MC Gregor Crane and 501-MOB-boat-davit - CARGOTEC - Manual SP2423-1-15 UM

PROJECT DOCUMENT Page 1 of 1
No. SP2423-1-15-UM
Customer Supplier Project number, supplier

Hellesy Verft AS Cargotec Norway AS SP2423-1
Andyveien 23
NO-4623 KRISTIANSAND Project name, customer
Norway NB150-023
P.O. number, customer

4440
User Manual
Equipment: MacGregor Crane
Type: HMC 1400 LK 30-18 (50-15) MOB27
Revision Reason for issue Date Author Checked by

th
0 As Built 9 Nov. 2012 TKN
This document and all information and data herein or herewith is the confidential and proprietary property of Cargotec 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 Cargotec Norway AS.
Cargotec Norway AS
www.cargotec.com
User Manual for Crane
Table of Contents
1 INTRODUCTION ................................................................................................................................ 1
1.1 General......................................................................................................................................... 1
1.2 Purchase information ................................................................................................................... 1
1.3 If problems occur .......................................................................................................................... 2
1.4 General security conditions .......................................................................................................... 2
1.5 Training ........................................................................................................................................ 2
1.6 Restrictions in guarantee .............................................................................................................. 2
1.7 After warranty period .................................................................................................................... 2
1.8 Restrictions in use ........................................................................................................................ 2
1.9 HSE Health, Safety and Environment ....................................................................................... 3
2 MAIN DATA ........................................................................................................................................ 5

2.1 Technical data .............................................................................................................................. 5
2.2 Weight & outline dimensions ........................................................................................................ 5
3 TECHNICAL DESCRIPTION .............................................................................................................. 6

3.1 General technical description ....................................................................................................... 6
3.2 Construction, main design ............................................................................................................ 6
3.2.1 Crane pedestal ...................................................................................................................... 6
3.2.2 Crane king structure .............................................................................................................. 6
3.2.3 Crane jib system .................................................................................................................... 6
3.2.4 Jib / knuckle cylinder.............................................................................................................. 7
3.2.5 Slew gear and slew bearing ................................................................................................... 7
3.2.6 Hydraulic system ................................................................................................................... 7
3.2.7 Hydraulic winch...................................................................................................................... 8
3.2.8 Hydraulic oil tank ................................................................................................................... 8
3.2.9 Manual Overload Protection System (Option) ....................................................................... 8
3.2.10 Diesel HPU back-up (Option) .............................................................................................. 8
3.3 Electrical system .......................................................................................................................... 9
3.3.1 Starter Cabinet ES400 ....................................................................................................... 10
3.3.2 Radio Remote Cabinet RRC97 .......................................................................................... 11
3.3.3 Electromotor and slip ring .................................................................................................... 12
3.3.4 Radio Remote -Control Terminal RRC97.1 ....................................................................... 12
3.3.5 Operator platform................................................................................................................. 12
CARGOTEC NORWAY AS
4 PRESERVATION, STORAGE AND INSTALLATION ...................................................................... 13

4.1 Introduction................................................................................................................................. 13
4.2 Unloading and Handling ............................................................................................................. 13
4.3 Storage ....................................................................................................................................... 13
4.4 Preservation ............................................................................................................................... 13
4.5 Installation .................................................................................................................................. 14
4.5.1 Welding to deck structure .................................................................................................... 14
4.5.2 Electrical installation ............................................................................................................ 14
4.6 Filling of hydraulic system oil ...................................................................................................... 14
4.7 First time start up........................................................................................................................ 15
4.8 Functional and load test ............................................................................................................. 15
4.9 Commissioning test procedure ................................................................................................... 16
5 OPERATING INSTRUCTIONS ......................................................................................................... 17

5.1 Start up of crane ......................................................................................................................... 17
5.1.1 General check before start .................................................................................................. 17
5.1.2 Check before and during operation ..................................................................................... 17
5.1.3 Start up ................................................................................................................................ 18
5.2 Operating the crane.................................................................................................................... 19
5.3 Safety instructions ...................................................................................................................... 19
5.4 Safety functions built into crane system ..................................................................................... 20
5.4.1 Emergency stop ................................................................................................................... 20
5.4.2 Hook stop............................................................................................................................. 20
5.4.3 Spring centred control valves .............................................................................................. 20
5.4.4 Overload protection ............................................................................................................. 20
5.4.5 Luffing cylinder limitation ..................................................................................................... 20
5.4.6 Load holding brakes ............................................................................................................ 20
5.4.7 Fail safe brakes ................................................................................................................... 20
5.5 Radio remote control system ...................................................................................................... 21
5.5.1 Radio remote cabinet RRC97 ............................................................................................ 21
5.5.2 Radio transmitter unit -RRC97.1.......................................................................................... 22
5.5.3 General warnings regarding use of radio remote control ..................................................... 26
5.6 Precautions during operation ..................................................................................................... 26
6 MAINTENANCE ............................................................................................................................... 27
6.1 Routine maintenance ................................................................................................................. 28
6.2 Periodic Maintenance Program .................................................................................................. 30
6.2.1 Steel wire ropes - care and maintenance, inspection and discard ...................................... 32
6.2.2 Bolts slew and foundation ................................................................................................. 34
CARGOTEC NORWAY AS
6.2.3 Electromotor ........................................................................................................................ 35

6.3 Standard Inspection form for Crane ........................................................................................... 36
6.4 Monthly inspections .................................................................................................................... 37
6.5 Lubrication instructions............................................................................................................... 38
6.6 Lubrication chart with lubrication points ..................................................................................... 39
6.7 Change of oil filter ...................................................................................................................... 40
7 PARTS LIST ..................................................................................................................................... 41

7.1 Component parts list .................................................................................................................. 42
7.2 Hydraulic hose list ...................................................................................................................... 43
7.3 Spare parts, service, inquiries .................................................................................................... 44
8 DRAWINGS and DATA SHEETS .................................................................................................... 45

8.1 Project drawings ......................................................................................................................... 46
8.2 Data Sheets................................................................................................................................ 47
8.2.1 Main pump MH01 .............................................................................................................. 47
8.2.2 Main control valve MH06 ................................................................................................... 48
8.2.3 Winch drive WH01 ............................................................................................................. 49
8.2.4 Winch gear WG01 ............................................................................................................. 50
8.2.5 Slew drive SH01 ................................................................................................................ 51
8.2.6 Slew gear SG01................................................................................................................. 52
8.2.7 Diesel HPU EH01 .............................................................................................................. 53
8.2.8 Filter with element MH05/MH10 ........................................................................................ 54
8.2.9 Electromotor M01 ............................................................................................................ 55
9 CERTIFICATES ................................................................................................................................ 56
9.1 Declaration of Conformity ........................................................................................................... 57
9.2 Third party approval ................................................................................................................... 58
9.3 Certificates for lifting equipment ................................................................................................. 59
9.3.1 Wire certificate ..................................................................................................................... 60
9.3.2 Hook & Shackle certificates ................................................................................................. 61
9.4 FAT report .................................................................................................................................. 62
10 Radio Remote Control User Manual ............................................................................................ 63
11 OTHER ........................................................................................................................................... 64
CARGOTEC NORWAY AS
1 INTRODUCTION
1.1 General
The User manual is based on the Norwegian Standard NS 5820.
Operators and maintenance personnel must read and understand this user manual before any operations or
maintenance of the equipment is commenced. The owner of the equipment is responsible to ensure that no
unauthorized personnel operate or maintain the equipment.
NOTE:
Illustrations/pictures used in this user manual are for illustrational purposes and may differ from the delivered
equipment.
1.2 Purchase information

Equipment: Knuckle jib slewing crane
Type: HMC 1400 LK 30-18 (50-15) MOB27
Customer: Hellesy Verft AS
Project/Vessel: 4440, NB150-023
Machine number: SP2423-1
CARGOTEC NORWAY AS 1
1.3 If problems occur

In case of any problems, please contact:
Cargotec Norway AS
Andyveien 23
NO-4623 KRISTIANSAND, Norway
+47 916 86 000
+47 38 01 87 01
krs.service@cargotec.com
+47 916 89751
Remember to refer to actual equipment machine number for exact definition of components and service advice.
1.4 General security conditions

No unauthorized personnel are allowed in the equipment working area. We will also emphasize that personnel
under the influence of drugs, alcohol, medication or other preparations which can affect a persons
consciousness must not be allowed to operate the equipment. All use of the equipment must comply with the
company security regulations.
1.5 Training
Cargotec Norway AS can provide tailor-made operation- and maintenance courses to all MacGregor
equipment. For more information, contact our Head office in Kristiansand. We recommend all our customers to
attend our courses.
1.6 Restrictions in guarantee

During the warranty period, all necessary spare parts must be supplied by Cargotec Norway AS. The use of
spare parts from other suppliers violates and forfeits the warranty. Unintended use and/or wrong/missing
maintenance of the equipment, forfeits the warranty. Removal and/or loss of the equipment identification plates,
also forfeits the warranty.
1.7 After warranty period

Contact your nearest Cargotec Service Office, http://www.macgregor-group.com/service
1.8 Restrictions in use

Unintended use can result in equipment damage and fatal injury to personnel.
1.9 HSE Health, Safety and Environment

Safety in Prior to any maintenance or repair work, the maintenance crew must ensure
Maintenance ability to operate the equipment, as well as good comprehension of technical
drawings and procedures.
Secure the maintenance work space!
When replacing heavier items, individual parts and/or heavy structural

components must be carefully attached to the lifting gear and safeguarded to
prevent collision with surroundings. Use only approved lifting equipment
with sufficient lift capacity.
Do not stay underneath or in the vicinity of a suspended load.
Only authorized personnel may perform work on the electrical installation or

the equipment.
Whenever inspection, maintenance or repair work requires voltage free

equipment this is done in the following ways:
For circuits above 50 VAC / 30 VDC, switch off and lock the main circuit
breaker on the supply side.
For instrumentation circuits (below 50 VAC / 30 VDC), isolate the
control cubicle from the main supply.
Open the fuses in the control cubicle, using the relevant (loop) drawings.
Isolate the relevant wires / cores from the terminal block in the control
cubicle.
Follow given procedure to troubleshoot, repair the equipment in question.
Before work proceeds verify that all circuits are voltage free.
Disconnection of live Warning!

circuits Do not disconnect a live circuit unless location is known to be non-hazardous.
Accidental Measures must be taken to prevent accidental activation of equipment

activation delivered by or controlled by a MacGregor product during maintenance.
This may include locking our power supply, display warning signs at relevant
locations and inform other people or organisations.
Electrical supply In case of disturbances in the electrical supply (voltage, frequency, harmonic
specification and other disturbances) the equipment must be switched off immediately.
Replacement parts To maintain the integrity of the equipment delivered by MacGregor its
important that all spare parts have identical or better specifications than
originally delivered. This is especially important for all protective equipment
as fuses and circuit breakers. Computer hardware should not be changed
without consulting Cargotec Norway AS.
When in doubt ASK!
Software The software delivered with the system is programmed by Cargotec Norway
AS, and is vital for a safe and secure operation of the equipment.
Only qualified personnel from Cargotec Norway AS must alter the system
software.
The software delivered with the system has a unique number and is filed at
Cargotec Norway AS. If modified software is detected in any system this will
void warranty responsibility with respect to the safe and normal operation of
the equipment. Consult Cargotec Norway AS prior to making any change to
the software.
Observing the MacGregor products will meet the contractual requirements if installed and
Installation operated as described in the installation guidelines and documentation
Guidelines received from Cargotec Norway AS.
Environment Environmental considerations should be kept in mind when disposing of any

part of the equipment delivered by Cargotec Norway AS.
2 MAIN DATA
2.1 Technical data

MAIN DATA
Crane type HMC 1400 LK 30-18 (50-15) MOB27
Machine SP2423-1
SWL @ 15 m 50 kN (5 metric tonnes)
SWL @ 18 m 30 kN (3 metric tonnes)
SWL @ MOB mode 27 kN (2.7 metric tonnes)
Dynamic factor 1.15
Working radius max.: 18 m
Working radius min.: ~2.7 m
Hoisting speed 0-30 m/min stepless variable
Hoisting height 20 m
Slew sector ~350 limited slewing
Slew speed 0-1 rpm stepless variable
WINCH DATA
Winch type HMW 50-007
Wire diameter 19 mm
Wire MBL 275 kN
HYDRAULIC DATA
Pump capacity 105 l/min
Operating pressure 250 Bar
Hydraulic oil volume ~600 liters
ELECTRIC DATA
El. motor type 14BG 208-4AA66-Z200L
Power supply 690 V, 60 Hz, 3~
Power, S6-40% 55 kW, 59 A, 1765 rpm
Power, S1-100% 43 kW, 69 A
El. motor heating element 2x40 W, 230V
Starting method DOL
Starting current ~475 A
2.2 Weight & outline dimensions

Weight of crane: ~8500 kg
Outline dimensions of crane: Reference to drawing C.1400.153.GA
3 TECHNICAL DESCRIPTION
3.1 General technical description

The HMC 1400 LK 30-18 knuckle jib deck crane is designed for long time operation in a tough and corrosive
environment.
The crane is designed for efficient and accurate handling of general cargo at max 18 metres working radius with
single fall.
The crane is delivered top coat painted and fully tested, adjusted and ready for installation onboard vessel by
welding to substructure and connection of electric power supply. The hydraulic power unit (HPU) is integrated
in the crane, with the electromotor in the foundation. The hydraulic pump which is directly connected to the
electromotor sits in the crane king, submerged in hydraulic oil.
The crane is designed for Rescue Basket and MOB boat operation, 2700 kg, according to latest NMD
requirements. The crane has an emergency diesel HPU suspended under the crane platform. It connects the
crane with hydraulic quick release connectors to the back of the crane.
The crane is normally operated from a side mounted platform on the king structure or from an optional radio
remote control unit. All selected equipment is chosen and installed to ensure the lowest possible emission of
sound and good access for service and repair.
3.2 Construction, main design
3.2.1 Crane pedestal

The crane pedestal (also called the foundation) acts as a structural base for the crane system and is designed for
welding to a suitable deck structure. The pedestal contains the vertically mounted electrical motor with the
hydraulic pump and the oil tank located in above located rotating king. A flexible coupling is installed in
between the el. motor output shaft and the pump shaft.
A door or access-hatch for inspection/service is provided in the pedestal structure. For cranes which require
electricity above the slew bearing, a slip-ring
system is installed in the pedestal to transfer
power to the relevant connection boxes and
cabinets in the moving king.
3.2.2 Crane king structure

