.8 or 10.9
qualities are used in this category. No higher than 10.9 quality is allowed. The
requirements to charpy test are given in DNV “Standard for certification of lifting
appliances Oct 2008, Ch. 2, Sec. 2, Table D4. Bolts with diameter less than Ø25mm has
no charpy test requirements. The requirements for bolts from Ø25mm are 42J for
offshore applications and 25J for other applications Test temperature (Td) is normally -
20 degC for offshore cranes and -10 degC for other cranes.
3 Tightening torques
• Carbon steel (not stainless) threaded fasteners, full section.

• Lubricated with anti-seize compound (e.g., Loctite 8009).
Tightening torques in N·m. Torque tolerance: ±5%.

Strength grade
Thread
8.8 10.9 12.9
M12 65 95 110
M14 100 150 175
M16 155 225 265
M18 220 315 370
M20 310 440 510
M22 410 590 690
M24 530 760 890
M27 780 1 100 1 300
M30 1 050 1 500 1 750
M33* 1 400 2 050 2 350
M36* 1 850 2 600 3 050
M39* 2 350 3 350 3 950
M42* 2 950 4 200 4 900
M45* 3 650 5 150 6 000
M48* 4 400 6 300 7 400
M52* 5 700 8 000 9 400
M56* 7 000 10 000 11 700
*) Bolts for crane slewing rings that are M33 or larger shall be tightened using a hydraulic
tensioning device; see section 4 below.

Doc. No.: T0001
4 Bolt tensioning forces
Bolt tension forces including tolerances for "large-clearance metric thread" – DIN 2510 –
Sheet 2 – using hydraulic tension cylinders.
Strength class to DIN/ISO 898 8.8 10.9

Yield point Rp 0.2 N/mm² 660 940
Metric Pitch Stress Core Tension force Theoretical Tension force Theoretical
ISO-thread area cross at yield point use of at yield point use of
DIN 13 section tension force tension force
As A3 F0.2 FM=0.9·F0.2 F0.2 FM=0.9·F0.2
mm mm² mm² kN kN kN kN
M33 3.5 668 617 440 396 627 564
M36 4 786 723 518 466 738 664
M39 4 943 873 622 559 886 797
M42 4,5 1,083 999 714 642 1,018 916
M45 4.5 1,265 1,174 834 750 1,189 1,070
M48 5 1,426 1,320 941 846 1,340 1,206
M52 5 1,707 1,590 1,126 1,013 1,604 1,443
M56 5,5 1,971 1,833 1,300 1,170 1,852 1,666
M64 6 2.599 2,426 1,715 1,543 2,443 2,198
M72 6 3,372 3,174 2,225 2,002 3,169 2,852
M80 6 4,245 4,023 2,801 2,520 3,990 3,591
M90 6 5,479 5,226 3,616 3,254 5,150 4,635
M100 6 6,858 6,575 4,526 4,073 6,446 5,801
Preload the bolts with the advisable care crosswise to the specified values. It is possible to
calculate with a tightening factor of αA of 1.2 to 1.6, depending on the tightening method, and to
use the yield point of the bolt up to 90%.
The preload of the bolt tightened first is influenced by the tightening of the other bolts so that a
minimum of two passes is required.
This will at the same time compensate for the settling produced by the smoothing out of the
unloaded mating surface during preloading (thread and nut contact surface).
As the tension force applied in this method will not only cause elongation in the shaft but also in
the thread, it is important to choose the correct thread series or thread tolerances acc. to
DIN 2510. An inadequate thread clearance may cause jamming of the nut, when the bolt is
elongated. Taking into account the nut height, consultation with the bolts manufacturer is
absolutely necessary.

Doc. No.: T0001
The bolts should be long enough to leave at least 1 · d above the nuts free for positioning the
tension cylinder.

Annex L - Slew Bearing Wear Measurement
The slew bearing is always under the influence of tilting

moments. Over time this will cause uneven wear on the
raceway of the three-row roller bearing surfaces in the slew
bearing. In order to keep precise control over the wear on
the roller raceway, annual measurements are necessary.
This is done between four measuring plates, welded/bolted
onto the foundation and the lower part of the rotating part of
the slew bearing.
Note: If the measuring plates are not already fitted, it is

recommended that the crane owner take appropriate action
to fit these measuring plates to the foundation within the
first two months of crane operation. The measurements
taken and logged in the slew ring wear measurement table in
this Annex, may be carefully examined by

international societies at a later stage in conjunction
with crane re-certification.
Measuring should be done with the main jib in its

highest angle and the knuckle jib in its innermost
position (contact between jibs), ref. photo above and
illustration at left.
Measuring principle: Four measurement points are

equally spaced around the foundation (denoted 1 to 4).
Measurements are to be taken at slew positions 0o, 90 o,
180 o and 270 o and written down. Start with
measurements in slew position 0 o, then 90 o etc. The
mean value of these measurements will indicate level
of slew bearing wear.
Paint on the slew bearing is removed at the initial

measurement. Corrosion protection (Tectyl or similar)
is to be applied after the measurements are taken.
6 Maintenance - Annex L
MACGREGOR NORWAY AS L1
Two typical measuring point setups on the crane pedestal.
L2 MACGREGOR NORWAY AS
Typical three –row roller bearing
In order to have comparable measurements it is important that the measurements are done in the exact same
slew positions each year and with the jibs in the same geometric position. The operator panel in the crane cabin
shows both jib and slew positions. These positions can be used for future reference.
The following table is to be used for recording measurements every 6 months following the initial
measurement. The accuracy of the measuring instrument is to be minimum ±0.01mm.
Depth micrometer
The photo below shows measurement at one of the four measurement points on the crane pedestal. The
maximum allowable deviation is:
Permitted increase in slack*

Axial reduction Tilt forward and
Crane measurement back
1077 2.00 2.60
1301 2.00 2.60
1400 2.00 2.60
1610 2.00 2.60
1800 2.60 3.20
1891 2.60 3.20
2201 2.60 3.20
2398 3.30 4.00
2806 3.30 4.00
3293 3.30 4.00
3568 1.20 2.00
3990 1.60 2.80
4240 1.60 2.80
4841 1.60 2.80
5150 2.00 4.20
6800 2.00 4.20
If the wear is found to have increased significantly, the time intervals between measurements should be
shortened. If the wear exceeds the given limit, consult MacGregor Marine Service.
*Deviations in flatness are measured in accordance with DIN EN ISO 1101 on the contact surfaces
**The value for increase in slack is a measurement of how much the hardened layers of the bearing are worn
Slew Bearing Measurement Table
Delivery date Date: Date: Date: Date: Date:

Running hours
Measuring Slew 1 Dev. 2 Dev. 3 Dev. 4 Dev. 5 Dev.
Basic
point position
1 0
2 0
3 0
4 0

Basic
point position
1 90
2 90
3 90
4 90

Basic
point position
1 180
2 180
3 180
4 180

Basic
point position
1 270
2 270
3 270
4 270
Slew Bearing Seal

The black rubber seal for the slew
bearing (photo at right) is a separate
component mounted to the slew bearing.
Every six months/200 hours the seal

must be visually inspected, both inside
and outside the crane, for damage (i.e.
cracks and leaks).
For correct operation, the seals must be

free from dirt. When cleaning the unit,
prevent the cleaner from contacting the
seals or from entering the raceways
system. If any of the seals are found to
be damaged, they must be replaced. Re-
lubricate the unit after this inspection.
Raceway Grease Samples

When annual wear measurements are taken, it is recommended
to take raceway grease samples for lab analysis as well. Thus
it is possible to determine the raceway wear rate and the actual
condition of the raceway system. Analysis and evaluation are
to be carried out by an authorized company. The original
sample results data are to be stored onboard the vessel.
Grease sampling:
Locate the two sampling ports (2 x180o) on the outside of the

slew bearing. Remove the blanking bolts and collect grease
samples while rotating the slew bearing. Use the table below
for recording the sample results. A grease sampling kit (photo
at right) specifically produced for the sampling action can be
provided by MacGregor Norway AS.
Slew raceway grease sample log
Sample No. 1 Sample No. 2 Sample No. 3 Sample No. 4 To be continued
Tester:
Signature:
Date:
Grease
sample
result

• Depth micrometer
• Glasses, gloves and hard hats
• Lift or ladder
2. Hazards
• In order to measure correctly paint may need to be removed.
• For any necessary paint removal for correct measurements, use a paint removal chemical or paint
removal sand paper.
• Ensure adequate protection is used for working with paint removal.
• Use Tectyl rust preventative after measuring to prevent rust.
Annex M - Wire Sheave Wear Measurement
Note: From early 2011, some cranes were equipped with tempered steel sheaves. For these cranes, the wire
sheave groove wear measurement is not applicable.
Obtaining good measurements of wire sheave groove wear will help the crane owner to apply appropriate
sheave maintenance actions in addition to providing relevant input to the crane maintenance schedule.
The wire sheave grooves include a two to three mm induction hardened layer beyond which the hardness
gradually decreases. The abrasion that the grooves are subject to can be monitored and understood by use of a
sliding gauge for measuring the depth of the groove. Measurements are taken to a tenth of a millimeter. Based
on the original inspection date, wear measurement trend analysis can be used to influence the measuring
schedule itself so that it continues to accurately indicate the health and future useful lifetime of the sheaves.
Requirements for the wear measurement:
• Vessel shore side.