The rotating crane king is installed on top of
the slew bearing above the pedestal. It
contains the oil reservoir and acts as the main
structural element between the pedestal and
the jib system. It is the mounting point for all
other parts of the crane.
Plain bushing-style bearings join the jib to the
top of the king and composite spherical
bearings connect the jib luffing cylinder to
the king. Slewing gear is integrated in the
base of the king along with the rotating part
of the slew bearing.
3.2.3 Crane jib system

The crane jib consists of a luffing main inner jib section and a knuckle jib section. Both jib elements are built
from plate elements, steel profiles and hollow sections. The main inner jib is connected to the king structure by
two main jib bearings at the top of the king and to the rod bearing of the cylinder in the lower end. The knuckle
jib is connected to the inner jib by two knuckle jib bearings and the hydraulic cylinder in the low/centre. Both
jib sections are hydraulically operated, each by one double acting, heavy duty marine cylinder with integrated
counter balance valves. The cylinder is connected to the jib system with composite bearings. The hydraulic
winch is installed on top of the cranes knuckle jib structure.
3.2.4 Jib / knuckle cylinder

The crane jib luffing motion and knuckle jib motion is driven each by one high quality luffing cylinder,
designed for marine use. The cylinder piston rod is chrome plated for improved corrosion protection. A load
holding valve is mounted directly to the cylinder ports to maintain a constant luffing speed independent of hook
load and to block the jib in case of a hose/pipe failure.
3.2.5 Slew gear and slew bearing

The slew bearing is a heavy duty marine slew ring equipped with internal gearing for transfer of the slew torque
from the output pinion of the slew gearbox.
The slew gear system consists of a hydraulic driven planetary gear with built in fail-safe dynamic multidisc
brakes. The brakes are dimensioned to take the full
load at the maximum list, plus any additional
dynamic force acting on the slew gear. In the case of
hose or pipe failure, the brake blocks the slewing
immediately. A heavy duty hydraulic motor is
flanged onto the gearbox. The slew motor, controlled
by the main control valve, and the counter balance
valve in the loop, give smooth and accurate slewing
of the crane.
3.2.6 Hydraulic system

Oil is supplied to the hydraulic gear pump from the
oil tank, or reservoir, integrated in the rotating part
of king. Its mounted on top of the adapter flange.
Between the shafts on the el-motor and the pump,
there is a flexible coupling in order to reduce the
torsion-vibrations.
The flexible coupling does also compensate for axial,
radial and angular shaft misalignments.
The figure shows a cross-section through parts of the pedestal and king (typical layout)
3.2.7 Hydraulic winch

The winch consists of a steel drum with a flanged on planetary gearbox driven by a hydraulic motor. The gear
box is fitted with fail-safe multi disc brakes. The brakes are dimensioned to take the full load plus any additional
dynamic forces acting on the winch. In case of a hose or pipe failure, the brakes will block the load
immediately. A counter balance valve is mounted in the winch loop ensuring smooth and accurate winch
operation independent of winch load.
The winch has a mechanical hook stop system. This ensures by-pass of hydraulic oil flow when hook reaches its
upper position. Excessive oil pressure will open a relief valve and oil is fed back into the hydraulic oil tank.
The winch is equipped with a galvanized non rotating wire rope and a counterweight/swivel hook of required
capacity.
3.2.8 Hydraulic oil tank

The hydraulic oil tank is integrated into the rotating crane
king. The high pressure, gear type hydraulic oil pump is
submerged in the oil tank to reduce the noise level to an
absolute minimum. The tank has a gauge glass for visual oil
level inspection, a breather filter, an oil return/filling filter
(photo at right) and a ball-type drain valve for use when
changing oil and cleaning of the oil tank.
A thermometer may also be included near the pump's
suction line.
Access to tank is possible through inspection hatch at the
crane king side.
3.2.9 Manual Overload Protection

System (Option)
The winch may optionally have a Manual Overload Protection System (MOPS) installed. The purpose is to
protect the crane against the effect of a gross overload during operation. If the winch is hooked on to another
vessel or to an object on the seabed and a power failure occur onboard the vessel it works by allowing the actual
hook to be pulled away from the crane in any direction without causing significant damage to the crane.
When the system is activated the winch will pay out wire. During the payout situation the winch maintains a
retaining force corresponding to the actual SWL.
3.2.10 Diesel HPU back-up (Option)

The diesel HPU back-up system consists of a standard marine diesel engine with an integrated fuel tank and an
auxiliary hydraulic pump feeding the hydraulic
system.
This back-up system can operate until the fuel is
depleted and makes it possible to operate all the
crane functions as normal though at reduced
speed.
Both jib operating speed and winch speed is
reduced because the diesel engine uses a smaller
pump and thus delivers less flow.
3.3 Electrical system

The structure of cranes electrical system is shown below. It is also enclosed in this manual in chapter 8.
CUSTOMER SUPPLY MacGREGOR SUPPLIED UNITS
LOCATED BY CUSTOMER Radio Remote Cabinet

GENERATOR SUPPLY LOCATED ON -RCC97
Remote Start / Stop
CRANE KING OPER. AND IND.: -W250.XYV1A 2x0.75mm
/503.E1
-XYV1 A MAIN JIB UP
-OP12.1 -W251.XYV1B 2x0.75mm
-XYV1B MAIN JIB DOWN
-OP12 /503.E2
- Power avail. lamp -W252.XYV2A 2x0.75mm KNUCKLE JIB IN
-XYV2 A
- Emergency Stop - Radio Remote Active lamp -W253.XYV2B 2x0.75mm
-XYV2 B KNUCKLE JIB OUT
- Stop
- Crane Control Local/Remote /503.E3
- Start -W254.XYV3A 2x0.75mm
-XYV3 A SLEW LEFT
- Start button
- Running lamp -W255.XYV3B 2x0.75mm
-XYV3 B SLEW RIGHT
- Stop button
3G1.5mm /503.E4
-W196 - Em.Stop button 2x0.75mm WINCH HOIST
-W256.XYV4A -XYV4 A
Stainless Steel Prot.shield
- Horn button -W257.XYV4B 2x0.75mm
WINCH LOWER
4G1.5mm -XYV4 B
-W195 - Horn
- Oil Heater OFF/Auto button /503.F5
- Oil Heater active lamp -W258 3G1.5mm
-XY1 CONST ANT TENSION
LOCATED INSIDE 3G1.5mm RESCUE BASKET

-W259 -S6
VESSEL ON/OFF
/503.F8
3G1.5mm RESCUE BASKET
-W260 -XY2 ON/OFF
Starter Cabinet
-ES400
OPERATION AND
INDICATION:
- Start button Slipring
- Stop button LOCATED INSIDE -JB450
LOCATED OUTSIDE
- Emergency stop button
- Motor running lamp
CRANE PEDESTAL CRANE PEDESTAL
- Motor heater lamp
- Hour counter
- Power available lamp
- Motor overload lamp
Radio Remote Consol
Junction Box
SUPPLY 3x690VAC, 60Hz Start/Stop Signal -W129 6+PE
-RCC97
ref. Note Motor -M01 -JB35
-W01 3+PE 3G1.5mm TRANSMITTING UNIT
Power -W194 -W193
OPER. AND IND.:
Total Power Consumption:
3+PE 4G1.5mm
37 kW (S1-100%) Start/Stop Signal -W191 -W192 - Start / Stop HPU
HPU Main Pump Motor
130x130x100mm - Main Jib Up / Down
/601.F1 - Knuckle Jib Out / In
DOL 3+PE u-v-w - Slew Right / Left
-W11 M
Heater 2+PE Heater 3~ - Winch Lower / Hoist
-W121
Therm
-M01
Thermistor -W122 2+PE - Emergency stop
- Warning Horn
Electrical Block Diagram (typical layout)
The electrical system comprises the following main elements:
Starter Cabinet ES400

Radio Remote Cabinet RRC97
Radio Remote Console RRC97.1
Remote Start/Stop Cabinet OP12
Warning horn E15
Main pump motor M01
Slip ring JB450
3.3.1 Starter Cabinet ES400

Starter cabinet ES400 (ref. to Electrical Block Diagram in chapter 8) enables start and monitoring of HPU
main pump motor. Its normally located inside the ship. Electric power for the starter cabinet is supplied from
the main electric plant on the vessel. Starter cabinet has the following functions:
Start, stop and emergency stop of the HPU motor

Thermistor based motor overload alarm (activated by thermistor relay)
Motor protection by means of thermistor relay in the starter cabinet
Power supply for anti-condensate motor space heater
Providing running hours counter reading
STARTER CABINET
-ES400
Motor Motor Motor Power mller

Running Overload Heater Available
-P1
00001 21 h
-H4 -H3 -H2

HR76.1
-H1
Hour Counter
Em.stop
START STOP
I 0
-S3 -S1 -S2
EMERGENCY
STOP
690V
Starter Cabinet ES400 (typical layout)
3.3.2 Radio Remote Cabinet RRC97

The Radio Remote Cabinet RRC97 is installed on the crane king. Radio remote cabinet is supplied with power
from the starter cabinet ES400 (located by customer inside the vessel). The radio receiver module sits inside,
connected to an outside mounted antenna. The cabinet has the following functions:
Power available lamp

Radio remote active lamp
Local/Remote switch
Start/stop buttons
Horn button
Emergency stop of the HPU motor
Power Radio Remote Rescue Basket Rescue Basket

Available Active ON OFF/ON
O
1
-H1 -H2 -H3 -S6
START STOP Horn

Local/Remote
-S1 -S2 -S4 -S5

Em.Stop
-S3
Typical Radio Remote Cabinet RRC97
3.3.3 Electromotor and slip ring

The electric power is supplied to the electric motor from the vessels main electric power plant. Power
connection is done to the centre located electric motor junction box inside crane pedestal. The electric motor is
mounted in suspension inside the crane foundation, just below the slew bearing. The electric motor shaft is
coupled to the pump shaft by a radial split flexible coupling. The electric motor is equipped with heating
element for moisture level reduction and PTC thermistors for excessive temperature protection.
The slip ring assembly for transfer of electric power to the rotating part of the crane is also mounted inside the
crane pedestal.
Below left: Electric motor and junction box visible from the pedestal access hatch.
Below right: Slip rings protrude from the top of a crane pedestal. The electrical junction box is mounted to the
framework beside them and the electric motor is partially visible in the pedestal beneath.
The electric motor is bolted to a framework in the top of the pedestal passing its rotating movement to the pump
via a flexible coupling. Electrical power is directed via the junction box, normally to a set of slip rings between
the stationary crane pedestal and rotating king above in order to transfer electrical power to functions on the
rotating crane. These are normally the PLC cabinet (base unit) on the king and any other electrical device such
as warning horns or jib-mounted lights.
3.3.4 Radio Remote -Control Terminal RRC97.1

Radio remote control enables the crane operator to control the crane from a distance. Radio remote control
comprises a portable RF transmitter unit, and a receiver unit installed in the remote control cabinet RRC97.
for the crane operator.
3.3.5 Operator platform

The crane has a platform placed at the side of the crane king, providing a safe working place with a good view
for the crane operator.
4 PRESERVATION, STORAGE AND INSTALLATION
4.1 Introduction
The purpose with these procedures is to:
1) Ensure that the units are handled / lifted in a safe and correct way in order to avoid damage to personnel
or equipment.
2) Ensure up to 2 years storage with quality, performance and total lifetime unaffected.
3) Ensure that the installation/first time start up, is performed in a safe and correct way.
4.2 Unloading and Handling

The crane is equipped with two pairs of lifting lugs for handling during installation.
Weight of crane is specified on supply list. Make sure that lifting gear with sufficient capacity is available
during installation.
The crane structure is normally delivered without any packaging.
The securing of cylinder is not to be removed until the crane is lifted onboard and made ready for installation.
4.3 Storage
The crane may be stored for 6 months without any preservation when stored indoor or under weather protection.
For storage beyond 6 months, we recommend that the crane is preserved acc. to 4.4 in this manual.
4.4 Preservation
Storage prior to installation (0-6 months):
The crane is delivered as shown in transport drawing.
When it is stored temporarily (until 6 month) before installation at site, following requirements for preservation
should be performed:
Item to be checked Preservation Performed Sign.

To be washed free from saltwater and dried
In general for all items on the
before being stored indoor or in plastic
crane
wrapping. Placed on wooden pallets
All loose hydraulic hoses and all
Plugged and blinded with solid metal plug
hydraulic component ports
Hydraulic cylinder rods,
Apply a thin grease layer
extended rods
All lubrication nipples All nipples to be filled with standard grease
To be temporarily protected by applying a

All machined surfaces without
thin tectyl or grease layer. To be washed off
surface protection
before installation
Gear box Filled to normal oil level
All outside machined surfaces for

interconnection to substructure
Waxed or treated with a tectyl product
Check that all parts of crane is fully painted,

Paint, in general
according to procedure
Storage beyond 6 months:

Same procedure as for 0-6 months, including following additional points:
1. All checkpoints according to table above to be performed every 6th month.