• Follow normal crane maintenance safety instructions.
• Two personnel required: one certified crane operator and one maintenance worker.
• 2-way communications are established between crane operator and maintenance worker.
Groove Measuring
There are normally eight wire sheaves to be measured
(four for the main winch and four for the whip winch
wire). The measurement shall be taken at the same
reference position on the wire sheave every time. This is
to avoid "false" wear indications. The reference position
is normally marked on the wire sheave flange by means
of a sign plate (shown here by an arrow).
Each wire sheave is individually numbered according to

their position on the crane (ref. drawing for the main
winch wire sheaves later in this section).
Note: It is imperative that maintenance workers verify

that the crane control system key switch in the cabin is
in the OFF position prior to approaching the wire
sheaves.
Wire sheave marking sign

6 Maintenance - Annex M
MACGREGOR NORWAY AS M1
Wire measurement procedure.
Operate the crane (rotate wire sheaves) to make the measuring point indicators on the wire
1
sheaves clearly visible and accessible.
Locate the mark (photo at previous page) which exactly indicates where the measurement should
2
be taken.
Perform depth measurement by means of a steel rule and a sliding gauge (or equivalent) to
3
measure the distance from top of flange to bottom of groove (photo below).
Record the measurement/deviation in the "wire sheaves log", an example of which is provided on
4
next page.
5 Repeat procedure for all wire sheaves.
groove depth measurement
Scheduled Maintenance
Due to the characteristics of wire sheave groove wear, it is recommended that the measuring frequency is set to
once every six months initially for a period of one year. Thereafter it will be at the crane owner's discretion to
adjust the maintenance schedule based on the previous depth measurements and the crane owner's inherent
technical experience and expertise.
M2 MACGREGOR NORWAY AS
Wire Sheaves Log
No. 5 sheave No. 6 sheave

No. 1 sheave No. 2 sheave No. 3 sheave No. 4 sheave
Measurement to be taken every 6 th (King) (Wire spooler)
month after first day of operation.
main whip main whip main whip main whip main whip main whip
winch winch winch winch winch winch winch winch winch winch winch winch
Initial measurement:
Date: Measurement:
Deviation:
Date: Measurement:
Deviation:
Date: Measurement:
Deviation:
Date: Measurement:
Deviation:
Date: Measurement:
Deviation:
Date: Measurement:
Deviation:
Date: Measurement:
Deviation:
*Note: The table provided in this page is standardized. The amount of sheaves may differ from crane to crane.
The initial measurement value in the table above is the value for the first measurement taken for each individual wire sheave. If, upon receipt of this procedure,
the values are not already stated measurements should be carried out and logged in conjunction with the cranes’ Harbor Acceptance Test or equivalent.
MACGREGOR NORWAY AS M1
Blank Page.
Wire sheave numbering sequence for the main winch wire
MACGREGOR NORWAY AS

• Lift or ladder to achieve appropriate height.
• Gloves, glasses and hardhats
• Slide calliper
2. Hazards
• Ensure to clean the area before measuring to achieve accurate results.
• If a lift or ladder is used it is advised to use a safety harness.
Annex N - General Electrical System
1. Control Cabinets (CC) and Junction Boxes (JB)

The crane has numerous electrical cabinets installed in different locations in the system. In addition, several
junction boxes (JB) is located outside the king. These must be checked regularly for moisture and corrosion.
Check Cortec VCI due date and replace according to Periodic Maintenance Program 6.2.
The following must be done on all cabinets and JB:
• Open and check that the doors gaskets are in good condition (apply Vaseline, silicone, or similar if dry).
• Check regularly for water ingress, corrosion, damage, loose glands, and ambient conditions in excess of
the specifications.
Tighten all cable terminal Tighten all cabinet Check and clean the
connections and fuses bushings drain plug (if applicable)
VCI device
plate at JB
(see photo
Tighten all cable
below)
terminal connections
and fuses
Electrical cabinet. Junction box.
VCI device plate at JB
6 Maintenance - Annex N
MACGREGOR NORWAY AS N1

• None required.
3. Hazards
• Ensure power is turned off before accessing electrical cabinet or junction box. This is in order to avoid
electrocution. Working with live wires is extremely dangerous.
6 Maintenance - Annex N
N2 MACGREGOR NORWAY AS
Annex O - Motion Reference Unit (MRU)
1. Inspection
A visual inspection of the MRU through the Trend Screen display is to be done every three months. This is to
verify that the MRU is working properly, and that is does not require any immediate recalibration.
On the operator terminal, go to the Trend picture via the Menu button and set MRU Heave Velocity and MRU
Heave Position to trend pens. Verify that the MRU Heave Velocity signal varies around zero and has no offset.
Also verify that MRU Heave Velocity is zero when the MRU Heave Position changes direction. If there seems
to be an offset on the MRU Heave Velocity signal, the MRU must be recalibrated.
6 Maintenance - Annex O
MACGREGOR NORWAY AS O1
2. Recalibration
Two MRU types are used on active heave compensated cranes, either
MRU type Z or type H. The replacement procedure is the same for both.
The recalibration interval for these is as follows:
• MRU Z - recalibrate once a year.

• MRU H - recalibrate every four years.
When the MRU needs to be recalibrated, MacGregor Norway

Kristiansand must be informed. A recalibrated MRU will be shipped out to the vessel. When it arrives, replace
the old MRU with the recalibrated one and ship the old MRU back to MacGregor Norway.
During the MRU replacement, the vessel should be alongside the quay since the MRU must not
experience any movement during the initialization period.
The replacement procedure is rather simple and can be done by an electrician:
• Shut down the crane.

• Unscrew the cable connected to the old MRU, placed in the CC-300 cabinet in the crane pedestal (an
alarm will then be shown at the operator terminal, stating "MRU error").
• While holding the MRU, unscrew the four hexagonal socket cap screws (5mm) on top of the MRU
housing.
• Remove the MRU from its housing, and note which direction the R+- arrow (photo below) is pointing.
• Install the new, calibrated MRU with the R+- arrow pointing in the same direction as the old one.
• Tighten the four hexagonal socket cap screws.
• Screw on the cable to the bottom of the MRU.
• Wait for approximately five to ten minutes while the MRU initialization sequence runs.
During the initialization period (approximately

five to ten minutes) after an MRU replacement,
an alarm stating "MRU failure" will be shown
on the operator terminal. As soon as the
initialization is completed, the alarm will
disappear.
The old MRU must immediately be returned to

MacGregor Norway.
Required tools:
• Allen key - 5 mm.
6 Maintenance - Annex O
O2 MACGREGOR NORWAY AS
Annex P - Pressure Transmitters
1. Inspection
1.1. General
The pressure transmitters have been calibrated to a certain pressure range, and sends a 4-20 mA signal,
corresponding to the calibrated range to an analogue input channel in the PLC system.
However, to secure correct pressure readings, an inspection of the most "essential" pressure transmitters must to
be done. MacGregor Norway recommend to do this at least every two years to verify accuracy and followed up
by a recalibration (often replacement) if needed.
The transmitters on active boost cranes which must be checked is listed in the table below, while those for semi-
active cranes are listed on the following page. In the tables, the name of the transmitter, its tag number and
maximum allowed deviation is provided.
Active Boost
For active boost cranes, the following pressure transmitters are evaluated to be "essential" and must be checked
frequently:
Pressure transmitter Tag no.: Max. allowed deviation

Main winch motor displacement pressure 1 -PT204A (or -PT204) 0.5 bar
Main winch motor displacement pressure 2 -PT204B (or -PT205) 0.5 bar
LS pressure A -PT219A (or -PT219) 2.0 bar
LS pressure B -PT219B (or -PT220) 2.0 bar
Main pump regulator pressure -PT203 2.0 bar
6 Maintenance - Annex P
MACGREGOR NORWAY AS P1
Semi-Active
For semi-active cranes, the following pressure transmitters are evaluated to be "essential" and must be checked
frequently:
Pressure transmitter Tag no.: Max. allowed deviation

Displacement:
Motor disp passive left 1 -PT240 0.5 bar
Motor disp passive left 2 -PT241 0.5 bar
Motor disp passive right -PT242 0.5 bar
Motor disp act motor 1 -PT243 0.5 bar
Motor disp act motor 2 -PT244 0.5 bar
* Whip winch displacement pressure (* if whip winch AHC) -PT260 0.5 bar
Other:
Replenishment pressure -PT203 2.0 bar
Servo pressure -PT202 2.0 bar
LS pressure A -PT216 2.0 bar
LS pressure B -PT217 2.0 bar
Main winch passive motor B pressure -PT208 2.0 bar
LP/HP accumulator high pressure A -PT211 2.0 bar
LP/HP accumulator high pressure B -PT212 2.0 bar
LP/HP accumulator low pressure A -PT213 2.0 bar
LP/HP accumulator low pressure B -PT214 2.0 bar
Main pump A/B pressure -PTxxx 2.0 bar
Recommended tools:
• Hand pump.
• T-joint (2x).
• Calibrated pressure transmitter (0-60 bar).
• Calibrated pressure transmitter (0-460 bar) for main pump transmitters.
• Portable data recorder / measurement device.
P2 MACGREGOR NORWAY AS
1.2. Inspection Process

MacGregor Norway recommend the following method for checking the pressure transmitters:
• Portable data recorder and a hand pump.
1.2.1. Portable Data Recorder & Hand Pump

When possible, the transmitter that is being tested should be removed from its location (see section 2 -
"Replacement" for removal description) and connected together with a calibrated transmitter. The two
transmitters are then connected to a measurement device and applied pressure upon by means of a hand pump
(see illustration below).
After the transmitter is unplugged from the crane, testing is done in the following order:
1. Connect the hand pump to a T-joint.

2. Connect the transmitter that is being tested on one side.
3. Connect a calibrated transmitter on the other side.
4. Connect the two transmitters to the applicable port on the measurement device via an additional T-joint.
5. Apply pressure and compare the two transmitters.
Note: The pressure should be applied step by step between 5-10 bar. If the deviation exceeds the maximum
allowed value, the transmitter must be changed. The consequence of having too high deviation will differ from
transmitter to transmitter. Please contact MacGregor Norway for advice!
Transmitter to be tested
Hand pump Calibrated transmitter

Measurement device
MACGREGOR NORWAY AS P3
2. Replacement
Replacement of pressure transmitters is done in the following order:
• Stop the HPU.