2. Lubrication applied at every lubrication point on the crane each 6th month according to chapter 6 in this
manual.
3. Power supplied to the el. motors internal space heater elements. This is to prevent condensation in el.
motor.
4. All packages with electrical components to remain unpacked and stored indoor to maintain dry conditions.
4.5 Installation
4.5.1 Welding to deck structure

HM cranes are normally delivered for welding directly to deck or some other type of substructure.
As a minimum requirement the deck structure must be designed to withstand the cranes maximum bending
moment with necessary safety factor. (See general arrangement for forces to substructure)
CHECK THE FOLLOWING:

; Deck structure must be free from cracks, rust, oil and other elements that will inhibit welding of foundation
to surface.
; The foundation is equipped with a groove at deck, as a minimum this groove must be filled. Welding must
be done only by certified welders.
; Prevent any kind of particles, dust or other pollution from contaminating the hydraulic system
4.5.2 Electrical installation

The crane is delivered as a complete unit with the electromotor built into the crane base. The motor is equipped
with heating element(s), which must be "on" when the crane is not in use.
Work is only permitted to be carried out by qualified specialists on the stationary motor, while disconnected and
prevented from being switched on again. This also applies for the auxiliary power circuits (e.g. Anti-
condensation heaters).
CHECK THE FOLLOWING before start up of system:

; Connect the electromotor in accordance with the electric starter diagram. The crane is running in S6-40%
mode according to NVE-1990-FEA-M
; Always check el. connection with the motor sign
; Connect electric starter and remote start/stop in accordance to the electric starter diagram
; Provide a drain in the foundation in order to avoid damaging the electric motor, due to condensation etc.
; Certified electrician to be used
4.6 Filling of hydraulic system oil

After installing the crane onboard, fill hydraulic system oil on tank located in crane king. The hydraulic oil shall
be filled through a quick release coupling placed at the systems oil filter. Oil filter is placed in crane king.
Fill the approved hydraulic system oil into tank. The oil level should be visible at all times. (To be filled to top
of level glass).
Always use new, clean oil. Under no circumstance water, dirt or other impurities must be allowed to enter the
tank. Impurities and moisture will reduce the efficiency and shorten the lifetime of the hydraulic system.
4.7 First time start up

As a final check before first time start up, check the rotation of the electric motor. This is done by a SHORT
start of the motor while observing the rotation. If the rotation is wrong, interchange 2 phases and check again.
It is very important to ensure correct rotation direction for the

hydraulic pump before taken into service. Any discrepancy
between indicated rotation on electromotor and pump must be
clarified with Cargotec Norway AS prior to start up of new or
changed equipment.
The hydraulic pump must not be allowed to run in the wrong direction, as this will seriously affect its life span.
Some air will be present in the system when its started for the first time. Let the power pack run for a couple of
minutes with no load in hook, shut down for 10 minutes and restart. The winch and the slew will automatically
release air from its system when operated. Be sure that all air in system is ventilated before any load is applied.
Upon completion of initial test run, check the oil level in the system oil tank and top up if necessary.
4.8 Functional and load test

Execute all functions mentioned in the commissioning test procedure (enclosed), before the crane is taken into
normal operation.
The committed tests are usually a normal function test and a load test for 1.25 x SWL.
4.9 Commissioning test procedure
MacGregor Crane - HAT procedure
Customer Supplier Project number, supplier

Hellesy Verft Cargotec Norway AS SP2423-1
Andyveien 23
NO-4623 Kristiansand Project name, customer
NORWAY Bygg 150
P.O. number, customer
HAT Procedure
Equipment: MacGregor Shipboard crane
Type: HMC 1400 LK 30-18(50-15)MOB27
Harbour / Commisioning acceptance test procedure in accordance with

DNV Lifting appliances- Standard for certification No 2.22
Revision Description Date Author Checked by

0 Issued for use 30.03.2012 OHA RMA
This document and all information and data herein or herewith is the confidential and proprietary property of Cargotec 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 Cargotec Norway AS.
Cargotec Norway AS
www.cargotec.com
Pages: 6
SP2423-1 HAT 1
CONTENT
1. INTRODUCTION
2. PREREQUISITES
3. FUNCTION TEST EMPTY HOOK
4. OVERLOAD TESTING
5. TESTING OF MONITORING AND SAFETY DEVICES
6.TESTING OF RADIO REMOTE CTRL
7. AFTER TEST
8.APPROVAL OF COMPLETED FAT / SIGNATURES
9.DEVIATION AND PUNCH LIST
Abbreviations
KJ : Knuckle Jib
MJ : Main Jib
CT : Constant tension system
AOPS : Automatic Overload Protection system
MOPS : Manual Overload Protection system
SWL : Safe Working Load ( Rated load / capacity /Actual hook load for given condition)
Ls : Load sensing
SP2423-1 HAT 2
1.1 Introduction
This document describes the test after installation for MacGregor crane according to specific regulation.
The crane is designed in accordance to DNV Lifting appliances- Standard for certification No 2.22
1.2 References
Ref General Arrangement drawing : C.1400.153.GA01
1.3 Specification
Load (Metr tons) Max outreach (m) Test load (Metr tons)
Main winch 5 15 6,25

Safe Working single line:
Load (SWL): Rescue
basket 2,7 10 2,7
mode
Main winch
NA NA NA
double line:
Project no: SP2423-1

Client: Hellesy Verft
Project Bygg 150
Test site: __
Test date:
Project manager: Bjrn Aamold
Test manager:
Client Repr.
Approving auth.
All loads in this document are specified in metric tonnes ( t )
NOTE! The speeds mentioned in this technical specification are based on average volumetric
efficiencies provided by our suppliers of hydraulic components. A speed tolerance of +10 to -5% is
within the accepted range and should be taken into consideration.
If electrical power / frequency at test stand differ from the specific for the particular crane, an
estimate for corresponding speeds during test has to be calculated / provided for verification.
SP2423-1 HAT 3
MacGregor Crane- HAT procedure
2 PREREQUISITES
Ref.: Description of activity: Specified data: Verification: Accepted
2.1 Crane is welded / bolted to vessel Heel: 0 degr.
fundation according to drawings
Trim: 0 degr.
2.2 Certified test weights needed for load Weight according to
testing shall be made available load/overload test
2.3 Main supply:
3x690V
Crane is hooked up to vessel el
60Hz
power suply
Aux. supply:
NA
2.4 Check of Oil Levels - System oil
Levels to be checked and top up if
required after first start up
2.5 Visula check of hoses / pipes Check for acceptable routing
2.6 Electric motor

- Verify correct rotation direction on
motor(s)
3. FUNCTION TEST, NO LOAD

3.1. Main Jib / Knuckle Jib
3.1.1. Move main jibs in extreme positions. Check for clearances in steel
structure, and that hydr.
Hoses or el. cables are not
squeezed
3.2. Main winch up/ down Check rotating drum for
clearance and wire guidance
in sheaves and brackets.
3.2.1. Check hook stop in upper position Movements stops when

upper limit is reached.
3.2.2. Check movement when emergency Movement stops when
stop is activated emergency stop is activated.
3.3. Slew motion

3.3,1 Slew the crane in both directions
- Verify slew in all positions
3.3.2 Slew crane both direction to check Verify function of slew limit
slew sector valves CW / CCW ( slew
stops)
SP2423-1 HAT 4

4. OVERLOAD TESTING
4.1. Test Load ( t ) Max reach (m)
6,25 15
4,1,1 Winch lifting performance
- Operate winch down, and verify
control performance Stop lowering and keep load
- Verify brake holding function in air for 2 min
4.1.2 Jib performance
-Operate Jib(s) in all positions
according to Load chart / GA drawing
4,1,3 Slewing performance

Testload to be slewed 360deg at
max radius ( maximum possible slew
sector to be tested)
5 TESTING OF MONITORING SYSTEM AND SAFETY DEVICES

5,1.
Emergeny suply pump system
5.1.1 Check availibility of emergency
operation procedure
5.1.2 Simulate main / utility power failure Testload =SWL
and operate the crane by means of Check movement of all
the pump system according to basic crane function.
procedure
5,1,3 Disconnect emergeny power and
h k crane on normall power suply
check l
SP2423-1 HAT 5

6 TESTING OF RADIO REMOTE CTRL
Select " Remote ctrl " from cabinet
6.1 and verify that remote ctrl is
operational
Verify correct operation of functions

6.2 by using portable panel
7. AFTER TEST
7.1. Visual check for physical and Visual check by competent
structural damages after testing. person
7.2. Visual inspection of crane Oberve leakages, safety rails
, painting etc.
7.3. Check / adjust winch Ls relief valve
to original setting if adjusted during
HAT
8. APPROVAL OF COMPLETED TEST AND SIGNATURES

Representative Name Signature Date
Cargotec Norway AS
9. DEVIATION AND PUNCH LIST

No: Description and correction Ref. Date Sign
1.
2.
3.
4.
5.
6.
7.
8.
9.
SP2423-1 HAT 6
5 OPERATING INSTRUCTIONS
5.1 Start up of crane
5.1.1 General check before start

Before the crane is started and a new lifting operation is performed the operator must check the crane to make
sure its fit and ready for the job.
The following conditions are to be checked by the operator but are not limited to:
1. Weight, COG and shape / added mass of the load(s) to be lifted.
2. Weather / environmental conditions.
3. Evaluate if the actual lift job is secure with respect to pts. 1 and 2.
4. Check that lifting- / loose gear is fit for purpose by a visual inspection of equipment and certificates.
5. A visual check of crane, wires, wire sheaves, engine room with pumps, hoses, oil tank level and
valves. Check for leakages, visual defects etc. before start up.
5.1.2 Check before and during operation

Make sure that starter cabinet (customer supply) is powered from the vessel. If not, provide starter cabinet with
power. No crane operation is possible until the electric motor is running.
The following conditions are to be checked by the operator but are not limited to:
1. Communication between crane operator and slinger is satisfactory.
2. Correct function of crane control system, limiting devices, indicators and protection systems (when
applicable).
3. A plan is made for safe lifting operation. Correct crane lifting mode to be selected considering the
environmental conditions within the given limits, correct use of slings, shackles, chains etc.
4. Pay attention to the crane control system and respect the warnings and alarms given by the system
(when applicable).
5. Check that the crane is fit and rigged for the actual job. Winch, single part, double part, hook height
above deck, actual radius etc.
6. Deck area for pick up and landing of loads and the routing between must be checked for
obstructions, clear view and maximum load impact limitations to deck.
5.1.3 Start up
The HPU motor is operated either from the Radio Remote Cabinet RRC97 (on the platform banister), the
portable radio transmitter unit RRC97.1, the Starter Cabinet ES400 (located by customer inside vessel) or the
Start/Stop panel OP12 (located by customer).
1. From Radio Remote Cabinet RRC97

First:
Check for lit white indicator lamp POWER AVAILABLE
Turn switch CRANE CONTROL LOCAL REMOTE to LOCAL position
Then:
push green START button to start HPU motor
When pump is running, the crane is ready for operation.
2. From Radio Remote Console RRC97.1

First:
Turn switch CRANE CONTROL LOCAL REMOTE to REMOTE position
Then:
activate the unit by turning key switch to ON position
Check for lit blue lamp RADIO REMOTE ACTIVE on RRC97, indicating established
contact with receiver in Radio Remote Cabinet RRC97
push START button to start HPU motor
3. From Starter Cabinet ES400

First:
Then:
4. From Start/Stop Panel OP12

First:
Then:
Check for lit green lamp Motor Running
5.2 Operating the crane

The crane is normally operated from an operator platform or from an optional radio remote control unit. The
optional high quality radio remote control system includes a heavy-duty lightweight portable unit for full step
less control of all crane motions.
The hydraulic control levers are located on the platform banister and operates the main proportional control
valve inside the crane king. The valve consists of the following sections (see picture below):
Slew left/right, Knuckle jib in/out, Main jib up/down, Winch up/down
The hydraulic lever operated control valves (typical layout)
5.3 Safety instructions

Never handle loads exceeding the winch lifting capacity. The jib system is able to lift heavier loads at reduced
radius. When lifting heavy loads always make sure that the winch is able to handle the load before any further
jib operation.
Always observe the risk of collision with superstructures when slewing. Be careful when override is used.
5.4 Safety functions built into crane system
5.4.1 Emergency stop

There are several emergency stop push buttons and one lever operated in the system. All emergency stop push
buttons are hardwired to stop pumps immediately. The emergency stop pushbuttons are of push pull type and
are found on these locations:
Emergency stop 1 sits on the Starter Cabinet (ES400)
Emergency stop 2 sits on the Radio Remote Cabinet (RRC97)
Emergency stop 3 sits on the Radio Remote Console (RRC97.1)
Emergency stop 4 sits on the Remote Start/Stop Panel (OP12)
Emergency stop 3 is functional only when the radio remote control is activated.
Activating emergency stop 1 to 4 will immediately stop the main pump and the pressure will drop.
5.4.2 Hook stop

The winch system is fitted with a hydro-mechanical hook stop up system. As the hook is hoisted into the
hook-stop a valve is triggered, stopping the hoisting function.
5.4.3 Spring centred control valves

All control levers, separate and joy stick type, except Rescue Basket selector and MOPS (option), are spring
centred. In order to operate the crane the relevant control lever has to be pushed in the required direction to
cause the desired motion. Once the lever is released it will return to its centre position, and the activated motion
will stop immediately.
5.4.4 Overload protection

The crane is protected from overload by hydraulic relief valves. If a particular motion that exceeds the designed
crane load is tried, the relief valve relevant for the particular motion will feed a return flow of the hydraulic oil
into the oil tank. Hence, the crane motion is disabled and cannot be executed. The load is also monitored by a 6
ton load cell.
5.4.5 Luffing cylinder limitation

The hydraulic cylinder for luffing of the crane jib is fitted with a mechanical stroke limitation. The limitation
allows the luffing to be executed at full speed.
5.4.6 Load holding brakes

The hydraulic cylinder for luffing of the crane jib section is fitted with pilot operated load holding valve. The
valve is mounted directly to the cylinder port and has a dual function:
1 Maintaining the luffing speed at a constant value independent of the load
2 Blocking the cylinder motion in the case of hydraulic pressure loss. This will freeze the cylinder
in case of a hose or pipe failure.
5.4.7 Fail safe brakes

All crane functions which include a drive gear (winch and slew functions) are fitted with hydraulically operated,
oil submerged, failsafe, multi disc brakes. This means that hydraulic pressure releases the brakes internal spring
pressure for normal operation. If hydraulic pressure is lost, the hydraulic system (motor) inhibits movement
(assuming no significant leaks). In addition, the brakes plate springs compress the brake discs, locking the
brakes. Its important to note that the brakes do not stop the motion - they are static brakes designed to HOLD
the STOPPED drive system.
5.5 Radio remote control system

Radio remote control system comprises a radio remote cabinet RRC97 and RF transmitter unit RRC97.1. An
RF communication device sits inside the radio remote cabinet RRC97 and its connected to an outside
mounted antenna.
5.5.1 Radio remote cabinet RRC97

Before any radio remote operation is carried out, be sure the listed conditions are met:
RC Cabinet RRC97:
Lit white indicator lamp POWER AVAILABLE
Switch LOCAL REMOTE to REMOTE position
Radio transmitter unit switched on. Check for lit blue lamp RADIO REMOTE ACTIVE,
indicating an established connection.
Power Radio Remote Rescue Basket Rescue Basket

Available Active ON OFF/ON
O
1
-H1 -H2 -H3 -S6
START STOP Horn

Local/Remote
-S1 -S2 -S4 -S5

Em.Stop
-S3
Radio Remote Cabinet (typical layout)
5.5.2 Radio transmitter unit -RRC97.1
C A
D RF Transmitter unit (typical layout) E
A EMERGENCY STOP push button
B Activation key and cable connector

C System status yellow LED
D Speed selector
E Warning horn
The transmitting unit is equipped with two joysticks:

C
Left joystick: Slew left/right
Main jib up/down
Right joystick: Knuckle jib out/in
Winch up/down
Power on and starting

Check that unit has a fully charged battery and that EMERGENCY STOP button on the right hand side is not
engaged (pushed). Turn the key on the left hand side to ON position. After a short self test the terminal will
establish contact with the base unit.
The transmitter unit switches on only if the battery is sufficiently charged

and all the actuators are inactive.
Commands
It is possible to control the crane only when the transmitting unit is radio linked to the receiving unit (signalled
by lightning up of ENABLE pilot light on the receiving unit (see chapter 10 Radio Remote Control User
Manual).
Start also activates warning horn -E15 (see Loop Diagram 502 in chapter 8). This horn can be used to alert
people in vicinity of the crane. Do not hesitate to alert possible dangerous situations with the horn.
Start/Stop Hydraulic Power Unit

Push the Start HPU button to start hydraulic power unit.
Push the Stop HPU button to stop hydraulic power unit.
Emergency STOP
To immediately stop the crane, press the EMERGENCY STOP button; the transmitter unit switches off and an
emergency security circuit stops hydraulic power unit.
To resume operation, disengage the EMERGENCY STOP button and repeat the power on and starting
procedure.
Using EMERGENCY STOP button is mandatory when the crane has to be stopped
immediately to avoid a dangerous situation
LED signals
Some transmitting unit operating conditions are indicated by a yellow signaling LED:
TYPE of SIGNAL LED Action
Steady light Normal operation None
Slow flashing Low battery voltage Replace battery
Replace radio
3 flashes with a stop Radio fault
module
Turn terminal OFF

6 flashes with a stop Inactivity shutdown
and ON to resume
For complete legend, see chapter 10
When the battery is nearly discharged, the LED will start flashing. In this situation, the operator must return the
machine to a safe condition by switching off the transmitting unit or pressing the Emergency Stop button.
Recharge the battery and/or refit a fully charged battery.
Constant tension
In normal operation the constant tension mode can be selected for hoisting, after the cargo is connected to the
hook. The CT mode is designed to increase safety and comfort by eliminating slack-wire when the cargo is
connected to the hook and riding the waves.
Power off
Turn the key to OFF.
Always remember to remove the starting key and put it in a safe place.
Automatic power off

The transmitting unit will switch off automatically when:
- the battery is not sufficiently charged and/or
- the radio remote control is remained unused for 3 minutes
Recharging the battery

Remove the battery from the transmitting unit and insert it to the battery charger. The ON CHARGING
tricolor LED will illuminate red to indicate charging of the battery. Once the battery is fully charged, the LED
will illuminate green. Leave the battery in the charger until needed. If battery or charger is outside the
temperature range +10 C to +40 C, the LED will illuminate yellow and charging will fail.
See chapter 10 for further instructions, warnings and technical data

regarding batteries and battery charger.
Wire control
Its possible to operate the crane from the Radio remote unit in non-radio mode. It is called Wire control. In
this mode battery may be removed from the transmitting unit. Supplied purple coloured cable is intended for
wire control.
Operator should connect operator panel and transmitting unit by means of wire control cable.
Radio remote cabinet RRC97 is equipped with a cable connector (see picture below). It is typically mounted in
the enclosure bottom, next to the antenna.
Underside radio remote cabinet RRC97 (typical layout)
Follow the instructions to establish wire control:
1) Remove connector plug cover from the cable connector on the bottom of RC cabinet RRC97 (see
picture above). The cover is removed by turning it CCW
2) plug cable into cable connector on RC cabinet RRC97
3) remove connector plug cover from transmitting unit RRC97.1 cable connector
4) plug cables loose end into connector on RRC97.1 transmitting unit, left side
5) proceed with power on and starting procedures: turn the key to ON
6) push START HPU to start HPU motor
7) perform crane operations by using joysticks
8) when crane operations are finished push STOP HPU to stop HPU motor
9) turn the starting key to OFF. Always remember to remove the starting key and put it in a safe place
10) unplug cable both from transmitting unit and operator panel
11) replace connector plug covers
12) keep the cable in a safe place
5.5.3 General warnings regarding use of radio remote control
The operator must only utilize the radio remote control when this manual is read and fully understood
and necessary skill is obtained through adequate training
Every time the transmitting unit is powered, ensure that Emergency Stop button operates correctly.
When pressed, crane movements should instantly be interrupted. If this doesnt happen, dont use the
radio remote control
The operator should always check for damages on units, including gaskets, bellows and hoods of
actuators (joysticks, selectors, pushbuttons). If any, the radio remote control must not be used until
required repair is done
To work efficiently and to prevent possible emergency situations, it is necessary to select a position
from where it is possible to:
remain within the typical working range of the radio remote control
visually follow the crane, its movements and a possible load at all times
During operation
The operator must:
switch off the transmitting unit each time work is stopped
NEVER leave the transmitting unit unattended with the starting key inserted
avoid working if the battery is almost flat
The operator should never switch on and activate the transmitting unit unless ready to start working.
A radio link may establish even outside the active range and from enclosed places, making the radio
remote controlled crane carry out undesired commands.
In case of danger
If a dangerous situation arises, the operator must intervene immediately by pressing the
EMERGENCY STOP button, which instantly interrupts crane movements.
As not all damages are caused by the radio remote control + crane system, the operator should
always be careful and alerted towards potential emergency situations within the working area. The
operator should, also in this case, intervene manually by a activating the EMERGENCY STOP
button.
In case of fault
In case of faults or damaged parts, ALWAYS STOP the radio remote control + crane system until
the problem has been solved. Damaged parts can be replaced ONLY by personnel authorized by
manufacturer, utilizing original spare parts.
5.6 Precautions during operation

Even though the crane is designed, built and tested to ensure maximum security, the operators attention and
skill is crucial for a safe operation.
Personnel intended for operation need training in order to maintain this safety level. Upon request, Cargotec
Norway AS will offer training for personnel.
6 MAINTENANCE
Maintenance!
During the warranty period, all maintenance described in this
user manual must be carried out and documented. Either in the
enclosed maintenance log or in the vessels maintenance log.
Lack of documented maintenance violates and forfeits the
warranty.
6.1 Routine maintenance

Cargotec Norway AS has developed a periodic maintenance program in accordance with the suppliers
maintenance program for each of the crane components. Adhering to this program will ensure long-time,
trouble-free operation and significantly reduce unexpected problems.
During the warranty period, maintenance performed on the equipment must be documented, either in the
maintenance log provided by Cargotec Norway AS, or in the vessel's own maintenance log. All maintenance
action specified by the program belongs to one of the following categories:
1. Lubrication
2. Inspection
3. Overhaul
4. Replacement
Lubrication: Lub. includes the following:
Apply grease to grease nipples
Apply lubricant or oil to surfaces to minimize friction or corrosion
Refill or change oil to system or component
Inspection: Insp. usually involves running the equipment and includes the following:
Check component for any damage
Check for correct function of each component
Check for deviant noise from each component
Check for any abnormal vibration from rotating components
Check for correct oil quantity
Check paint condition on all components
Check for leakages
Check for corrosion
Check lifting wire for wear
Overhaul: Ovhl. includes the following:

Remove the component from the unit
Disassemble the component and inspect each part
Repair if necessary:
o Bearings
o O-rings, gaskets and seals
o Wear of mechanical parts due to friction
o Hydraulic valves fittings and hoses
o All fasteners (bolts, nuts, washers etc)
Clean all components before reassembling the assembly
Replace or repair components as required, before reassembling the assembly
Repair any paint damage
Replace: R. REPLACE DOES NOT MEAN REPAIR. Replace includes the following:
Remove original component and exchange with a new component.
The time intervals listed below are generally based on equipments running time.
Equipment or parts of it exposed to weather, chemicals, heat, vibrations or other impacts apart
from normal wear and tear from running will require additional attention.
From time to time and at least once a year, we recommend checking the hydraulic system oil.
Regular checking of oil will help keep the hydraulic system in excellent condition and reduce the
need to change the oil. We recommend that a sample of the oil is sent to a recognised laboratory
(oil company) or to Cargotec Norway AS who will perform an analysis and evaluate the quality of
the oil. The result of the analysis will decide whether the oil will have to be replaced or processed.
As a general recommendation all hydraulic hoses should be replaced as follows:

o Outdoor conditions every 5 years
o Indoor conditions every 10 years
Maintenance log!
During the warranty period, either the enclosed maintenance
log or the vessels own maintenance log should be used to
document crane maintenance as this will be called upon
should a warranty issue occur.
6.2 Periodic Maintenance Program

Cargotec Norway's 1Y and 5Y inspections should be done in conjunction with the customer's own inspections.
Notes: H=hours, W=Weeks, M=Months, Y=Years.
PERIODIC MAINTENANCE PROGRAM
Equipment Lub. Insp. Ovhl. R. Action
General inspection for hydraulic system leakages
1M
Quantity of oil, to be in top of level glass
1 All functions including winch
General Emergency operation (if applicable)
Inspection Accumulator oil pressure (if applicable)
Check for structural damage, corrosion and paint condition.
6M
Check for damages to lifting equipment and wire
Apply grease to all grease nipples. Include wire sheaves,
1M/ 100H
2 cylinders, el. motor and docking head (if applicable)
Grease nipples Inspect for proper function, damage & corrosion.
3M/ 100H
(General) Remove excess grease.
! Replace if damaged
3 1M/ 100H Apply special grease to drive pinion and ring tooth
Winch/slew gear 1Y/500H Check for wear / abnormal tooth clearance
drive pinion ! Replace if damaged
3M/200H Apply grease onto wire
Inspect for corrosion & wear. Rub length of wire with a
4 1M/ 200H
cloth to detect broken strands
Steel wire rope
3M/ 100H Inspect wire secured to winch drum and check torque.
Inspect for corrosion, wear, cracks. Check bolts. Inspect
5 6M/ 200H
that wire sheave rotates freely
Wire sheaves
6M/ 200H Inspect general condition. Check nitrogen pressure value
6 according to flow diagram. Use MacGregor manometer
Accumulators fill/check instrument. Check mounting bracket (bolts, nuts)
(If mounted) Overhaul or replace if unable to hold the necessary charge.
! !
Contact Cargotec Norway.
7 Inspect all exposed cylinder rods. Must be free from dirt,
6M/ 200H damage and other foreign contaminants. Check condition
Cylinders (paint, leaks, corrosion)
Inspect for deviant noise, vibration and leaks. Inspect
8 3M/ 100H
valves (paint, leakages & corrosion)
Winch/slew
5Y Overhaul component
motor
Inspect for deviant noise and vibration. Tighten bolts if
3M/ 100H
required. Inspect general condition (paint, leaks, corrosion
9
3M/ 50H Check gear oil level
Winch/slew
1Y Change oil
gearbox
5Y Overhaul component
10 3M/ 200H Inspect for deviant noise, vibration, corrosion, leaks
Electromotor, 3Y/5000H 5Y Overhaul the component
hydraulic pump,
HPU ! Replace if damaged
PERIODIC MAINTENANCE PROGRAM

Equipment Lub. Insp. Ovhl. R. Action
11 Sliding
3M/200H 3M/200H 1Y Check for wear, apply grease, adjust sliding pads
surfaces
12 6M/ 200H Check condition of hoses
Hydraulic hoses,
fittings, couplings
Inspect for deviant noise or function.
6M/ 200H Inspect condition (paint, leakages, corrosion)
13
Apply grease to the valve levers (the rubber cap must be
Hydraulic valves removed and replaced)
14 Inspect the entire crane for structural damage. Check for
6M/ 200H
Mechanical corrosion. Inspect paint condition
components ! Replace if damaged
15
Check oil level and take oil sample for analysis. Change if
Hydraulic system 1Y
necessary
oil
6M/ 500H Inspect filter for abnormal contamination. Note 1
16
6M
Hydraulic oil
/50 Replace
filter
0H
17 Inspect all bolts and nuts on davit. Foundation bolts
6M/ 500H
Bolts and nuts especially
Note 1: This inspection action is added IN ADDITION to the replacement action in order to ensure that
special attention is paid to the quality / possible contamination of the oil when the filter is replaced.
6.2.1 Steel wire ropes - care and maintenance, inspection and discard
A wire rope on a crane is regarded as an expendable component, requiring replacement when the results of
inspection indicate that its condition has diminished to the point where further use would be unwise from a
safety standpoint.
By following well-established principles, such as those detailed in ISO 4309, along with any additional specific
instructions provided by the manufacturer of the crane or hoist and/or by the manufacturer of the rope, this point
should never be exceeded.
In addition to encompassing the guidance on storage, handling, installation and maintenance, ISO 4309 also
provides discard criteria for those running ropes which are subjected to multi-layer spooling, where both field
experience and testing demonstrate that deterioration is significantly greater at the cross-over zones on the drum,
than at any other section of rope in the system.
When correctly applied, the discard criteria given in ISO 4309 are aimed at retaining an adequate safety margin.
Failure to recognize them can be extremely harmful, dangerous and damaging.
On delivery the wire ropes have received offshore lubrication, i.e. all strands and core is heavy lubricated during
core closing, rope lightly lubricated during final closing (to avoid trapping water 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 wire sheaves.
Compacted strands means high wear resistance, high transversal stiffness and corrosion resistance.
When to inspect
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 of unwanted situations below).
NOTE!
Any deterioration, resulting in a suspected loss of original rope strength, should be carefully
examined and a decision made as to whether further use of the rope would constitute a safety hazard.
PERIODIC MAINTENANCE
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 moist can penetrate, thus becoming trapped inside.
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.
Recommended maintenance (lubrication)

A high pressure wire lubrication system (e.g. Masto lubrication
system, see figure below) will maintain a good wire rope condition
by penetrating the entire cross-section which is necessary to keep
friction low and corrosion away.
The frequency of lubrication depends on the environmental
conditions in which the wire rope operates along with usage and
the result of the routine inspections. Generally, if the wire rope
appears dry, lubrication should be initiated. As a minimum, check
every 3rd month if the wire rope shows signs of lubrication
deterioration.
Masto wire lubrication system
Wire protrusion
External corrosion
Crown wire breaks Strand protrusion
Kinked wire
Local increase in rope diameter due to core distortion
Basket deformation (Birdcage)
6.2.2 Bolts slew and foundation
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.
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 6th month interval, the knock-test and re-tensioning can be performed every other time.
T0001 Tightening Torques & Bolt Tensioning Forces: See the following pages.
TECHNICAL REQUIREMENTS
This document and all information and data herein or herewith is the confidential property of Cargotec 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 Cargotec Norway AS.
Cargotec 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
MGHM doc. no.:
T0001
K2 CARGOTEC NORWAY AS
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 mechanics judgment.