• Verify that there is no pressure where the pressure transmitter is fitted. (There will be pressure in the
system, but it is important to bleed off the pressure
where the pressure transmitter is located).
• Remove the old pressure transmitter.
• Install the new pressure transmitter.
• Verify that it is properly fitted/tightened.
• Install the electric cable to the transmitter (use
Vaseline in the plug).
• Turn on the power to the crane.
Required tools:
• Wrench/spanner - 27 mm.

• Hand pump.
• T-joint (2x).
• Calibrated pressure transmitter (0-460 bar) for main pump transmitters.
• Portable data recorder / measurement device.
• Wrench/spanner - 27 mm.
4. Hazards
• Ensure system is depressurised.
• Clean area after maintenance to avoid slippery surfaces.
• Use drip tray.
P4 MACGREGOR NORWAY AS
Annex Q - Encoders
1. General
All pulse encoders must be inspected and checked for proper
function, damage and corrosion every 3M/500H, whichever
occur first. They are located the following places:
• Main jib (2x).

• Knuckle jib (2x).
• Main winch.
• Whip winch.
• Slew pinion.
• Spooling device (if applicable).
Jib angle encoder
Slew rotation encoder Winch rotation encoder (main winch)
6 Maintenance - Annex Q
MACGREGOR NORWAY AS Q1
2. Inspection
Inspection of a pulse encoder is done in the following order:
• Unplug and remove the encoder.

• Disassemble it by unscrewing the two
crosshead screws.
• Verify that there is no moisture and/or corrosion
inside the encoder.
• Verify that the O-ring is not damaged and that it
is in its slot when re-assembling the encoder.
The O-ring must be lubricated with Vaseline.
• Before re-assembling the encoder, lubricate the
flange with a thin layer of Vaseline.
• Verify that the encoder shaft is in the centre of
the flexible coupling (bottom photo next page).
This prevents bias to the shaft.
The flexible coupling (if applicable) should be
retightened as these have a tendency to loosen.
• Re-plug the cables and verify that the connections are tight.
• Verify that the crane is in exactly the correct position (normally parked position) before resetting the
encoder.
• Reset the encoder via the Setup screen ("Encoder reset") on the operator terminal.
Required tools:
• Small screw driver.

• Spanner/wrench - 15 mm.
Q2 MACGREGOR NORWAY AS
3. Replacement
If a pulse encoder is damaged, it must be replaced. Replacement is a simple procedure which may be undertaken
by an electrician.
• Unplug and remove the old encoder.

• Disassemble it by unscrewing the two
crosshead screws and check the address
dip switch combination (Profibus
address) for the old encoder (circled in
the photo at right).
• Disassemble the new encoder.
• Make sure that the address dip switch
combination in the new pulse encoder is
identical to the old one so the control
system identifies the encoder correctly.
• Verify that the O-ring is in its slot when
re-assembling the encoder. The O-ring
must be lubricated with Vaseline.
• Before reassembling the encoder,
lubricate the flange with a thin layer of
Vaseline.
• Verify that the encoder shaft is in the
centre of the flexible coupling (photo
below). This prevents bias to the shaft.
The flexible coupling (if applicable)
should be retightened as these have a
tendency to loosen.
• Re-plug the cables and verify that the
connections are tight.
• Verify that the crane is in exactly the correct position (normally parked position) before resetting the
encoder.
• Reset the encoder via the Setup screen ("Encoder reset") on the operator terminal.
Required tools:
• Small screw driver.

• Spanner/wrench - 15 mm.
Encoder with flexible coupling attached

(the plastic type coupling used for slew
only)
MACGREGOR NORWAY AS Q3
Blank page.
Q4 MACGREGOR NORWAY AS
Annex Z - Maintenance Log

Periodic Maintenance Program
Maintenance Log
Crane type: MacGregor Offshore Crane ID Number: SP
System Maintenance Date Comments Sign. Date Comments Sign. Date Comments Sign
Action
1
2
HYDRAULIC
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
6 Maintenance - Annex Z
MacGregor NORWAY AS Z1

Maintenance Log
Action
20
MECHANICAL
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38

Maintenance Log
Action
39
ELECTRICAL
40
41
42
43
44
45
46
47
48
49
7 Component Parts List

Table of Contents
1. Overview ..........................................................................................................................................1
2. Component Parts List Hydraulics .....................................................................................................2
3. Hydraulic Hose List ..........................................................................................................................3
4. Component Parts List Electro...........................................................................................................4
5. Ordering Spare Parts .......................................................................................................................5

MACGREGOR NORWAY AS
1. Overview
Included in this chapter are the component parts list for the hydraulic and electrical system (see following
pages). The parts lists for crane mechanical are incorporated on the crane assembly drawings as follows:
Crane main assembly: 20975660
Main winch mechanical assembly: 20963254 King main assembly: 20975492
Whip winch mechanical assembly: 20131999
Main jib assembly: 21010114
Knuckle jib main assembly: 21012062 Foundation main assembly: 20960053

2. Component Parts List Hydraulics

Page 1 of 4
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MacGregor Norway AS 4:07 PM
Item number Product name Item group

2552-1-07HYD SP2552-1 HMC 3990 LKO 200-45 SW
2552-1-07HYD-0A
Item number Position Product name CertType Item type Group Qty Per series Unit Line type Weight Notes
SP25521LXA000 00 SP2552-1 MISC. None Item SW 1.0000 1 pcs Item 0.00