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

Typical applications of this document are mostly MacGregor Hydramarine 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 there are no charpy test
requirements. 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 are no charpy test
requirements. 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.
CARGOTEC NORWAY AS K3
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 25 mm has no charpy test
requirements. The requirements for bolts from 25 mm are 42J for offshore applications and 25J for
other applications Test temperature (Td) is normally -20 C for offshore cranes and -10 C 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 Nm. 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.
K4 CARGOTEC NORWAY AS
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/mm 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=0.9F0.2 F0.2 FM=0.9F0.2
mm mm mm 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 A 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.
The bolts should be long enough to leave at least 1d above the nuts free for positioning the tension cylinder.
CARGOTEC NORWAY AS K5
6.2.3 Electromotor
Irrespective of the operating hours, the grease should be changed due to aging after commissioning at least on
the occasion of the main inspections (approx. every 3 years). Some of the motors have a separate nameplate
with information about the bearings and the lubrication intervals. In the case of motors operating under special
conditions, such as vertical motor position, frequent operation at maximum speed nmax, heavy vibration, sudden
load changes and frequent reversing operation, the bearing should be changed at considerably more frequent
intervals than at the operating hour stated above.
Type of grease for standard machines: (Fa. ESSO / UNIREX N3).
Special greases are introduced on the lubricating data plate.
LUBRICATION LNNE MOTORS

Motor size Poles DE-bearing NDE-bearing
4AP 56 2 to 8 6200-ZZ C3 6200-ZZ C3 The motors are permanently lubricated;
7AA 56 2 to 8 6201-ZZ C3 6201-ZZ C3 the grease lifetime is, for mean temperature 25 C
4AP 63 2 to 8 6201-ZZ C3 6201-ZZ C3 * 2-pole motors 20 000 h
7AA 63 2 to 8 6201-ZZ C3 6201-ZZ C3 * 4-pole motors and higher 40 000 h
7AA 71 2 to 8 6202-2Z C3 6202-2Z C3 The bearing lifetime is the grease lifetime for
7AA80 2 to 8 6204-2Z C3 6204-2Z C3 enclosed bearings (2Z).
7AA90 2 to 8 6205-2Z C3 6205-2Z C3 The nominal bearing lifetime is 100 000 h for
7BA/7AA100 2 to 8 6206-2Z C3 6206-2Z C3 a coupling drive
7AA112 2 to 8 6206-2Z C3 6206-2Z C3 At speeds up to 1800 rpm: 15 000 hours
7BA112 2 to 8 6306-2Z C3 6306-2Z C3 At speeds above to 1800 rpm: 7 500 hours
7AA132 2 to 8 6208-2Z C3 6208-2Z C3
7BA132 2 to 8 6308-2Z C3 6308-2Z C3
7AA160 2 to 8 6209-2Z C3 6209-2Z C3
7BA160 2 to 8 6309 C3 6309 C3 Lubrication Poles Interval 40C
14BG 180 2 to 8 6310 C3 6310 C3 160-180 2 4000h/20g
14BG 200 2 to 8 6312 C3 6312 C3 160-180 4,6,8 8000h/20g
14BG 225 2 to 8 6313 C3 6313 C3 200-225 2 4000h/20g
14BG 250 2 to 8 6315 C3 6315 C3 200-225 4,6,8 8000h/20g
250 2 4000h/25g
250 4,6,8 8000h/25g
14BG 280 2 6217 C3 6217 C3 280 2 4000h/25g
14BG 280 4 to 8 6317 C3 6317 C3 280 4,6,8 8000h/30g
14BG 315 2 6316 C3 6316 C3 315 2 3000h/30g
14BG 315 4 to 8 6319 C3 6319 C3 315 4,6,8 6000h/40g
6.3 Standard Inspection form for Crane
Inspection report :
Machine : SP2423-1
(Use a copy of this report for each inspection)
Object Inspection date Checked by Condition Actions taken
General Inspection
Grease nipples
Winch / slew gear pinion
Wire and hook
Wire sheaves
Accumulator (if mounted)
Cylinders
Winch / slew motor
Winch / slew gear box
Electromotor / hydr. pump
Sliding surfaces
Hydraulic hoses, fittings etc.
Hydraulic valves
Hydraulic system oil
Hydraulic oil filter
Bolts and nuts
Paint condition
General Inspection
This report should be copied, filled in for each service interval and filed onboard
6.4 Monthly inspections

Crane type :
HMC 1400 LK 30-18 (50-15) Inspection date Checked by Condition Actions taken
Inspection report :
10
11
12
13
14
15
16
17
6.5 Lubrication instructions
Quality of lubricants
Use the following specifications when servicing the hydraulic parts:
LSS-01 Lubrication nipples is general

LSS-02 Wire and sliding surfaces
LSS-03 Slew gear box
LSS-04 Winch gear box
LSS-05 Hydraulic system oil
LSS-08 Drive pinions
LSS-11 General purpose grease
LSS-21 HM Winch
LSS-22 Electric motor
These "Lubrication Specification Sheets" are standard documents explaining lubricant details. They are referred
to in the following lubrication chart drawing.
Quantity of lubricants
Grease nipples: Lubricate until grease is visible in area (ex. el. motor)
Hydraulic system oil: Approx. 600 litres
Winch-gearbox: Approx. 4 litres
Maintenance system for MacGREGOR Hydramarine
products
Doc. ID. : Rev. / date : Page:
TEK-MEC-WI-001-LSS-01 02 / 28.04.09 1 of 1
nipples
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 :
products
TEK-MEC-WI-002-LSS- 03 / 28.04.09 1 of 1
02 wire
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 :
products
TEK-MEC-WI-003-LSS-03 slew 03 / 28.04.09 1 of 3
gear BRE
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.
products
gear BRE
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

products
gear BRE
Lubricating Instruction:
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.
products
LSS-04 winch BW5200.doc 01 / 23.09.03 1 of 2
HYDRAMARINE STANDARD LUBRICATION SPECIFICATION
Specification no. :
LSS- 04 BW5200
WINCH
Specified in lubrication instruction next pages.
DIN 51517 / 3 CLP

ISO VG 150
Texaco MEROPA 150

Castrol ALPHA 150
Comments / notes:
products
LSS-04 winch BW5200.doc 01 / 23.09.03 2 of 2
Lubrication Instruction:
WINCH LUBRICATION INSTRUCTION
General
- The system consists of to separate chambers, planetary gear unit and multi-disk/motor
unit. The planetary gear unit is gained through the plugs shown in the diagram below. The
multi-disk brake and motor is lubricated by the circulating hydraulic motor oil.
Oil changes.
Oil should be changed when hot to prevent build up of sludge deposit. Do not mix
oils of different types even of the same make. Never mix mineral and synthetic
oils.
products
TEK-MEC-WI-011-LSS- 02 / 26.10.05 1 of 1
05 Hydraulic oil
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 >+20 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 >+20 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 >+20 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
Maintenance system for MacGREGOR products

LSS-08 Drive 05 / 30.04.2009 1 of 1
pinion.docx
MacGREGOR STANDARD LUBRICATING SPECIFICATION
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:
Klber: Klberplex 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: 30110 C (for Kluberplex AG 11-462)
Recommended temperatures: 3150 C (for Omega 73)
Recommended temperatures: 1060 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
products
TEK-MEC-WI-015-LSS- 01 / 29.04.2009 1 of 1
11 Heavy duty grease
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 mm/s ISO 12058*
Base oil viscosity at 100 C: 106 mm/s ISO 12058*
Recommended temperatures: 20120 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.
products
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.
Approved Suppliers Lubrication Specifications:
Reference is made to the following LSS procedures:

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

Maintenance system for HM products.

LSS-22 Electric 0 / 18.01.11 1 of 1
motors.docx
Specification no:
LSS- 22
ELECTRIC MOTORS
50 / 60 Hz
On Lnne 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.
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.
6.6 Lubrication chart with lubrication points

Lubrication is the first of the four maintenance categories and directly extends the lifespan of the equipment. As
a form of preventive maintenance aimed at protecting the equipment, lubrication must be carried out according
to the periodic maintenance program.
The following Lubrication Points drawing gives a complete overview of the "what" and "where" of lubrication
for all parts of the crane. The drawing refers to numbered LSS documents. These "Lubrication Specification
Sheets" are standard documents explaining lubricant details.
See the following page for a typical Lubrication Points Drawing (Individual models and their lubrication
points may vary).
6.7 Change of oil filter

This system is equipped with a high quality return oil filter (MH05). The filter element (MH10) shall be
changed every 500 hours of duty, or more often if required.
How to change the filter element:

1. Ensure there is no pressure on the return line
2. Open the cover and remove the filter-element
3. Dismount the split pin and the crown nut
4. Remove the filter element and replace
5. Remove the magnet from the lock bolt and clean
6. Mount the magnet on the lock-bolt and screw up the nut
7. Mount the new filter element with spring and spring retainer
8. Unscrew the crown nut until the split pin hole becomes visible and mount the split-pin
9. Mount the cartridge into the house and put on the spring at the cover side
10. Unscrew the cover. Ensure the O-ring is clean and undamaged
Breather filter
Replace breather filter (MH04, ) every 2nd year unless extremely polluted air has entered the tank for a longer
period of time.
7 PARTS LIST
7.1 Component parts list
Cargotec Norway AS (Offshore) Page 1
8/11/2012
Component Part list 2423-1-07ML SP2423-1 MATERIAL LIST 10:26:29 am
Item number Item name Item group Unit

2423-1-07ML SP2423-1 MATERIAL LIST 299-007 ea
Item number Position NameAlias Oper. No. Quantity Item type Unit Weight Note
2423-1-07HYD HYDRAULIC COMPONENTS 1.00 BOM ea 0
11105273 EH01 HPU DIESEL 1.00 Item ea 0
11014931 EH02 ENCLOSURE 1.00 Item ea 0
11011228 EH03 BRACKET 1.00 Item ea 3
10000494 EH04 CHECK VALVE 1.00 Item pcs 0
11006169 JH01 HYDRAULIC CYLINDER 1.00 Item ea 0
10000529 JH02 BALANCE VALVE 1.00 Item pcs 3
11105479 JH03 HYDRAULIC CYLINDER 1.00 Item ea 0
10000529 JH04 BALANCE VALVE 2.00 Item pcs 6
11105121 JH05 PRESSURE RELIEF VALVE 1.00 Item pcs 0
10001193 JH07 DIRECTIONAL VALVE 1.00 Item pcs 1
10001674 JH08 SUBPLATE 1.00 Item pcs 0
10001461 JH10 TEST COUPLING 1.00 Service pcs 1
10001193 JH11 DIRECTIONAL VALVE 1.00 Item pcs 1
10001674 JH12 SUBPLATE 1.00 Item pcs 0
10002477 MH01 HYDRAULIC PUMP 1.00 Item pcs 24
10003411 MH02 OIL LEVEL GAUGE W TERMOMETER 1.00 Item pcs 0
10000425 MH03 BALL VALVE 1.00 Item pcs 0
10000008 MH04 BREATHER FILTER 1.00 Item pcs 0
10007275 MH05 FILTER,RETURN 1.00 Item pcs 5
11028008 MH06 PROPORTIONAL VALVE 1.00 Item ea 40
10001461 MH07 TEST COUPLING 4.00 Service pcs 2
10009400 MH10 FILTER ELEMENT 1.00 Item pcs 1
10001810 MH14 SAE 3000 PSI FLANGE 1.00 Service pcs 1
10000342 MH15 BOLT SOCKET HEAD CAP BLACK S 4.00 Service pcs 0
10001815 MH16 O-RING 1.00 Service pcs 0
10006130 MH17 GASKET SAE-C4 1.00 Item pcs 0
10000721 MH18 QUICK DISCONNECT COUPLING MA 1.00 Item pcs 0
10000724 MH19 DUST CAP 1.00 Item pcs 0
10000722 MH20 QUICK DISCONNECT COUPLING FE 1.00 Item pcs 0
10000726 MH21 DUST PLUG 1.00 Item pcs 0
10005379 MH23 DIRECTIONAL VALVE 1.00 Item pcs 2
10003737 MH24 SUBPLATE 1.00 Item pcs 1
8/11/2012
10003737 MH26 SUBPLATE 1.00 Item pcs 1
10004845 MH27 CHECK VALVE 1.00 Item pcs 0
10002488 MH28 BALL VALVE 1.00 Item pcs 1
11005260 MH29 BALL VALVE 1.00 Service ea 0
11015127 MH40 OIL COOLER 1.00 Item ea 30
10000421 MH41 RESTRICTOR VALVE HS 06 1.00 Item pcs 0
10004715 MH42 PRESSURE REDUCING VALVE 1.00 Item pcs 0
10004716 MH43 VALVE HOUSING 1.00 Item pcs 1
11000579 MH44 CHECK VALVE 1.00 Item ea 0
10009536 SG01 SLEW GEAR 2.00 Item ea 590
11002551 SG02 PINION 2.00 Item ea 0
11019001 SG03 ADAPTER-SETT (X=44) 2.00 Item ea 8
10009709 SG04 OIL TANK 2.00 Item pcs 2
11015108 SH01 HYDRAULIC MOTOR 2.00 Item ea 0
11015310 SH02 SLEW BLOCK 2.00 Item ea 9
11012953 SH03 BOLT M10x65 8,8 8.00 Item ea 0
10000633 SH04 RESTRICTOR CHECK VALVE HST 0 1.00 Item pcs 0
10000421 SH05 RESTRICTOR VALVE HS 06 1.00 Item pcs 0
11003088 WG01 WINCH GEAR 1.00 Item ea 140
11019001 WG02 ADAPTER-SETT (X=44) 1.00 Item ea 4
10004634 WH01 HYDRAULIC MOTOR 1.00 Item ea 20
11009323 WH02 CHECK VALVE 1.00 Item ea 0
10000516 WH03 BALANCE VALVE 1.00 Item pcs 2
10003985 WH04 SEQUENCE VALVE 1.00 Item pcs 1
10009275 WH05 PRESSURE RELIEF VALVE 1.00 Item pcs 0
10000418 WH06 RESTRICTOR CHECK VALVE HST 0 1.00 Item pcs 0
10001804 WH10 SAE 6000 PSI FLANGE 1.00 Service pcs 0
10001814 WH11 O-RING 1.00 Service pcs 0
10000530 WH14 SHUTTLE VALVE 1.00 Item pcs 0
10008950 WH15 VALVE HOUSING 1.00 Item pcs 0
8/11/2012
10001461 WH20 TEST COUPLING 2.00 Service pcs 1
10000530 WH21 SHUTTLE VALVE 1.00 Item pcs 0
11105300 X HYDRAULIC TAG SET 1.00 Item Set 0
2423-1-07MEC HMC 1400 LK 30-18(50-15)MOB27 1.00 BOM ea 0
C1400153AS01 SP2423-1 HMC 1400 LK 1.00 BOM ea 0
C1400153AA01 01 SP2423-1 HMC 1400 LK 1.00 BOM ea 0