SP25521LXA000-0A
SP25521LXA001 01 SP2552-1 TANK SYSTEM None Item SW 1.0000 1 pcs Item 0.00
SP25521LXA001-0A
11023435 MH01 SDA0100 AF-100 BUTTERFLY VALVE None Item HV 3.0000 1 pcs Item 10.50
11001709 MH02 3 1/2" SAE SDKSS90 K16S-90 COMPENSATOR None Item HL 3.0000 1 pcs Item 6.00
10002853 MH03 2" BSP 25 BAR BALL VALVE BRASS None Item HV 1.0000 1 pcs Item 1.30
10000425 MH04 3/4" BSP 25 BAR BALL VALVE BRASS None Item HV 4.0000 1 pcs Item 0.88
10006257 MH05 BUTTERFLY VALVE SDA00063W AF NG 63 None Item HV 1.0000 1 pcs Item 1.95
10001471 MH06 M 16 - R 1/4" MANOMETER TEST COUPLING None Item Item 1.0000 1 pcs Item 0.00
11015347 MH07 GR55 300L-S3/MS132-2, 440V/60HZ None Item HW 1.0000 1 pcs Item 99.00
10001461 MH08 SMK20-G1/4" MINIMESS TEST COUPLING None Item Item 6.0000 1 pcs Item 0.48
10000500 MH09 VU2F-0,3 CHECK VALVE 2" BSP 0,3 BAR (150 bar) None Item HV 1.0000 1 pcs Item 3.98
11004477 MH10 LEVELARMATURE,SET UP/DOWN,2010BRONZE PN6 1/2X1/2" None Item HW 1.0000 1 pcs Item 0.50
11005260 MH11 1/2" BSP 25 BAR BALL VALVE BRASS None Item Item 1.0000 1 pcs Item 0.22
10005789 MH12 292 B 0+100GR R1/2" MS L=100mm THERMOMETER None Item HW 1.0000 1 pcs Item 0.28
10006111 MH13 BFP5G10W1.0 BREATHER FILTER COMPLETE None Item CB 4.0000 1 pcs Item 6.00
11001960 MH14 NF BN/HC2610 DP10D1.X/L-24 / NF BNHC2610 DP10D1.X/L-24 None Item CR 2.0000 1 pcs Item 66.40
1177171 MH15 2600 R 010 BN4HC/-VPN-S0564 FILTER ELEMENT None Item CR 2.0000 1 pcs Item 12.40
11006951 MH16 RF BNHC 1300 DP 10 D 1.0/-L24-A08-B1 FILTER None Item CR 2.0000 1 pcs Item 110.00
1178036 MH17 1300 R 010 BN4HC/-B1-VPN-S0564 FILTER ELEMENT None Item CR 2.0000 1 pcs Item 7.20
11007429 MH20 HFNI-990420, LEVEL/TEMP. INSTRUMENT None Item EH 1.0000 1 pcs Item 0.50
11105807 MH21 OK-P12LL/1,0/M/S/1/IBP3/S04 - 440V/60Hz None Item IA 4.0000 1 pcs Item 780.00
11105427 MH23 FA 9600107-3C HDU 27/81MZ-Z CJC 440V/60Hz None Item CR 1.0000 1 pcs Item 0.00
10001368 MH25 R1" BSP ISO STANDARD 7241-B MALE QUICK DISCONNECT None Item HL 2.0000 1 pcs Item 0.00
10001369 MH26 R1" BSP ISO STANDARD 7241-B FEMALE QUICK DISCONNE None Item HL 2.0000 1 pcs Item 0.00
10001472 MH29 0 - 10 BAR 63 MM, 1/4" BSP, PA 010 U, MANOMETER None Item Item 1.0000 1 pcs Item 0.21
11004478 MH30 PLA00004 LEVEL GLASS AKRYL PIPE 13/9mm x 2 MTR None Item HW 1.0000 1 pcs Item 0.50
11106080 MH32 VU2F2FI 2"BSP 4BAR 130BAR None Item HV 1.0000 1 pcs Item 4.10
11005155 MH34 NOR00101 LEVEL PIPE SHIELD 50x43mm à 2,0mtr None Item HW 1.0000 1 pcs Item 2.00
10009881 MH35 CJC B27/27 FILTER ELEMENT None Item CR 4.0000 1 pcs Item 14.00
SP25521LXA002 02 SP2552-1 PUMP SYSTEM None Item SW 1.0000 1 pcs Item 0.00
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SP25521LXA002-0A
11014448 MH50 A15VSO280DRSOA0V/10 MRVE4B4EU0000-0 HYDRAULIC PUMP None Item HP 3.0000 1 pcs Item 439.98
11004380 MH51 C5V-12-641-B1 CHECK VALVE SAE FLANGE 1 1/2" None Item HV 3.0000 1 pcs Item 3.00
11015042 MH52 PV046/14BG 440V 60Hz el. motor None Item HM 1.0000 1 pcs Item 70.00
10005411 MH53 DBDS 10 G1X/400 PRESSURE RELIEF VALVE None Item HV 1.0000 1 pcs Item 3.58
10001461 MH54 SMK20-G1/4" MINIMESS TEST COUPLING None Item Item 6.0000 1 pcs Item 0.48
10002011 MH55 S20A0X CHECK VALVE None Item HV 1.0000 1 pcs Item 0.92
10000423 MH56 1/4" BSP 25 BAR BALL VALVE BRASS None Item HV 1.0000 1 pcs Item 0.12
10001472 MH57 0 - 10 BAR 63 MM, 1/4" BSP, PA 010 U, MANOMETER None Item Item 1.0000 1 pcs Item 0.21
10005908 MH58 MKH112R BALL VALVE CROMATED 1 1/2" BSP 350 BAR None Item HV 3.0000 1 pcs Item 17.40
10006115 MH59 1 1/2" SAE 6000 PSI MALE THREADED FLANGE COMPLETE None Item Item 6.0000 1 pcs Item 15.00
10000421 MH60 9N600S RESTRICTOR VALVE 3/8" None Item HV 5.0000 1 pcs Item 1.75
10001471 MH61 M 16 - R 1/4" MANOMETER TEST COUPLING None Item Item 4.0000 1 pcs Item 0.00
20773295 MH61 Dwg 20773295 PUMP MANIFOLD DETAIL None Item SW 1 pcs Item 0.00
10000428 MH63 BKH38R BALL VALVE CROMATED 3/8" BSP 500 BAR None Item Item 3.0000 1 pcs Item 1.80
11108126 MH64 CVG 54-31 111496 MAIN CONTROL VALVE None Item HV 1.0000 1 pcs Item 525.00
11015955 MH65 PU 5967 M13, LS CONTROL BLOCK None Item HV 1.0000 1 pcs Item 7.00
10000431 MH66 BKH1R BALL VALVE CROMATED 1" BSP 315 BAR None Item HV 1.0000 1 pcs Item 2.30
10000420 MH67 9N400S RESTRICTOR VALVE 1/4" None Item HV 1.0000 1 pcs Item 0.20
11003748 MH68 DF BN/HC 660 F 5 D1.1/-L24-Z4-B6 HIGH PRESS. FILTE None Item CP 3.0000 1 pcs Item 90.00
10007055 MH69 0660 D 005 BN4HC FILTER ELEMENT 5 my None Item CP 3.0000 1 pcs Item 3.90
10005654 MH70 RDJA-LCN RELIEF VALVE CARTRIDGE T-18A 760 L/min 7 None Item HV 3.0000 1 pcs Item 4.53
10006113 MH71 LE6/T-HT195 VALVE HOUSING 1 1/2" 6000 T-18A (MOD. None Item HV 3.0000 1 pcs Item 39.00
10006248 MH72 VU38F-3,0 CHECK VALVE 3/8" BSP 3,0 BAR (350 bar) None Item HV 1.0000 1 pcs Item 0.50
SP25521LXA003 03 SP2552-1 JIB SYSTEM None Item SW 1.0000 1 pcs Item 0.00
SP25521LXA003-0A
11108234 JH01 Ø450/350 x 6080 NiCrBZ HYDR. CYLINDER (RH) None Item HC 1.0000 1 pcs Item 0.00
11108233 JH02 Ø450/350 x 6080 NiCrBZ HYDR. CYLINDER (LH) None Item HC 1.0000 1 pcs Item 0.00
11108236 JH03 Ø380/300 x 4855 NiCrBZ HYDR. CYLINDER (RH) None Item HC 1.0000 1 pcs Item 0.00
11108235 JH04 Ø380/300 x 4855 NiCrBZ HYDR. CYLINDER (LH) None Item HC 1.0000 1 pcs Item 0.00
10002639 JH06 DBDS 30 G1X/315 PRESSURE RELIEF VALVE None Item HV 1.0000 1 pcs Item 16.00
10001461 JH08 SMK20-G1/4" MINIMESS TEST COUPLING None Item Item 6.0000 1 pcs Item 0.48
11008457 JH10 RDFA-LCN RELIEF VALVE CARTRIDGE None Item HV 1 pcs Item 0.00
11015597 JH12 MWIA-LJN PILOT 3,0 :1CARTIDGE BALANCE VALVE None Item HV 1 pcs Item 0.00
11002999 JH13 CWGL-LGN SUN PATRON 990-023-007 None Item HV 1 pcs Item 0.00
11015597 JH14 MWIA-LJN PILOT 3,0 :1CARTIDGE BALANCE VALVE None Item HV 1 pcs Item 0.00
SP25521LXA004 04 SP2552-1 SLEW SYSTEM None Item SW 1.0000 1 pcs Item 0.00
SP25521LXA004-0A
11108104 SG01 SLS3003DCe/335406/162/FL450.8C/61101801480 None Item PT 7.0000 1 pcs Item 0.00