11018434 01 SP2422-1 HMC 1400 LK 1.00 Item ea 0
11018364 02 FOUNDATION 1.00 Item ea 0
11003432 03 HATCH 1.00 Item ea 0
10000258 04 BOLT HEX HEAD H.D.G. 10.00 Service pcs 0
10000315 05 WASHER H.D.G. 12.00 Service pcs 0
10001912 06 PIN BOLT BLACK STEEL 2.00 Item pcs 0
10000308 07 NUT H.D.G. 2.00 Service pcs 0
10004177 08 BOLT SOCKET HEAD CAP BLACK S 60.00 Item pcs 0
10000355 09 WASHER H.D.G. HARDENED 120.00 Service pcs 0
10000491 10 NUT BLACK STEEL 60.00 Service pcs 0
11002094 11 DBI-DUT 60.00 Service pcs 0
C1400153AB01 02 SP2423-1 HMC 1400 LK 1.00 BOM ea 0

11018435 01 SP2422-1 HMC 1400 LK 1.00 Item ea 0
11003435 02 SLEW GEAR FLANGE 2.00 Item ea 0
11011729 03 PLATFORM 1.00 Item ea 0
11003443 04 PLATFORM,GATEWAY 1.00 Item ea 0
11011704 05 LADDER 1.00 Item ea 0
11008192 06 BRACKET 2.00 Item ea 0
11008191 07 SLIP RING SCREEN 1.00 Item ea 0
10000222 08 BOLT HEX HEAD A4-80 4.00 Service pcs 0
10000252 09 WASHER A4 4.00 Service pcs 0
10000224 12 BOLT HEX HEAD A4-80 24.00 Item pcs 0
10000248 14 NUT A4-80 24.00 Service pcs 0
10000273 15 BOLT 4.00 Service pcs 0
8/11/2012
11003437 18 HATCH 1.00 Item ea 0
10001912 19 PIN BOLT BLACK STEEL 16.00 Item pcs 0
10000560 21 RUBBER GASKET 1.00 Service m2 5 535x535x3
11016733 22 COVER 1.00 Item ea 0
10003878 24 SIGN SLEW DRIVE 1.00 Item pcs 0
10003876 25 SIGN KN-JIB OUT-IN 1.00 Item pcs 0
11007781 26 SIGN 1.00 Item pcs 0
10003874 27 SIGN 1.00 Item pcs 0
11022009 28 MACHINE NO SIGN ALU MACGREGO 1.00 Item pcs 0 SP2423-1
10000248 32 NUT A4-80 4.00 Service pcs 0
11018445 33 PLATFORM 1.00 Item ea 0
11018444 37 BRACKET 2.00 Item ea 0
11018443 38 BRACKET POS.1 2.00 Item ea 0
10000248 42 NUT A4-80 4.00 Service pcs 0
11018438 43 BRACKET 1.00 Item ea 0
10002775 47 CHAIN 0.75 Item mtr 0
10000411 48 SHACKLE 2.00 Service pcs 0
11005223 49 SPRING HOOK 1.00 Item ea 0
10002349 51 ACCUMULATOR CLAMP STAINLESS 2.00 Item pcs 2
C1400153AD01 03 SP2423-1 HMC 1400 LK 1.00 BOM ea 0

11018436 01 SP2422-1 HMC 1400 LK 1.00 Item ea 0
11022011 02 SIGN SELFADHESIVE 2.00 Item pcs 0
10000798 03 SIGN YELLOW 2.00 Item ea 0 3T-18M , 5T-15M
11003449 06 SPACER 200162X15 2.00 Item ea 0
10002995 07 V-RING 2.00 Item pcs 0
10000809 08 BUSH 1.00 Item pcs 1
10008739 09 BUSH 1.00 Item pcs 1
10002128 10 NO 1 SELF-ADHESIVE NUMBER 4.00 Service pcs 0
8/11/2012
C1400153AE01 04 SP2423-1 HMC 1400 LK 1.00 BOM ea 0

11018437 01 SP2422-1 HMC 1400 LK 1.00 Item ea 0
10003038 02 WIRESHEAVE 2.00 Item pcs 19
11008282 03 SPACER 4.00 Item ea 0
11008291 04 BOLT 2.00 Item ea 7
1000043969 05 HYDRAMARINE WINCH 1.00 BOM ea 0

1000043971 01 STEEL ASSY 1.00 Item ea 35
10001686 06 BEARING HOUSING 1.00 Item pcs 9
10001690 07 SPHERICAL ROLLER BEARING 1.00 Item pcs 2
10001688 08 ADAPTER SLEEVE 1.00 Item pcs 1
11003223 12 BOLT HEX HEAD H.D.G. 18.00 Item pcs 4
1000028750 13 WIRE CLAMP 2.00 Item ea 1
1000043968 15 PLATE 2.00 Item ea 4
20005243 18 PLATE 2.00 Item ea 4
11013260 06 BOLT 4.00 Item ea 0
10000357 07 WASHER BLACK STEEL 4.00 Service pcs 0
11003458 11 SPACER 170142X15 2.00 Item ea 0
10000171 12 V-RING 2.00 Item pcs 0
10002325 13 BUSH 1.00 Item pcs 1
10008740 14 BUSH 1.00 Item pcs 1
11003259 15 LEVER 2.00 Item ea 0
11003260 16 WHEEL 2.00 Item ea 0
11003261 17 BRACKET 2.00 Item ea 0
11003262 18 BRACKET 2.00 Item ea 0
8/11/2012
C1400153AS02 05 SP2423-1 HMC 1400 LK 1.00 BOM ea 0

10000568 03 SLEW BEARING 1.00 Item pcs 292
10000491 13 NUT BLACK STEEL 57.00 Service pcs 0
11006695 15 SOCKET HEAD CAP BLACK STEEL 3.00 Item pcs 1
10000468 17 BOLT SOCKET HEAD CAP BLACK S 24.00 Service pcs 0
11017274 20 DISTANCE PIECE 1.00 Item ea 0
11017272 21 SPACER ELEMENT 1.00 Item ea 5
11017273 22 HUB 2.00 Item ea 0
11003563 24 HOT DIPGALVHEX HEAD BOLT 4.00 Item ea 0
11016659 32 PLATE 1.00 Item ea 0
11003446 08 BOLT MAIN JIB 1.00 Item ea 0
11003447 09 END CAP FOR BOLT MAIN JIB 1.00 Item ea 0
11016731 10 BOLT 1.00 Item ea 0
11003455 12 BOLT 1.00 Item ea 0
11003456 13 END CAP 1.00 Item ea 0
11016732 14 BOLT 2.00 Item ea 0
11003450 16 BOLT 1.00 Item ea 0
11003451 17 LOCK PLATE 1.00 Item ea 0
10000296 18 BOLT HEX HEAD H.D.G 1.00 Item pcs 0
8/11/2012
11017973 20 DIST RING 4.00 Item ea 0
11003452 21 BOLT 1.00 Item ea 0
11003453 22 END CAP 1.00 Item ea 0
11003459 25 BOLT FOR JIB CYLINDER 2.00 Item ea 0
11003460 26 LOCK PLATE 2.00 Item ea 0
11003461 29 SPACER 4.00 Item ea 0
10019120 30 WIRE 19mm 40.00 Item mtr 80 w/open sp.socket
11003445 31 WIRE STOPPER 1.00 Item ea 0
10019301 32 SHACKLE 1.00 Item pcs 0
10019800 33 SWIVELHOOK 8,1T 1.00 Item pcs 7
10006188 34 FORERUNNER 1.00 Item pcs 0
2423-1-07EL ELECTRICAL COMPONENTS 1.00 BOM ea 0
2423-1-EL-ES400 STARTER CABINET 1.00 BOM ea 0

11012856 -70 DRAIN PLUG M25 Service ea 0
11012857 -70.1 LOCKNUT M25 Service ea 0
11013814 -77.1 END BRACKET Service ea 0
11013815 -77.2 CONNECTOR MARKER Service ea 0
11013812 -81 END PLATE Service ea 0
11105622 -ES400 STARTER CABINET 1.00 Item ea 0
11013699 -ES400.0 ENCLOSURE 400x600x220mm WxHx Item ea 0
11008468 -F01 MOTORP ROTECTIVE CIRCUIT BRE Item ea 0
11003499 -F02 CIRCUIT BREAKER 2A 2pol C Service ea 0
11003499 -F03 CIRCUIT BREAKER 2A 2pol C Service ea 0
8/11/2012
11003174 -H1 SIGNAL LAMP BLUE Service ea 0
11002517 -H1.1 ADAPTER Item ea 0
11001858 -H1.2 LABEL MOUNT 50mm Item ea 0
11003178 -H1.3 LED ELEMENT WHITE 85-264VAC Service ea 0
11002532 -H2 SIGNAL LAMP WHITE Service ea 0
11002533 -H3 SIGNAL LAMP YELLOW Service ea 0
11002531 -H4 SIGNAL LAMP GREEN Service ea 0
11006311 -K1 AUX. CONTACTOR BLOCK 2NO+2NC Service ea 0
11009054 -K1.1 MOELLER CONTACTOR Service ea 0
11014190 -L1 TERMINAL BLOCK Item ea 0
11006314 -P01 THERMISTOR OVERLOAD RELAY 23 Item ea 0
11013709 -P02 HOUR METER Item ea 0
11012988 -PE EARTHBAR Item ea 0
11007975 -S1 COMPLETE_STOP MOELLER Service ea 0
11007971 -S2 COMPLETE_EM.STOP MOELLER Service ea 0
11007974 -S3 COMPLETE_START MOELLER Service ea 0
11002518 -S3.1 CONTACT ELEMENT 1NO Item ea 0
11014883 -T1 TRANSFORMER 400VA Item ea 0
10009482 -X10 TERMINAL BLOCK Service pcs 0
2423-1-EL-JB35 JUNCTION BOX 1.00 BOM ea 0

10009460 -JB35 FIBOX 130x130x100 1.00 Item pcs 0
10009482 -X10 TERMINAL BLOCK 3.00 Service pcs 24
10009482 -XA TERMINAL BLOCK 8.00 Service pcs 64
8/11/2012
11013807 -XA.1 EARTH TERMINAL BLOCK 1.00 Service ea 19
2423-1-EL-RCC97 RADIO CONTROL CABINET 1.00 BOM ea 0

10008121 -K4 RELAY 24VDC 1xNO FOR RAIL 1.00 Item pcs 0
11007989 -RCC97 REMOTE CONTROL STANDARD 4PR 1.00 Item ea 0
2423-1-EL-OP12 OPERATOR PANEL 1.00 BOM ea 0

11001258 -OP12 REMOTE START STOP BOX 1.00 Item ea 0
11001257 -OP12.1 PROTECTION SHIELD 1.00 Item ea 2
11105633 -JB450 SLIPRING 1.00 Item ea 0
11007194 -M01 EL.MOTOR 1.00 Item ea 230
7.2 Hydraulic hose list
Project no. : SP2423-1
Revision Code : 2
Date : 11-Oct-2012 Project - Hose List
Created By : aessli
Drawing no. : C.1400.153.HF01
System : crane
Reference : As Built
Hose No. Code Hose Total Length Cut Length Coupl. no 1 Coupl. no 2
mm mm
100 G5K16 1619,2 1500,00 G5362516 G5362516
102 0 G5K16 1704,2 1550,00 G5362516 G5372516
103 0 G120 2000,2 1850,00 G3363820 G3373820
110 M5K06 2170,8 2100,00 G3331206 G3351206
111 M5K06 512,1 450,00 G3331206 G3341206
112 M5K06 1720,8 1650,00 G3331206 G3351206
113 M5K06 720,8 650,00 G3331206 G3351206
114 M5K06 482,1 420,00 G3331206 G3341206
115 M5K06 662,1 600,00 G3331206 G3341206
116 M5K06 2062,1 2000,00 G3331206 G3341206
117 M5K06 1892,1 1830,00 G3331206 G3341206
118 M5K06 2012,1 1950,00 G3331206 G3341206
119 M5K06 1559,8 1500,00 G3331206 G3331206
120 M5K06 2070,8 2000,00 G3331206 G3351206
122 M5K06 562,1 500,00 G3331206 G3341206
123 M5K06 2120,8 2050,00 G3331206 G3351206
G:\Avdelinger\Teknisk avdeling\03 Hydraulic\04 - Project overview\Project hoselists\SP2423-1\C.1400.153.HF01.xlsx 1 of 4

124 M5K06 1900,8 1830,00 G3331206 G3351206
125 G116 1480,2 1350,00 G3363016 G3372516
130 M5K06 939,8 880,00 G3331206 G3331206
131 M5K06 979,8 920,00 G3331206 G3331206
132 M5K06 899,8 840,00 G3331206 G3331206
136 M5K06 1012,1 950,00 G3331206 G3341206
143 M5K06 919,8 860,00 G3331206 G3331206
144 M5K06 859,8 800,00 G3331206 G3331206
200 M4K10 2086,3 2000,00 G3331810 G3351810
201 M4K10 2166,3 2080,00 G3331810 G3351810
202 M4K10 1460,6 1400,00 G3331810 G3331810
203 M4K10 1480,6 1420,00 G3331810 G3331810
204 M4K10 1327,9 1250,00 G3331810 G3341810
205 M4K10 1077,9 1000,00 G3331810 G3341810
206 M4K10 1086,3 1000,00 G3331810 G3351810
207 M4K10 986,3 900,00 G3331810 G3351810
209 M5K08 1219,7 1150,00 G3331508 G3341508
210 M5K04 1360,8 1300,00 G3331004 G3341004
211 M5K08 1076,4 1000,00 G3331508 G3351508
212 M4K10 577,9 500,00 G3331810 G3341810
213 M5K04 560,8 500,00 G3331004 G3341004
214 M5K06 1020,8 950,00 G3331206 G3351206
215 M5K04 560,8 500,00 G3331004 G3340804
218 M5K06 999,8 940,00 G3331206 G3331206
219 M5K06 1170,8 1100,00 G3331206 G3351206
220 M5K06 1970,8 1900,00 G3331206 G3351206
221 M5K06 1070,8 1000,00 G3331206 G3351206
300 M4K10 1527,9 1450,00 G3331810 G3341810
301 M4K10 1577,9 1500,00 G3331810 G3341810
304 M4K10 1936,3 1850,00 G3331810 G3351810
305 M4K10 1986,3 1900,00 G3331810 G3351810
306 M4K10 1460,6 1400,00 G3331810 G3331810