10009709 SG04 1 LTR OIL TANK W/PIPE None Item HW 7.0000 1 pcs Item 14.00
11001772 SH01 AA2FM 80/61 W-VQDN 510 HYDRAULIC MOTOR None Item HM 7.0000 1 pcs Item 163.10
Page 3 of 4
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11105817 SH02 SLEW MOTOR VALVE BLOCK AA2FM80 10:1 (HM200785) None Item HV 5.0000 1 pcs Item 81.00
11105816 SH03 SLEW MOTOR VALVE BLOCK AA2FM80 4.5:1 (HM200784) None Item HV 2.0000 1 pcs Item 32.40
10000530 SH04 VFC-NC 05.99.05.00-09 SHUTTLE VALVE 1/4" None Item HV 2.0000 1 pcs Item 0.40
10000418 SH05 9F400S RESTRICTOR CHECK VALVE 1/4" None Item HV 2.0000 1 pcs Item 0.44
10001471 SH06 M 16 - R 1/4" MANOMETER TEST COUPLING None Item Item 1.0000 1 pcs Item 0.00
11000741 SH10 VB-424670A SLEW FUNC. ACC. BLOCK None Item HV 1.0000 1 pcs Item 24.00
10002392 SH11 EHV 32-330 BLADDER ACCUMULATOR None Item HA 1.0000 1 pcs Item 81.00
10002393 SH12 FK 220-2-316,CLAMP FOR ACCUMULATOR None Item HA 2.0000 1 pcs Item 2.20
10001438 SH13 A22120/K2 DAMPER RING FOR ACCUMULATOR None Item HA 1.0000 1 pcs Item 0.25
10007386 SH14 2" - 1" BSP REDUCER W/O-RING . None Item HA 1.0000 1 pcs Item 0.70
10000430 SH17 BKH34R BALL VALVE CHROMATED 3/4" BSP 420 BAR None Item HV 1.0000 1 pcs Item 1.60
11105880 SH18 : AS32061a-G24, WANDFLUH NG6 None Item HV 1.0000 1 pcs Item 1.89
10003737 SH19 645 EZ 121009 SUBPLATE NG6 3/8" None Item HV 1.0000 1 pcs Item 1.50
SP25521LXA005 05 SP2552-1 20T MAIN WINCH None Item SW 1.0000 1 pcs Item 0.00
SP25521LXA005-0A
11028039 WG01 SLW4003-G3/../70,5/FLs960.14C-OR-AD, WINCH GEAR None Item SW 1.0000 1 pcs Item 390.00
11028040 WG02 SLW4003-G3/../70,5/FLs960.14C-AO-AD,WINCH GEAR None Item PH 1.0000 1 pcs Item 390.00
10004246 WH01 A2FM 200/63W-VAB 010 HYDRAULIC MOTOR None Item HM 2.0000 1 pcs Item 130.00
11028028 WH02 VB425680J, MOTOR VALVE BLOCK None Item HV 2.0000 1 pcs Item 100.00
10000530 WH03 VFC-NC 05.99.05.00-09 SHUTTLE VALVE 1/4" None Item HV 1.0000 1 pcs Item 0.20
10002245 WH04 1SB252P3W6S SEQUENCE VALVE (NC 15-75BAR) None Item HV 1.0000 1 pcs Item 0.64
10001471 WH05 M 16 - R 1/4" MANOMETER TEST COUPLING None Item Item 3.0000 1 pcs Item 0.00
11002087 WH08 210511 MOPS/ EMERGENCY PAY OUT BLOCK None Item HV 1.0000 1 pcs Item 110.00
10001435 WH11 EHV 50-330 BLADDER ACCUMULATOR None Item HA 2.0000 1 pcs Item 190.00
10002393 WH12 FK 220-2-316,CLAMP FOR ACCUMULATOR None Item HA 4.0000 1 pcs Item 4.40
11009315 WH13 BVIGG12-275-G24-22C02 WANDFLUH PRESSURE None Item HV 1.0000 1 pcs Item 1.78
10001437 WH14 A22020 CONSOLE FOR ACCUMULATOR None Item HA 2.0000 1 pcs Item 2.80
10004011 WH15 DFE052/3A-18ES-W201-24VDC DIRECTIONAL CONTROL VAL None Item HV 2.0000 1 pcs Item 3.18
10000430 WH16 BKH34R BALL VALVE CHROMATED 3/4" BSP 420 BAR None Item HV 1.0000 1 pcs Item 1.60
10001438 WH17 A22120/K2 DAMPER RING FOR ACCUMULATOR None Item HA 2.0000 1 pcs Item 0.50
11002436 WH18 PRDB-LWN PRESSURE REDUCING/RELIEF VALVE None Item HV 1.0000 1 pcs Item 0.20
11002437 WH19 E4U/S+ CXCD - XAN VALVE HOUSING INC. CHECK VALVE None Item HV 1.0000 1 pcs Item 1.30
10002265 WH20 BKH14R BALL VALVE 1/4" None Item HV 2.0000 1 pcs Item 0.80
10001461 WH21 SMK20-G1/4" MINIMESS TEST COUPLING None Item Item 1.0000 1 pcs Item 0.08
10006247 WH24 VU38F-1,0 CHECK VALVE 3/8" BSP 1,0 BAR (350 bar) None Item HV 2.0000 1 pcs Item 0.34
11016783 WH25 203-406-220 SINDAL CABINET AISI 316 400x600x220 None Item EQ 1.0000 1 pcs Item 17.00
10001594 WH26 DBDS 6 G1X/315 PRESSURE RELIEF VALVE None Item HV 1.0000 1 pcs Item 1.56
10007029 WH36 PRDB-LBN PRESSURE REDUCING CARTRIDGE VALVE None Item HV 1.0000 1 pcs Item 0.23
10004716 WH37 ECU/S VALVE HOUSING 3/8" T-11A None Item HV 1.0000 1 pcs Item 0.87
10000494 WH38 VU38F-0,3 CHECK VALVE 3/8" BSP 0,3 BAR (350 bar) None Item HV 1.0000 1 pcs Item 0.12
SP25521LXA006 06 SP2552-1 10T WHIP WINCH None Item SW 1.0000 1 pcs Item 0.00
SP25521LXA006-0A
Page 4 of 4
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11003058 UG01 SLW4003-G3/../56,8/FL750.14C-OR WINCH GEAR None Item PH 1.0000 1 pcs Item 382.00
11003668 UG02 SLW4003-G3/../56,8/FL750.14C.AO WINCH GEAR None Item PH 1.0000 1 pcs Item 380.00
11005265 UG03 61136002160 ADAPTER SET (X=109) None Item HW 2.0000 1 pcs Item 14.00
11009173 UH01 A2FM 107/61W-VAB010 HYDRAULIC MOTOR None Item HM 2.0000 1 pcs Item 65.00
11015860 UH02 VB-425680G VALVE BLOCK WHIP LINE None Item HV 1.0000 1 pcs Item 0.00
11015861 UH03 VB-425700G VALVE BLOCK WHIP LINE None Item HV 1.0000 1 pcs Item 0.00
11002087 UH04 210511 MOPS/ EMERGENCY PAY OUT BLOCK None Item HV 1.0000 1 pcs Item 110.00
10000530 UH05 VFC-NC 05.99.05.00-09 SHUTTLE VALVE 1/4" None Item HV 2.0000 1 pcs Item 0.40
11002436 UH06 PRDB-LWN PRESSURE REDUCING/RELIEF VALVE None Item HV 1.0000 1 pcs Item 0.20
11002437 UH07 E4U/S+ CXCD - XAN VALVE HOUSING INC. CHECK VALVE None Item HV 1.0000 1 pcs Item 1.30
10002265 UH08 BKH14R BALL VALVE 1/4" None Item HV 2.0000 1 pcs Item 0.80
10001471 UH09 M 16 - R 1/4" MANOMETER TEST COUPLING None Item Item 3.0000 1 pcs Item 0.00
10002245 UH10 1SB252P3W6S SEQUENCE VALVE (NC 15-75BAR) None Item HV 1.0000 1 pcs Item 0.64
10001435 UH11 EHV 50-330 BLADDER ACCUMULATOR None Item HA 2.0000 1 pcs Item 190.00
10002393 UH12 FK 220-2-316,CLAMP FOR ACCUMULATOR None Item HA 4.0000 1 pcs Item 4.40
10001438 UH13 A22120/K2 DAMPER RING FOR ACCUMULATOR None Item HA 2.0000 1 pcs Item 0.50
10001437 UH14 A22020 CONSOLE FOR ACCUMULATOR None Item HA 2.0000 1 pcs Item 2.80
10000430 UH16 BKH34R BALL VALVE CHROMATED 3/4" BSP 420 BAR None Item HV 1.0000 1 pcs Item 1.60
10005379 UH22 AD3E-16-E-M-003 EL. ACTIVATED DIRECTIONAL VALVE None Item HV 2.0000 1 pcs Item 3.00
10003737 UH23 645 EZ 121009 SUBPLATE NG6 3/8" None Item HV 2.0000 1 pcs Item 3.00
10000494 UH24 VU38F-0,3 CHECK VALVE 3/8" BSP 0,3 BAR (350 bar) None Item HV 1.0000 1 pcs Item 0.12
11009984 UH25 203-606-220 SINDAL 600x600x220mm AISI316 None Item EQ 1.0000 1 pcs Item 26.00
10007029 UH36 PRDB-LBN PRESSURE REDUCING CARTRIDGE VALVE None Item HV 1.0000 1 pcs Item 0.23
10004716 UH37 ECU/S VALVE HOUSING 3/8" T-11A None Item HV 1.0000 1 pcs Item 0.87
10001594 UH51 DBDS 6 G1X/315 PRESSURE RELIEF VALVE None Item HV 1.0000 1 pcs Item 1.56
11009315 UH52 BVIGG12-275-G24-22C02 WANDFLUH PRESSURE None Item HV 1.0000 1 pcs Item 1.78
10004011 UH54 DFE052/3A-18ES-W201-24VDC DIRECTIONAL CONTROL VAL None Item HV 2.0000 1 pcs Item 3.18
3. Hydraulic Hose List

4. Component Parts List Electro

5. Ordering Spare Parts

Direct all enquiries regarding service and spare parts to:
MacGregor Norway AS
Andøyfaret 15
NO-4623 Kristiansand
NORWAY
Phone: +47 91 68 60 00
Fax: +47 380 18701
krs.spareparts@MacGregor.com
krs.service@MacGregor.com
Or look up your nearest MacGregor Marine Service station:
www.MacGregor.com
Remember to refer to the actual equipment machine number for exact definition of components and service
advice.
IMPORTANT NOTICE:
During the warranty period, all necessary spare parts must be supplied by MacGregor. The use of spare parts
supplied by other suppliers violates and forfeits the warranty.

8 Drawings & Data Sheets
See User Manual volume 2.

Blank page.
9 Statements and Certificates
Table of Contents
1. SP2552-1 Declaration of Conformity ................................................................................................1
2. ABS Approval Letter ........................................................................................................................3
3. Main and Whip Winch Wire ..............................................................................................................5
4. Main Hook........................................................................................................................................7
5. Whip Winch Hook ............................................................................................................................9
6. Main & Knuckle Jib Cylinders .........................................................................................................11
7. Slew Bearing ..................................................................................................................................13
8. Main Electric motors.......................................................................................................................15
9. Wire Sheaves ................................................................................................................................17

MACGREGOR NORWAY AS
Blank page.

MACGREGOR NORWAY AS
1. SP2552-1 Declaration of Conformity

Blank page.
2. ABS Approval Letter

Blank page.
Electronically published by ABS Piraeus.
Reference T1239510, dated 15-SEP-2014.
MACGREGOR NORWAY AS (442509) Reference: AM/KV/T1239510

ANDOYVEIEN 23, Project Number: 3224522
N-4623 KRISTIANSAND S, Class Number: YY251612
Norway,
ATTN : Mr. Leif Arne Gnzidem
Shipyard, Hull Number: FUJIAN MAWEI SHIPBUILDING LTD., MW610-2

Review Activity: Cargo Gear - HMC 3990 LKO 200-45 (600-25) (100-50) (Ref. SP2552-1)
Gentlemen,
We have received your electronic transmittals: CR1001967 dated 17 December 2013

CR1001972 17 December 2013
CR1002019 17 December 2013
CR1002030 17 December 2013
CR1015811 14 January 2014
CR1032407 12 February 2014
CR1035604 18 February 2014
CR1035633 18 February 2014
CR1035756 18 February 2014
CR1047506 07 March 2014
CR1055631 20 March 2014
CR1055669 20 March 2014
CR1093385 19May2014
CR1103779 04 June 2014
CR1107452 10 June 2014
CR1111082 16 June 2014
CR1123009 02 July 2014
as well as your emails dated: 06 February 2014

07 March 2014
09 March 2014
18 March 2014
24 April 2014
02 June 2014
16 June 2014
27 June 2014
02 July 2014
21 July 2014
06 August 2014
submitting documents and drawings for the subject crane, as specified in the attached drawing list. With
regard thereto, we advise that provided the comments in the attached list are addressed, the details and
arrangements as indicated and amended are adhered to, the material is ordered and tested to the Rule
requirements, the workmanship is to Surveyor's satisfaction, the crane is tested as a unit in accordance
with our requirements and the Rules in all other respects are complied with , then same will be approved for
the issuance of an American Bureau of Shipping Register of Lifting Appliances.
Our approval is based on an independent analysis which has confirmed that the factors of safety in the
principal structural parts of the crane are in accordance with the ABS "Guide for Certification of Lifting
Appliances - July 2007 (updated in September 2012)''. The safe operation of all offshore appliances is the
sole responsibility of the owner and operator.
A BS EUROPE DIVISION - PIRAEUS OFFICE
1, SACHTOURI STREET & POSIDONOS AVENUE, KALLITHEA. GR- 176 74, GREECE
TEL: +30-210-429-3215 FAX: +30-210-429-3218 Email: ABSPiraeusTech@eagle.orgwww.eagle.org
The approval of the crane is based on the design operating criteria as specified in the following documents
and as summarized below:
Drawing No Revision No Drawing Title

SP2552-1-N-XX-001 0 HMC 3990 LKO Load Radius Diagram Ship to Ship Single Part Mode
SP2552-1-N-XX-002 0 HMC 3990 LKO Load Radius Diagram Ship to Ship Double Fall Mode
SP2552-1-N-XX-003 0 HMC 3990 LKO Load Radius Diagram Ship to Ship Triple Fall Mode
HMC 3990 LKO 200-45 (600-25) (100-50)

Significant wave height (m) 0.0 0.5 1.0 1.5 2.0
Single Main Hoist Max. SWL (t) I Radius (m) 20/ 45 18 / 45 14 / 45 12 / 45 11/45
Fall Whip Hoist Max. SWL (t) I Radius (m) 10 / 50 8 / 50 7 / 50 6150 7150
Double Main Hoist Max. SWL (t) I Radius (m) 40 / 35 37 / 35 31 / 35 27 / 35 23 / 35
Fall Main Hoist SWL (t) I Max. Radius (m) 20 / 45 20 / 45 18 / 45 16 / 45 14 / 45
Triple Main Hoist Max. SWL (t) I Radius (m) 60 / 45 54 / 25 44 / 25 37 / 25 32 / 25
Fall Main Hoist SWL (t) I Max. Radius (m) 20 / 45 20 / 45 20 / 18 20 / 16 20 / 14
Heel (0 ) I Trim ( 0 ) 5/3
Maximum operating wind speed (m/s) 24
Design Service Temperature (° C) -10
We have received your declaration stating that the materials used in the system indicated in the submittal
are free from Asbestos.
The sheave structure is amended as noted on the drawing.
The personnel lifting operations are not part of this review, pending input to comment no. M-003, as
specified in the attached comments list.
The pedestal has been previously approved with our letter AM/KV/T1160487 dated 18 March 2014.
An electronic copy of the drawings, appropriately stamped to indicate our review, is available through the
ABS Eagle Construct Engineering Manager (02E), Web Portal. Our invoice covering the techn ical fee for
the above review will be forwarded to your good selves in due course.
If we may be of further assistance, please do not hesitate to contact Angelos Metaxas, email
AMetaxas@eagle.org, or the undersigned Evangelos Manousakakis. In all communications with ABS
regarding this approval please quote the Reference and the Approval Date of this letter.
Very truly yours,
Dimitrios G. Kostaras
Vice President of Engineering
ABS~ivision
By:
Evangelos Manousakakis
Managing Principal Engineer
CC: Calculation folder (02E)

ABS Surveyor (02E)
ABS EUROPE DIVISION - PIRAEUS OFFICE

1, SACHTOURI STREET & POSIDONOS AVENUE, KALLITHEA, GR-176 74, GREECE
Drawing List
~i_neering OfflCe:]~aeuSEnglneering Department - - - - --

!submitter: ][MACGREGOR NORWAY AS (442509) ------J
!Drawing No !!Revision No jjDrawing Title .
l
SP2552-1-R-XD-OOj~ JfHMC 3990 LKO 200-45 (600-25) (100-50) OFFSHORE CRANE j
[
[SP2552-1-R-XD-002 ][1 =--=--J ~~~~~:
l§ENERALARRANGEMENT
LKO 200-45 (600-25) (100-50)WORKl~G AREA -= · __J
[20975~ ____ ][g- _- )[CRANE-C3990CR~AINASSEMBLY - - · - -~_J
~~--=--=--Jc_-=_-= _j[g_RANE - C3990 KING MAIN ASSEM l?LY _ _ _ _ j
[20975473 m==-=i~RANE - C3990 KING STEEL STEEL ASSEMBLY_ _ _-~-~
[fil1011L _ ]~ _l~RA~C3990MAIN Ji BMJi.IN ASSEMBLY - - --=--=-~
:=JL _
[21010813
~2~
jjCRAN~ ~99~N JIB STEE~~ - - __ --~
-][2_____ =-=i~ANE-C3990 KNU~ETI[_MAIN ASSEMBLY ==~l -=
121012060
@0963254
~0000638
: ]12-= = ]CRANE .::c3990KNUCKLE JIB STEEL ASSEMBLY
=_][o - --]~00-019 MAIN WINCH
]@____ j[GA 0_!00~-03-'i_MW-S WINCH ASSEMB LY
--=- __ - - -
-- ~
--1
- =i
[SP2552-1 XI01 =1© ~]MAIN BLOCK DIAGRAM
s~~;G2-1 and - Ir ==1Ep DIAGRAM
===
~46273 =11o __] HMC LIFTING=LU~G=DETAIL