307 M4K10 1460,6 1400,00 G3331810 G3331810
308 M4K10 1247,9 1170,00 G3331810 G3341810
309 M4K10 1077,9 1000,00 G3331810 G3341810
310 M4K10 706,3 620,00 G3331810 G3351810
311 M4K10 786,3 700,00 G3331810 G3351810
312 M4K08 3976,4 3900,00 G3331508 G3351508
313 M5K08 1319,7 1250,00 G3331508 G3341508
500 M4K10 1586,3 1500,00 G3331810 G3351810
501 M4K10 1636,3 1550,00 G3331810 G3351810
502 M4K08 1458,6 1400,00 G3331508 G3331508
503 M4K08 1458,6 1400,00 G3331508 G3331508
504 M5K08 1369,7 1300,00 G3331508 G3341508
505 M5K08 1369,7 1300,00 G3331508 G3341508
600 M5K04 510,8 450,00 G3331004 G3340804
601 M5K06 1312,1 1250,00 G3331206 G3341206
602 M5K06 1609,8 1550,00 G3331206 G3331206
700 M5K08 1169,7 1100,00 G3331508 G3341508
701 M5K08 1696,4 1620,00 G3331508 G3351508
703 G112 1610,2 1500,00 G3362512 G3382512
901 M5K06 1470,8 1400,00 G3331206 G3351206
902 M5K06 1459,8 1400,00 G3331206 G3331206
903 M5K06 1112,1 1050,00 G3331206 G3341206
905 M5K06 612,1 550,00 G3331206 G3341206
906 M5K06 392,1 330,00 G3331206 G3341206
907 M5K06 562,1 500,00 G3331206 G3341206
909 M5K06 462,1 400,00 G3331206 G3341206
910 M5K06 459,8 400,00 G3331206 G3331206
911 M5K06 659,8 600,00 G3331206 G3331206
912 M5K06 1870,8 1800,00 G3331206 G3351206
913 M4K10 960,6 900,00 G3331810 G3331810
914 M4K10 910,6 850,00 G3331810 G3331810
915 M5K06 909,8 850,00 G3331206 G3331206

916 M5K08 1038,6 980,00 G3331508 G3331508
917 M5K06 1039,8 980,00 G3331206 G3331206
920 M5K06 1162,1 1100,00 G3331206 G3341206
921 M5K06 1112,1 1050,00 G3331206 G3341206
922 M5K06 1162,1 1100,00 G3331206 G3341206
923 M5K06 1012,1 950,00 G3331206 G3341206
924 M5K06 1292,1 1230,00 G3331206 G3341206
925 M5K06 1459,8 1400,00 G3331206 G3331206
926 M5K06 1262,1 1200,00 G3331206 G3341206
927 M5K06 1459,8 1400,00 G3331206 G3331206
928 M5K06 1459,8 1400,00 G3331206 G3331206
929 M5K06 1459,8 1400,00 G3331206 G3331206
930 M5K06 1459,8 1400,00 G3331206 G3331206
931 M5K06 1459,8 1400,00 G3331206 G3331206
933 M5K06 1462,1 1400,00 G3331206 G3341206

Project no. : SP2423-1
Revision Code : 2
Date : 10-Oct-2012 Project - Hose List
Created By : aessli
Drawing no. : C.1400.153.HF02
System : crane
Reference : As Built
Hose No. Code Hose Total Length Cut Length Coupl. no 1 Coupl. no 2
mm mm
133 M5K06 712,1 650,00 G3331206 G3341206
134 M5K06 712,1 650,00 G3331206 G3341206
135 M5K06 712,1 650,00 G3331206 G3341206
140 M5K06 562,1 500,00 G3331206 G3341206
141 M5K06 962,1 900,00 G3331206 G3341206
142 M5K06 562,1 500,00 G3331206 G3341206
145 M5K06 729,8 670,00 G3331206 G3331206
506 M5K08 819,7 750,00 G3331508 G3341508
507 M5K08 969,7 900,00 G3331508 G3341508
508 M5K08 869,7 800,00 G3331508 G3341508
509 M5K08 919,7 850,00 G3331508 G3341508
510 M5K08 869,7 800,00 G3331508 G3341508
511 M5K04 860,8 800,00 G3331004 G3340804
512 M5K08 1058,6 1000,00 G3331508 G3331508
513 M5K04 760,8 700,00 G3331004 G3340804
518 M5K06 512,1 450,00 G3331206 G3341206

519 M5K06 862,1 800,00 G3331206 G3341206
520 M5K08 1419,7 1350,00 G3331508 G3341508
521 M5K08 408,6 350,00 G3331508 G3331508
918 M5K06 1012,1 950,00 G3331206 G3341206
919 M5K06 709,8 650,00 G3331206 G3331206

7.3 Spare parts, service, inquiries

Should the equipment operator/owner have any inquiries regarding spare parts or require any kind of technical
assistance (for example, with trouble-shooting, service, upgrades or modifications etc), they should contact their
local Marine Service Station. For MacGregor equipment, the inquiries will be followed up by either the Spare
Parts or Service organization at Cargotec Norway Kristiansand. These groups work closely together and are
integrated within Cargotec Norway AS Marine Service.
More information can be found at www.cargotec.com Solutions and Services Services.
To locate your local Marine Service Station, go to www.macgregor-group.com Service.
Other contact information:

Cargotec Norway AS - Kristiansand reception phone and telefax:
+47 916 86 000
+47 38 01 87 01
krs.service@cargotec.com +47 916 89 751

krs.spareparts@cargotec.com
krs.trainingcentre@cargotec.com
Always refer to actual equipment machine number (SP....) for exact definition of components and service advice
IMPORTANT NOTICE!
During the warranty period, all necessary spare parts must be supplied
by Cargotec Norway AS. The use of spare parts from other suppliers
violates and forfeits the warranty.
8 DRAWINGS and DATA SHEETS
8.1 Project drawings
General arrangement drawing (GA)

Assembly drawings (AS01, AS02)
Hydraulic diagrams (HF01, HF02)
Electrical diagrams (101, 401, 500-503, 601, 602)
1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed
in whole or in part by or to anyone without written permission of Cargotec. CUSTOMER SUPPLY MacGREGOR SUPPLIED UNITS Note: Cables supplier
--- --- --- --- Cables supplied by Customer

____________ Cables supplied by MACGREGOR
A LOCATED BY CUSTOMER Radio Remote Cabinet A

GENERATOR SUPPLY LOCATED ON -RCC97
Remote Start / Stop
CRANE KING OPER. AND IND.: -W250.XYV1A 2x0.75mm
/503.E1
-XYV1A MAIN JIB UP
-OP12.1 -W251.XYV1B 2x0.75mm
-XYV1B MAIN JIB DOWN Note Motor: -M01
-OP12 /503.E2 EL.MOTOR DATA:
- Power avail. lamp -W252.XYV2A 2x0.75mm KNUCKLE JIB IN
-XYV2 A
Motortype: 14BG208-4AA66-Z200L
- Emergency Stop - Radio Remote Active lamp -W253.XYV2B 2x0.75mm
-XYV2 B KNUCKLE JIB OUT Supply: 690 VAC / 60 Hz / 3 phz
- Stop Motor Conn. Star-Delta: DOL
- Crane Control Local/Remote /503.E3
Rotation Speed:
- Start -W254.XYV3A 2x0.75mm
-XYV3 A SLEW LEFT 1773 rpm
- Start button Rating S1 - 100% duty: 37 kW / In=40,7 A
- Running lamp -W255.XYV3B 2x0.75mm
-XYV3 B SLEW RIGHT Rating S6 - 40% duty:
- Stop button 55 kW / In=58,3 A
7G1.5mm Rating S6 - 25% duty: -
-W196 - Em.Stop button /503.E4
B -W256.XYV4A 2x0.75mm
-XYV4 A WINCH HOIST Calc.Hydr.Rating: aprox.50,75 kW (S6-40%) B
- Horn button 2x0.75mm Isolation / Temp.Class: F/amb.temp.45C
Stainless Steel Prot.shield -W257.XYV4B -XYV4 B WINCH LOWER Start Method / Current: DOL / In x 6,89
- Horn IP-degree / Weight: IP 56 / 230kg
Internal Heater Element: 2x40 W / 230 VAC
/503.F5 Std. Cable Gland Thread: 2xM50 + 2xM20
3G1.5mm CONSTANT TENSION
-W258 -XY1 Thermistor Build In: 3PTC Thermistor
LOCATED INSIDE 3G1.5mm

/503.F8 RESCUE BASKET
-W260 -XY2
VESSEL ON/OFF
Starter Cabinet
-ES400
C OPERATION AND C
INDICATION:
- Start button
- Stop button
- Emergency stop button
- Motor running lamp
- Motor heater lamp
- Hour counter
- Power available lamp
Slipring
- Motor overload lamp
LOCATED INSIDE -JB450
LOCATED OUTSIDE
Start/Stop Signal -W129 6+PE CRANE PEDESTAL CRANE PEDESTAL
D D
Junction Box
Radio Remote Consol
-JB35
Power -W194 3+PE -W193 7G1.5mm -RCC97
TRANSMITTING UNIT
3+PE
Start/Stop Signal -W191 OPER. AND IND.:
130x130x100mm
- Start / Stop HPU
- Main Jib Up / Down
- Knuckle Jib Out / In
HPU Main Pump Motor
E - Slew Right / Left E
SUPPLY 3x690VAC, 60Hz
/601.F1 - Winch Lower / Hoist
ref. Note Motor -M01
3+PE u-v-w - Emergency stop
-W01 DOL -W11 M
2+PE Heater 3~ - Warning Horn
Thermistor -W121 -M01
Total Power Consumption: 2+PE Therm
Heater -W122
37 kW (S1-100%)
F F
Drawn by THE Dwg. No.
Hellesy Verft AS Date 30.12.2011 Main Block Diagram SP2423-1 +XO 101
SP2423-1 Sheet rev.
Z1 As built 07.11.2012 THE MPA Project rev. Z1 Electrical Block Diagram
HLA:
Z1
Next sheet
Rev. Description Date Modified by Approved HMC 1400 LK 30-18 (50-15) Loc: 401
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
in whole or in part by or to anyone without written permission of Cargotec. Starter Cabinet Junction Box Slipring Radio Remote Cabinet
-ES400 -JB35 -JB450 -RCC97
-X10 PE PE PE
A 1 A
1
2 YEGN
2 -X1
1 1
3 -X10 -JB450 1
1 3 1 1 2
4 1 1 2
3
6 -W191 3+PE 2
2
4 2
2
2
2 3 5 YEGN YEGN
7 3 PE
4
8
3
9 7G1.5mm 7G1.5mm 3
5 -W193 -W196 3
10
-XA -JB450 4
11 1 1 3 3
1 1 3 5
12 3+PE 2 2 4 4 4
2 -W194 2 4 6
B 13 PE YEGN 5 5 B
3 5 7
PE 8
5
9
-X2 -XYV1
1 1
1 2x0.75mm A1 Main Jib
2 -W250.XYV1A 2 Up
2 A2 -XYV1
1 1 Main Jib
3 2x0.75mm B1
2 -W251.XYV1B 2 Down
4 -XYV2 B2
1 1
C 5 2x0.75mm A1 Knuckle Jib C
Remote Start/Stop 2 -W252.XYV2A 2
6 A2 In -XYV2
1 1
7 2x0.75mm B1 Knuckle Jib
2 -W253.XYV2B 2
-OP12 8 -XYV3 B2 Out
1 1 1
1 Stop button 9 2x0.75mm A1
2 -W254.XYV3A 2 Slew Left
2 Stop button 10 A2 -XYV3
1 1
1 Em.Stop button 11 2x0.75mm B1 Slew Right
2 2 -W255.XYV3B 2
2 Em.Stop button 12 -XYV4 B2
-W129 6+PE 3
3 Start button 13
1 1
A1
-W256.XYV4A 2x0.75mm Winch Hoist
4 2 2
4 Start button 14 A2 -XYV4
1 1
X1 Running lamp 15 2x0.75mm B1 Winch Lower
5 2 -W257.XYV4B 2
X2 Running lamp 16 -XY1 B2
1 1
17 3G1.5mm A1 Constant Tension
D 2 -W258 2 On/Off D
18 A2
19
20
21
22 -XY2
HPU Main Pump Motor 1 1
23 3G1.5mm A1 RESCUE BASKET
2 -W260 2 ON/OFF
-M01 24 A2
-K1
1 1
2 U1
4
2
-W11 3+PE 2
V1
3 3
6 W1
PE
PE PE
E E
-X6
1 1
1 2+PE R1
2 -W121 2
2 R2
-X16
1 1
1 2+PE T1
2 -W122 2
2 T2
PE PE
PE
F F
Hellesy Verft AS Date 08.05.2012 External Wiring Diagram SP2423-1 +AP-XS 401
SP2423-1 Sheet rev.
Z1 As built 07.11.2012 THE MPA Project rev. Z1 HLA:
Z1
Next sheet
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
in whole or in part by or to anyone without written permission of Cargotec.
-JB35
-JB450
-RCC97 Radio Remote Cabinet
A A
230VAC +ES400-X10:12 -W194 11
-W194 -XA 1 -W193 1 1 -F1
/601E3
1 -W196 1 -X1 1 -G1:L 230VAC
/501B1
3 1
-G1:N 230VAC
4 2
/501C1
2A
230VAC +ES400-X10:13 -W194 22

-W194 -XA 2 -W193 2 2
/601E3
2 -W196 2 -X1 2 -G1:PE PE
/501C1
PE +ES400-PE -W194 PE PE PE
/601E3 -W196 YEGN
B PE B
PE
C C
D D
E E
F F
Hellesy Verft AS Date 08.05.2012 Loop diagram SP2423-1 +AB-XT 500
SP2423-1 Sheet rev.
Z1 As built 07.11.2012 THE MPA Project rev. Z1 -RCC 97
HLA:
Z1
Next sheet
Rev. Description Date Modified by Approved HMC 1400 LK 30-18 (50-15) Loc: +RCC97 501
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
in whole or in part by or to anyone without written permission of Cargotec. -RCC97 Radio Remote Cabinet
A Buscable A
TO BE MOUNTED
J-8 J-9 J1 ON THE MC-IRX2
MC-IRX-2
E-STOP -A1 TX-BUS RX-BUS
RADIO MODULE
MC-2WIRE
2 1 3 23 7 27 11 31 15 17 PLL-440C-STD -U2
35 37 -A2 433-443 MHz
4 24 8 28 12 32 19 20
24V IN
RS485 B
RS485 A
0V IN
0V OUT
24V OUT
5 25 9 29 13 33 16 18
36 38
6 26 10 30 14 34 39 40
22 21
J4 1 2 3 4 5 6
J-12 J-15 J-7 J-13 J-11