@_0966581 ~L - -j1C!3ANE - C3390 MAIN JIB SBAIC STEEL ASSEMBLY =3
~ro-
121009440
__ _jl___
] !CRANE - C3990 MAIN JIB WINCH FOUNDATION STEEL
ASSEMBLY l
r o~ _ ] [ ~1~~990 MAIN JIB WHIP WINCH FOUNDATION STEEL__j
[26971217 _ _ -JL -=-- _j~ E-C3990 KNUCKLE JIB BASIC STEEL ASSEMBLY ~
[21010897 - - - 1r2 -11CRANE - C3990 KNUCKLE JIB WHIP WINCH AFT STEEL ~
L- . ASSEMBLY -- J
@.Q00760o7 - -JF- = 1[HMC SP=FL_
=A=Y=T"-'
!§__
=H= =D=OOR ASSE~
_ !_ ~- - - ]
~~~1___ _)[1 _
120030307
_ J™~E - C3990 KING BASIC STEEL_ASSE~~--=--
)§__
- ] [LIFTING LUG SWL 8.5 -120T DETAIL
---=_J
_
~ 1001339 ==1~ ==ifCRANE - C3990 KNUCKLE JIB WHIP WINCH STEEL ASS
[21013866 -]~
l_
- llCRANE - C3990 KNUCKLE JIB WHIP WINCH TOP STEEL
L_
ASSEMBLy
J ]
~76159 - - I~-=_
!2096340.c=- -~~ ~
!209761.il_ _-_]o_ _
J[[Mw2oOF -
_o_u_N-DATl o N FOR ENCODER STEEL ASSEMBLY
]~W 200DRUM STEEL ASSEMBLY ~ - ~~
_ ][ MW 200 FOUNDATION FOR ENCODER STEEL ASSEMBLY j
==i l
~0010045 ] [5 _-__J~WIRE CLAMP DETAIL - _ I

~0131994 ==i@
Jl81'i0J-S 0100-0150 STEEL COMP~SY §>TD~RANE WINCH ~
120131984 IB =itHMW-S-0100-1500 FOUNDATION STEEL ASSEMBLY =:J
fu3~
@QI31991
!20016080
] 3
:=J~--
=
j[HMW-S-0100-1500 DRUM STEEL ASSEMBL'!'.:_
___
j[HMW-S-0100-0150 FOUNDATION STEEL ASSEMBLY
=1R - - j[tlMW WIR~CLAMP DETAIL_

TEL: +30-210-429-3215 FAX: +30-210-429-321B Email: ABSPiraeusTech@eagle.org www.eagle.org
~b 2552-1 -i-~-SA ][~ -~ _jL_EC-HNICALSECIFICATION - STEEL PRODUCTION ~

1
lsP2552-1-F-LA-019 I~ ~[!}ocu ~NTS FOR CLASS APPROVAL! INFORMATION · = = =
[SP"f552-1=-N-RA-ofil[9 _ _ __][ LEW FOR~Ei:2B_T . -
ISP2552-1 -N-RA-O@~ - _]QlBREST FORCE ~L -
~5~ -N--RA-oo§JIQ: - - - j @ogOMETRYDEFlNITION REPORT
~P2552-1-N-RA-=Oo[j~ - - l~ D~l"!!_ON R_§_~ -=--
!§_@~1-N-RA-008 I~ :=J@TR~ RAL DESIGN REPORT - INTRODUCTION_
~P2~-1-N-RA-O@l[-=-_-JIA:NALYSIS RESULTS REPORT -
@f2552-1-F-LA-of i l!f: =i!DRAWING LIST - -- - -
~~52-1-N~J]Jfi=:= _
[SP2552-1 -N-RA-00f)~ _
_]IAUxli.IARY WINCH REPORT
[SP2552-1-N-RA-011 )[1 ~_]I.MAIN WINCH REPORT
j~LINDER FORCES REPORT -
___
---- ~
~l --=- _ -=
l~-~552-1-RA-011 ] [ ~ _=]~IN WINCH REPORI_ _ ~ _ _ _ __ _ ~
!§?2552-1 -N.:Xx-002 ][6= - j~__Q]_ADIUS DIAGRAM SHIP TO SHIP DOUBLE FALL MODE -I
~P2552-1 -N-XX-OO[)~ _ - j [LOAD RADIUS DIAGRAM ~ T~ HIP TRIPLE FALL MO ~ _j
[21090267 J lQ:___ ==ilBMW
100-041 _WINCH 10T 150M ---- I
~2552-1-MRB =:J[ _
~~terial Traceability_ _ _
[$P2552-1-N-XX-001 Jf1 - - ]
HMC 3990LKO LOAD RADIUS DIAGR= A=
Moo-S=H=IP~T=o= sH=1=
p=s=
1N=G=L-=-
E=
l_ I__ PART MODE
1~~~552=1-Z-KA~003 j[ -'°~ FATP~du~_ _ _ ~- j
SP2552-1 -Z-KA-004 1rr--

HAT L ___ - L
J HAT Procedure -
~
l
[®~ l[-- _jJEMERGENCY OPERATION PROCEDURE -
~§__ _
[qwG01
~
- _
-~[-
][ _
_IE -
_-=ijEMERGENCY OPERATION PROCEDURE
f i lwsEARING / FouNDATl.Q!i __
j[KI NG/SLEW~A~ -(~G) - -
-=-__ . --=- -,
~- __
----
-~ ~
li:i@6287 ~c= = 1l§QNDURA TYPE 6.6 -

[1102~ _ lr j[BOND~ T~E 6.6 ==
lii.Q::26289 -=:JE ![BONDURA TYPE 6.6 - -~---
[11026245 IC: -
==i~N ~A TYPE 6.6 -
[SP2552-1 N-RA-~@=_ ~IANALYSIS OF WHIP LINE STRUC
=T=U
=R=E=====-"=====
:=!lo- -· -=:J~ANE - C3990 BOLT 0130.L=410 -~_J
[?1023330
1
21054257
L
JflO- l
_ _
fCRANE LIBRARY BOLT WIRE SHEAVE 0130.- L=220 STEEL-
" SSEMBLY - --- ~
[9oco4 __=][ !~DURA TECHNOLOGY MATERIAL TRACEABILITY LIST ~
l@!_Q1 .=Jr=- :=J1FM~P~L MAIN CONTROL VALVE _ J
IAttachment No.1=][ :=J[LOAD DIAGRAM SUBSTITUTION FORM =1
[Attachment-A1 ]a -=i~ummary_of results """!

TEL: +30-210-429-32 15 FAX: +30-210-429-321 8 Email: ABSPiraeusTech@eagle.org www.eagle.org
Comments List
J -~ction J
I
!hr_ead No J:comment Text
A-001 1
_ ___
(100-50) WORKING AREA DIAGRAM I

__ _ __ Facilities
SP2552-1-R-XD-002 - HMC 3990 LKO 200-45 (600-25) ~ 1Mw610-2[0penfi1surveyor 1
SP2552-1-R-XD-001 - HMC 3990 LKO 200-45 (600-25) I
Ii (100-50) OFFSHORE CRANE GENERAL ARRANGEMENT,
_20975660 - CRANE - C3990 CRANE MAIN ASSEMBLY
Jlsince the design service temperature is -10 deg. Celsius, the machinery components w-=rri-
have to comply with sections 2-6/9 and 2-3/15 of the CLA Guide, to the attending Surveyor's
_J~isfaction. _ _ _ __ _ _____
I
fA-002- I SP2552-1-R-XD-002 - HMC 3990 LKO 200-45 (600-25)
(100-50) WORKING AREA DIAGRAM I
DOC05 - DESIGN APPROVAL ABS - REPLY COMMENTS ,

I SP2552-1-R-XD-001 - HMC 3990 LKO 200-45 (600-25) It
(100-50) OFFSHORE CRANE GENERAL ARRANGEMENT j __
- - - Tslew bearings are to complywith the-toughness requirements- of section 2-3/11 of our CLA
_ j 'Guide to our attending Surveyor's satisfaction.
1
1
~-001 J SP2552-1 x101 1 01 - MAIN BLOCK DIAGRAM ELECTRICAL~ I MW610-2[0pen]-rSurveyor ,.
I
CUSTOMER INTERFACE,
SP2552-1 XI01 - MAIN BLOCK DIAGRAM
SP2552-1 and AP-XU - LOOP DIAGRAM
I
1 _
I
We have noted the existence of a thermistor for main pump motors' running protection. In this!
l
E-002 1
I jregard, our attending Surveyor is to verify that same is set at a temperature corresponding to J
l!Q.9-125~ of motor rated current. _
SP2552-1 XI01 101 - MAINBLOCK DIAGRAM ELECTRICAL
_ _
MW610-2[0pen] surveyor l
_ _
CUSTOMER INTERFACE ,
l SP2552-1 XI01 - MAIN BLOCK DIAGRAM

I
,
, - - l1The construction of electric cables is to be as per section 4-8-3/9 of the Steel Vessel Rules- to
~
j
l
. the satisfaction of our attending Surveyor.
[E-003 - ]- SP2552-1 XI01 101 - MAIN BLOCK DIAGRAM ELECTRICAL MW610-2[0pen] rsurveyor _,
l
CUSTOMER INTERFACE ,
SP2552-1 XI01 - MAIN BLOCK DIAGRAM
I
I I
I
liThe motor starter is to have a minimum degree of protectionln- compliance with section~~-1
4-8-3/Table 2 of our Steel Vessel Rules. The enclosures and assemblies are to be
constructed of steel or other suitable material, as per section 4-8-3/5.3.1 of our Steel Vessel
Rules_. The ab~ve are !_o be verified by !he attending Surveyor.
E-004 SP2552-1 XI01101 - MAIN BLOCK DIAGRAM ELECTRICAL MW610-2[0pen] 1Su rvey~r
1
I 1cusroMER INTERFACE ,
Ir
l t-?P2552-1 XI01 - MAIN BLOCK DIAGRAM
LSP2552-1 and AP-XU - LOOP DIAGRAM
I J
J lnternal wiring is to be in accordance with section 4-8-3/5.3.6 of the Steel Vessel Rules, to
the attending Surveyor's satisfaction.
-SP2S52-=-1 '.X101 101- - MAIN BLOCK DIAGRAM ELECTRICAL 1'MW61-0-2[0pen]-r urveyor ~
j
CUSTOMER INTERFACE,
1 SP2552-1 X101 - MAIN BLOCK DIAGRAM, ,I
J SP~552-1 and AP-XU - LOOP DIAGRAM I _ _ j
A motor disconnecting device , operated externally of the controller~ to be provided, as -per l
Jsection 4-8-4/9.3.2 of the Steel Vessel Rules, to the attending Surveyor's satisfaction.
l~M=
-0=0-"
1= _?1010105 - CR~NE - C3990 MAIN JIB WHIP WINCH - JMW610-2[0pen] lfe~h_!:li~al]
FOUNDATION STEEL ASS. ,

90000638 - GA 0100-0150-03 HMW-S WINCH ASSEMBLY,
20131991 - HMW-S-0100-0150 FOUNDATION STEEL
:ASSEMBLY I
120131984 - HMW-S-0100-1500 FOUNDATION STEEL

ASSEMBLY I
120131994 - HMW-S 0100-0150 STEEL COMP. ASSY STD.

CRANE WINCH I
20131999-WINCH MECH ASSY I
20963254 - HMW 200-019 MAIN WINCH I

20976159- HMW 200 FOUNDATION FOR ENCODER STEEL
ASSEMBLY I
21009440- CRANE- C3990 MAIN JIB WINCH FOUNDATION
·sTEEL ASSEMBLY •
120976141 - HMW 200 FOUNDATION FOR ENCODER STEEL I
1tASSEMBLY _
- -iiTh~ pins connecting the-main and auxiliary winch on the crane- are to beSubmitted for our- 1
Jrev1ew.
rM-002 l-6P2552-1-R-XD-002 - HMC 3990 LKO 200::-45 (600-25) MW610-2[0pen] Surveyor J
1(100-50) WORKING AREA DIAGRAM I
SP2552-1-R-XD-001 - HMC 3990 LKO 200-45 (600-25)
(100-50) OFFSHORE CRANE GENERAL ARRANGEMENT , J
I
,- 20975660 - CRANE - C3990 CRANE MAIN ASSEMBLY
l Evidence of ABS certification for hydraulic cylinders, accumulators, winch and ~ew gears afel
L__
M-003
J:to be fun:iished to our attending Surveyor. -~
SP2552-1-N-XX-003 - LOAD RADIUS DIAGRAM SHIP TO
SHIP TRIPLE FALL MODE I
__ _
I
_____ _ _I
MW610-2[0pen] ~echnical
I
SP2552-1-L-XA-003 - HMC 3990 OFFSHORE CRANE JIB
SYSTEM HYDRAULIC FLOW DIAGRAM I I
IL1ST01 - FMEA TYPICAL MAIN CONTROL VALVE I
SP2552-1-L-XA-002 - HMC 3990 OFFSHORE CRANE PUMP

SYSTEM HYDRAULIC SYSTEM FLOW DIAGRAM ,
1SP2552-1-L-XA-006- HMC 3990 OFFSHORE CRANE 20T
WHIP WINCH MOTORS & BLOCK HYDRAULIC FLOW
DIAGRAM I
SP2552-1-L-XA-001 - HMC 3990 OFFSHORE CRANE TANK
·SYSTEM HYDRAULIC FLOW DIAGRAM I
ISP2552-1-L-XA-004 - HMC 3990 OFFSHORE CRANE SLEW
SYSTEM HYDRAULIC FLOW DIAGRAM ,
SP2552-1-N-XX-001 - HMC 3990LKO LOAD RADIUS
DIAGRAM SHIP TO SHIP SINGLE PART MODE
SP2552-1-N-XX-002 - LOAD RADIUS DIAGRAM SHIP TO
I I
1SHIP DOUBLE FALL MODE I
SP2552-1-L-XA-005 - HMC 3990 OFFSHORE CRANE 20T

I
MAIN WINCH MOTORS & BLOCKS HYDRAULIC FLOW
DIAGRAM
I
With regard to the requirements of section 2-9/13 of our CLA Guide, we have noted t he
existence of an emergency HPU however we have also noted that the emergency HPU
;
I
I
!operates through the same piping system and control valves. Furthermore, we have received
your FMECA regarding the main control valve, however, the same indicates that some valve
1
failures, such as nos. 1.2.2.4, 1.2.2.5, 1.2.2.6, 1.2.2.7, 1.2.2.8, may lead to crane
I
!components being inoperable and specific motions, such as hoisting or slewing, that are
required in order to recover the personnel to a safe position not being able to be performed.
,In this regard, you are kindly requested to provide your justification of how you consider that
TEL: +30-210-429-3215 FAX: +30-210-429-3218 Email: ABSPiraeusTech@eagle.org www.eagle.org
The recovery of lifted personnel from any position in the event ofa single failure in thecontrol '
!system (including piping) is possible to be performed, giving special attention to possible j
1.failures of the main control valve, as well as the condition of the personnel basket being
J below~essel~s deck level.
M-004 - 90000638 -GA 0100-0150-03HrVlW -S WINCH ASSEMBLY JMW610-2[0pen)1lsurveybr-
I
20131977 - HMW-S-0100-1500 DRUM STEEL ASSEMBLY I
120131994 - HMW-S 0100-0150 STEEL COMP. ASSY STD.

!CRANE WINCH I
I
120131999 -WINCH MECH ASSY I
120963404 - HMW 200DRUM STEEL ASSEMBLY

L 20963254 - HMW 200-019 MAIN WINCH _J I _
l
l
,Five-(5) wraps of wire rope are to remain on the drum of the hoisting wi nchWith theh ookl n
lits lowest position, as per section 2-4/1 of our CLA Guide, to our attending Surveyor's
satisfaction. '.
·P-001___ jSP2552-1-L-XA-003- HMC 3g 90 OFFSHORE CRANE JIB IMW610-2[0pe!if Techn~al I
' SYSTEM HYDRAULIC FLOW DIAGRAM I ' I
SP2552-1-L-XA-002 - HMC 3990 OFFSHORE CRANE PUMP
1
I
SYSTEM HYDRAULIC SYSTEM FLOW DIAGRAM ,
WHIP WINCH MOTORS & BLOCK HYDRAULIC FLOW
DIAGRAM I
SP2552-1-L-XA-001 - HMC 3990 OFFSHORE CRANE TANK
I'
1
SP2552-1-L-XA-004 - HMC 3990 OFFSHORE CRANE SLEW
MAIN WINCH MOTORS & BLOCKS HYDRAULIC FLOW
-It appears,
-- based
DIAGRAM
- on our independent
- - calculations,
- -that the used -high pressure
- pipes are- not l
suitable for their intended working pressures, where, their wall thickness is to be according to
section 4-6-2/5.1 of our "Rules for Building and Classign Steel Vessels 2013" (Steel Vessel
jRules). In this regard, the maximum working pressure, the ultimate tensile strength, the yield
strength, the average stress to produce rapture in 100,000 hours at design temperature, as
;well as the percentage of the negative manufacturing tolerance of each pipe, as per section
4-6-2/5.1.1 of our Steel Vessel Rules, are to be submitted for our further consideration .
IThe hydraulic diagr~ms are retained pending re~~ipt of ~our input on the above._ _ J
I SP2552-1-R-XD-OO~HMC 3990LKO 200-45 (600-25)- 1 MW610-2[0pen] r urveyof j
,(100-50) WORKING AREA DIAGRAM I
SP2552-1-R-XD-001 - HMC 3990 LKO 200-45 (600-25) I
(100-50) OFFSHORE CRANE GENERAL ARRANGEMENT , :I
20975660 - CRANE - C3990 CRANE MAIN ASSEMBLY j
r - - - - i The load block/swivel used for personnel lifting, is to be permanently marked-with the -
maximum safe working load to be used for lifting personnel and is to be provided w ith latches
,fitted with positive locking means, as per section 2-9/5 of our CLA Guide. The above is to be
__ ~erifieq_by the attending Surveyor. _ _

T EL: +30-21 0-429-3215 FAX: +30-210-429-3218 Email: ABS PiraeusTech@eagle.org www.eagle.org
Reference T1255587, dated 15-OCT-2014.
Reference T1255587, dated 15-OCT-2014.
3. Main and Whip Winch Wire

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4. Main Hook

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5. Whip Winch Hook

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Manufacturing Documentation
Test Report EN 10204 - 2.2
Certificate No.: C14-03566
Client : MacGregor Norway AS S.O. No. : R140175-1-1

P.O. No. : 381787 P.O. Date : 15-01-2014
Product code : BG 10.500.C

Fabrication No. : RX1375
Description Size / Material Heat No. Remarks

Part Dimension
Hook 5 34CrNiMo6 6633 Y1=120

Nut 100 34CrNiMo6 A201 - 63873
Suspension 170 S355J2N A274 - 52021
Studeye 45 S355J2N CU87 - 390258
Body 410 S355J2N 13620945
Third party certificate(s): ABS witness/survey certificate
Remarks:
We hereby certify that:

- The above mentioned product is in accordance with the requirements of the order.
- The above mentioned product has been inspected in accordance with the specifications and has met the requirements.
EC :
The undersigned certifies on behalf of his company, that the above mentioned product is correct and that the intended hoisting equipment
or application continued can be declared according the regulations of the Machine Directive 2006/42/EC, appendix II-A or II-B, after assembly.
Products must not be put in service until the final application has been declared in conformity with the provisions in the 2006/42/EC directive.
The assembling, testing and examination was carried out under the supervision by a competent person and certified under DNV MSA R-2366.
Our Quality Management System is certified by DNV Business Assurance The Netherlands, certificate No. 132207-2013-AQ-NLD-RvA.
Reference standards, used (partly or as whole) where applicable and considered state of the art:
- EN 13001, 13135, 13411, 818, 1677, 13889 - DIN 15400, 15401, 15402, 15018, 15020, 15061, 15063, 82017
- ISO 4301, 4308, 8087, 3189, 9927, 17558 - FEM 1.001, 5.004
- NEN 3318, NEN 3320, 3508, 3305, 2729 - US Fed. Spec. RR-S550D, RR-C-271
- Standards and rules as mentioned in the contract and/or drawings.
Signed for and on behalf of Ropeblock B.V. / The Netherlands
Name: Ing. J. Eertman / Technical Director
Date: 7-4-2014
1/1 KZ-217/1
Inspection Certificate
EN 10204 - 3.1
Manufacturer : Ropeblock B.V. - Oldenzaal - The Netherlands Marking:

Certificate No. : 2014070
Type of Hook : Point hook acc. DIN 15401
Size : 5V
Quantity :5
5V
Heat No. : 6633 (99839) 6633
Material : 34CrNiMo6 DIN 15401
Chemical analysis
C Mn Si Ni Cr S P Mo Al Cu Nb V
EN 10083-1
% % % % % % % % % % % %
Rated values 0.30 - 0.50 -  1.30 - 1.30 -   0.15 -

0.38 0.80 0.40 1.70 1.70 0.035 0.035 0.30
Actual values 0,36 0,61 0,25 1,56 1,53 0,003 0,009 0,21 0,03
Mechanical properties
Tensile Yield Elongation Impact test ISO V
DIN 15400 RM (N / mm²) ReH / Rp0.2 (N / mm²) A (%) J T (°C)
Rated values --- 620 (min.) ---  27J -20°C
Actual values 952 830 21 134-132-135 -40
Heat treatment
Hooks are treated to the values of solidity class: V
The heat treatment of the materials is in accordance with the applicable material specification.
NDE Examinations
Dimensional examination All measurement deviations under tolerance
Ultrasonic examination Satisfactory, free of internal seperations which may effect utilization
Magnetic Particle examination Satisfactory, free of surface cracks which may effect utilization
Remarks
The above mentioned product is correct and that the intended hoisting equipment or application continued can be declared according the
regulations of the Machine Directive 2006/42/EC, appendix II-A or II-B, after assembly.
Products must not be put in service until the final application has been declared in conformity with the provisions in the 2006/42/EC directive.
The reported values are strictly in accordance with the original mill certificates.
Quality certificate for forged load hooks according to DIN 15404.
For and on behalf of Ropeblock B.V. / The Netherlands

Name : J.H. Eertman
Position : Technical Director
Date : 26-2-2014
KZ190/2
Heat No.: 63873
Re-Marking: A201
Re-marking
R QA/QC Dept.
B Ropeblock BV
Heat No.: 52021
Re-Marking: A274
Re-marking
R QA/QC Dept.
B Ropeblock BV
Heat No.: 52021
Re-Marking: A274
6. Main & Knuckle Jib Cylinders

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7. Slew Bearing

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8. Main Electric motors

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9. Wire Sheaves

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10 Other
10 Other
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10 Other

60t Crane SP2552-1-15-1 UM

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60t Crane SP2552-1-15-1 UM

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User Manual for Crane

The user manual is divided into three (3) volumes:

• SP2552-1-15-1 System Description

MacGregor Norway AS +47 38 01 87 01

After warranty period:

Contact your nearest MacGregor service office.

4. General Security Conditions

7. HSE – Health, Safety and Environment

Do not stay underneath or in the vicinity of a suspended load.

Before work proceeds verify that all circuits are voltage-free.

7.2. Disconnection of Live Circuits

7.3. Accidental Activation

7.4. Electrical Supply Specification

7.5. Replacement Parts

7.7. Observing the Installation Guidelines

2. Regulations and Design Criteria

10. Crane Operation

11. Surface Treatment

12. Weight and Dimensions of Crane

See drawing No. SP2552-1-R-XD-001 General Arrangement

Annex A - Technical Description of the Hydraulic System...................................................................A1

2.2. Slew Bearing

As the slewing pinions in the underside of the

Photo at right: a slew pinion under the crane

A crane's size is specified based on the slew

2.3. Crane King

2.4. Slew Gear

In cases where the crane has a defined slewing sector,

2.5. Operator Cabin

Steel bars on the front window and a grille

2.5.1. Communication System / ROV Monitor Signals

2.5.2. Monitor for Remote Installation

2.6. Crane Jib System

Aircraft Warning Lights

Two heavy-duty marine-grade pendulum floodlights are fitted to the

2.7. Luffing Main and Knuckle Jib Cylinders

In addition, a safety valve is hydraulically connected the rod

The cylinders are connected with spherical bearings. A load

Bondura bolts are typically used to connect the hydraulic

2.8.2. Main Winch

2.8.3. Whip Winch

3. Hydraulic System Design

Circulation pump Drain filters x 3

King floor plate Main pump (double) x 1

Main HPU motor Slew ring

Main HPU motor

CJC offline filter

4. Electrical System Design

4.2. Main Electric Motors

5. Control System Design

• Knuckle (2x) and main jib (2x) position encoders

Type HMC 3990

2 Issued for Information 12.12.13 CCU HZH

Technical Description of the Hydraulic System

Customer: Project name.:

HM project no.: P.O. No.:

HM doc. no.: Customer doc. no.: No.of attachments: No. of pages:

1 HPU (Hydraulic Power Unit)

1.1 Reservoir with Accessories

The reservoirs are equipped with the following accessories:

• Suction Valves (Butterfly valves or ball valves)

1.2 Oil Coolers

1.3 Filtration Unit Assembly