+ + - - A B - + A B - + + A3 A2 A1 A0 D3 D2 D1 D0 - A B - + IRX2-J16 1 2 3 4 5 6
41 42 43 44 45 46 47 48 53 54 55 56 1 2 3 4 5 6 7 8 9 10 49 50 51 52 -W1
B B
-A1:21 -- -A3:4 +
/502A1 /503C6
-A1:1 -- -A3:3 --
/502A1 /503B6
L + 1 -F2 1
/500A8
230VAC -F1:2 -G1 -A1:5 +
/502A1
-A3:2 B
/503B6
N +
-K4:14 +
/503C7
230VAC -F1:4 -
-X2:24 -- -A3:1 A
/500A8 230VAC/24VDC /503C7 X1 /503B6
-
240VA/10A -H1
PE PE FROM SOLDER
/500B8
SIDE
Power
1 2 3 4
Available X2
2 4
C -H2:X2 -- C
/502D1 3 1
-J1 M35017
Installed in cabinet door
D D
E E
F F
SP2423-1 Sheet rev.
Z1 As built 07.11.2012 THE MPA Project rev. Z1 -RCC97
HLA:
Z1
Next sheet
Rev. Description Date Modified by Approved HMC 1400 LK 30-18 (50-15) Loc: +RCC97 502
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-- -A1:44 -RCC97 Radio Remote Cabinet

/501B4
A -- -A1:44 A
/501B4
+ -H1:X1 -A3:2 +
/501B4 /503C1
2 1
ON/OFF
1 11 21
-A1
-S1
2 12 22
B Local/Remote B
22 21
10 9 8 7 6 5 4 3 2 1 IRX2-J13
12 14
-K3
11
12 14
-S6:4 +
-K1 12 14
11
/503C6 -K2 11
25 23
35
-A1 -S6:3 +
/503C6
C 15 19 STOP C
-A1 5 -A1 3
START
Installed in cabinet door -X1 6 7 -X1 8 9 -X1 3 -X1 4 5

X1 A1 A1 A1 A1 X1
-H2 -H3
-K1 -K2 -K3 -K4 Yellow 24
/503.D8 -S5 3 -S2 3 -S4 1 -S3 1
Radio Remote A2 A2 A2 A2 Rescue Basket
Active X2 Active X2
-A1 4 Horn 4 START 4 STOP 2 Em.Stop 2
D D
-- -H1:X2 -A3:1 --
/501C4 /503C1
-X2 19 20
-
-E1
Horn
Customer Supply
From -ES400
Starter Cabinet
E E
+JB35 Junction Box
-JB450 Slipring
230VAC +ES400-X10:3 -W191 1 -X10 1 -W193 3 3
/601C7 Stop/Em.stop signal 3 -W196 3
230VAC +ES400-X10:7 -W191 2 2 -W193 4 4
/601C7 Stop/Em.stop signal 4 -W196 4
230VAC +ES400-X10:9 -W191 3 3 -W193 5 5
/601D7
Start signal 5 -W196 5
F F
SP2423-1 Sheet rev.
HLA:
Z1
Next sheet
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
in whole or in part by or to anyone without written permission of Cargotec. -RCC97 Radio Remote Cabinet
A MC-IRX-ANA A
OPTIONAL PWM OPTIONAL PWM OPTIONAL PWM
OUTPUT OUTPUT OUTPUT
-A3
XREF XREF XREF
1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6
J-1 J-4 J-7 J-6

A B - + - + 1- 1+ 2- 2+ - + 1- 1+ 2- 2+ - + 1- 1+ 2- 2+
1 2 3 4
B MC-IRX-ANA-PWM MC-IRX-ANA-PWM A -A1:45 B

/501C6
0-3 A 0-3 A
B -A1:46
/501B6
-A3 -A3
-- -A1:47
/501B6
- + V2 H2 V1 H1 - + V2 H2 V1 H1
1 2 3 4 5 6 1 2 3 4 5 6 + -A1:48
/501B6
C C
-- -X2:20 + -K3:A1 -- -G1:-

/502D5 /502C4 /501C2
+ -A1:4 + -K4:A1 + -G1:+
/502A6 /502C4 /501C2
6 12 14
-K4 /502.D4
11
-A1 26
D D
3
RESCUE BASKET
ON/OFF
4
-X2 1 2 3 4 -X2 5 6 7 8 -X2 9 10 11 12 -X2 13 14 15 16 17 18 -X2 21 22 -X2 23 24

E E
-W250.XYV1A 2
-W251.XYV1B 2
-W252.XYV2A 2
-W253.XYV2B 2
-W254.XYV3A 2
-W255.XYV3B 2
-W256.XYV4A 2
-W257.XYV4B 2
-W258 2
-W260 2
-W250.XYV1A 1
-W251.XYV1B 1
-W252.XYV2A 1
-W253.XYV2B 1
-W254.XYV3A 1
-W255.XYV3B 1
-W256.XYV4A 1
-W257.XYV4B 1
-W258 1
-W260 1
A1 A1
A1 B1 A1 B1 A1 B1 A1 B1
/101.A7 -XYV1A -XYV1B /101.B7 -XYV2 A -XYV2B /101.B7 -XYV3 A -XYV3B /101.B7 -XYV4 A -XYV4B -XY1 -XY2
A2 B2 A2 B2 A2 B2 A2 B2 A2 A2
MAIN JIB UP MAIN JIB DOWN KNUCKLE JIB IN KNUCKLE JIB OUT SLEW LEFT SLEW RIGHT WINCH HOIST WINCH LOWER CONSTANT TENSION RESCUE BASKET
F F
SP2423-1 Sheet rev.
HLA:
Z1
Next sheet
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and L3
in whole or in part by or to anyone without written permission of Cargotec. L2 POWER SUPPLY
L1 FROM VESSEL
A
PE 690VAC/60Hz/3ph Starter Cabinet -ES400 A
Install jumper between

PE 21 14 -S1 1 -X10:1 and -X10:2, if optional
STOP start/stop panel is not in use
-P01 /601.D4
-L1 -L2 -L3 22 13 2
Motor-protective -S2 1 To -OP12

circuit-breaker F1 Em.stop
adjusted to 1,8 A 2 +OP12-OP12:1
B -X10 1 -W129 1 230VAC B
/602A2
+OP12-OP12:2
-X10 2 -W129 2 230VAC
-F01 1 3 5 /602B2
1 3 1 3
-F03 2A -F02 2A To -JB35
I> I> I> +JB35-X10:1
1.6-2.5A 2 2 4 2 4 -X10 3 -W191 1 230VAC
4 6
/502E1
-X10 4
1 3 5 -X10 5
+OP12-OP12:3
-K1 150A 21 31 -X10 6 230VAC
C 690V 230V -X10 12 13
-W129 3
/602C2 C
2 4 6 460V
-K1
22 32 +JB35-X10:2
440V -T1 -X10 7 -W191 2 230VAC
400V /502E1
0V 0V A1
690V/230V
400VA /601.B6 -P01 14 -S3 3
START
A2 T1 T2
-K1 13 4
+OP12-OP12:4
-X10 8 -W129 4 230VAC
/602D2
+JB35-X10:3
-W194 PE
-W194 2
D D
-W194 1
-X10 9 -W191 3 230VAC

/502F1
X1 X1 X1 X1 2
-H1 -H2 -H3 -H4 -P02 A1
h -K1 150A
Motor Power Motor Motor Hour A2
+JB35-XA:PE
Heater X2 Available X2 Overload X2 Running X2 Counter 3 +OP12-OP12:X2

+JB35-XA:2
+JB35-XA:1
-X10 10 -W129 5 230VAC

/602E2
-X10 11
-X16 1 2 -X6 1 2
PE MAIN
CONTACTOR
THERMISTOR SIGNAL
-W11 YEGN
230VAC
230VAC
FROM MOTOR MOTOR SPACE

PE
-W11 2
-W11 3
HEATER
-W11 1
E E
/500B1
/500A1
/500B1
W1
PE
U1
V1
R1 -W121 1
R2 -W121 2
/101.E5 M
3 ~ T1 -W122 1
T2 -W122 2
-M01
HPU Main Pump Motor
F F
Hellesy Verft AS Date 08.05.2012 Loop diagram SP2423-1 +AP-XT 601
SP2423-1 Sheet rev.
Z1 As built 07.11.2012 THE MPA Project rev. Z1 -ES400
HLA:
Z1
Next sheet
Rev. Description Date Modified by Approved HMC 1400 LK 30-18 (50-15) Loc: +ES400 602
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-Start/Stop Panel
A A
230VAC +ES400-X10:1 -W129 1

/601B8
Stop 2
B B
1
Em.stop 2
230VAC +ES400-X10:2 -W129 2

/601B8
C C
230VAC +ES400-X10:6 -W129 3

/601C8
Start 4
230VAC +ES400-X10:8 -W129 4

/601D8
D D
X1
Run
X2
230VAC +ES400-X10:10 -W129 5

/601E8
E E
F F
Hellesy Verft AS Date 08.05.2012 Loop diagram SP2423-1 +AP-XT 602
SP2423-1 Sheet rev.
Z1 As built 07.11.2012 THE MPA Project rev. Z1 -OP12
HLA:
Z1
Next sheet
Rev. Description Date Modified by Approved HMC 1400 LK 30-18 (50-15) Loc: +OP12 1
1 2 3 4 5 6 7 8
8.2 Data Sheets
8.2.1 Main pump MH01
MacGregor item : 10002477
Position: MH01
8.2.2 Main control valve MH06
Position: MH06
8.2.3 Winch drive WH01
Bosch Rexroth Mobile Hydraulics http://www.boschrexroth.com/mobile-hydraulics-catalog/Vornavigatio...
Language Imprint Legal information MacGregor Item : 10004634

Position: WH01
www.bosch.com Search Contact Addresses Sitemap
www.bos c hrex roth.c om
Axial Piston Units Search
Variable Motor A6VM/63
Product Catalog Mobile
Search
Hydraulics
Axial Piston Units Documentation
Fixed Pumps
A6VM/63
Variable Pumps
Fixed Motors
Variable Motors
A6VM/63
A6VM/71
A6VE
A10VM
A10VE Sizes 28...1000 Standard motor
External Gear Units Axial tapered piston bent-axis design Wide control range (can be swiveled over zero), high
Radial piston motors Series 6 speeds and high torque
Open and closed circuits Option: Counterbalance valve, flushing and boost
Mobile Controls
Nominal pressure pressure valve
Compact Hydraulics
Sizes 28...200: 400 bar Option: Swivel angle indicator (sizes 250...1000)
Gears Sizes 250 ...1000: 350 bar
Mobile Electronics Peak pressure
Accessories Sizes 28...200: 450 bar
Systems Sizes 250...1000: 400 bar
Spare Parts Mobile Hydraulics
Size A6VM 28 55 80 107 140 160 200 250 355 500 1000
Swept volume V g m ax cm 28,1 54,8 80 107 140 160 200 250 355 500 1000
Swept volume V g,1 cm 18 35 51 68 88 101 126 190 270 385 762
1) at V g m ax nm ax rpm 5550 4450 3900 3550 3250 3100 2900 2700 2240 2000 1600
Speed
at V g < V g,1 nm ax rpm 8750 7000 6150 5600 5150 4900 4600 3600 2950 2650 2100
Flow at nm ax qVm ax l/min 156 244 312 380 455 496 580 675 795 1000 1600
Torque p = 350 bar Tm ax Nm - - - - - - - 1391 1978 2785 5571
p = 400 bar Tm ax Nm 179 349 509 681 891 1019 1273 - - - -
Weight (approx.) m kg 16 26 34 47 60 64 80 90 170 210 430

) Maintaining qV max
HD EP HZ EZ HA DA
Hydraulic control, pilot Electrical control, with Hydraulic two-point Electrical two-point Automatic control, Hydr. control,
pressure-related proportional solenoid control control high-pressure-related speed-related
Vg = Displacement
pSt = Pilot pressure
I = Control current
pB = Operating pressure
Product Catalog Mobile Hydraulics, online version, last changed 2010-03-11

Bosch Rexroth AG, subject to change
1 av 1 11.10.2010 08:25
Art no: 10004634
Data sheet Page 1 / 1

Art no: 10004634

Art no: 10004634

Art no: 10004634

Art no: 10004634

Art no: 10004634

Art no: 10004634

Art no: 10004634

Art no: 10004634

Art no: 10004634

Art no: 10004634

Art no: 10004634

Art no: 10004634

8.2.4 Winch gear WG01
PWD3150 Position: WG01

n2 = 15 rpm
i=
65,7 72,6 81,5 94 112,1 141,2
TFEM M5(T5 - L2) [Nm.] 9.700 6.900
TSTAT [Nm.] 20.000
ATTENZIONE: per classi di appartenenza diverse dalle FEM M5(T5-L2), vedi tab. 1 pag 12.
Per valori diversi di n2 = 15 rpm, contattare il Servizio Tecnico Commerciale Brevini Riduttori.
IMPORTANT: for mechanism groups other than FEM M5 (T5-L2), see table 1 on page 12.
For output speeds other than n2 = 15 rpm, contact Brevini Riduttoris Technical Service.
ACHTUNG: fr Zugehrigkeitsklassen, die von den FEM - Klassen M5(T5-L2) abweichen, siehe Tabelle 1, Seite 13.
Wenden Sie sich fr Werte, die von n2 = 15 U/min abweichen, an die technische Verkaufsberatung
Brevini Riduttori.
ATTENTION: pour les classes dappartenance diffrentes de FEM M5(T5-L2), voir tab. 1 page 13.
Pour les valeurs diffrentes de n2 = 15 rpm, contacter le Service technico-commercial Brevini Riduttori.
ATENCIN: para categoras diferentes de la FEM M5 (T5-L2), vase la tabla 1 de la pg. 14.
Para valores de n2 diferentes de 15 rpm, contactar con el Servicio Tcnico de Brevini.
ATENO: para classes diferentes da FEM M5(T5-L2), consultar tab. 1 pg. 14.
Para valores diferentes de n2 = 15 rpm, entrar em contato com o Servio Tcnico Comercial da
Brevini Riduttori.
Type Connection Type Connection
SAE J 744C 00 611....(see page 98) Hydromatik A6VE 55 Z Integrated

*
Hydromatik A2FE 28 A 64600001730 Hydromatik A2FE 45 Z Integrated
*
Hydromatik A2FE 28 Z 64600001220 Samhydraulik H1CR 45 Integrated
*
Hydromatik A2FE 32 A 64600001730 Samhydraulik H1CR 55 AD Integrated
AD *
Samhydraulik H1CR30 64600001220 Samhydraulik H2VR 55 Integrated
*
Volvo F12 - 30 64600001730
Freni - Brakes - Bremsen - Freins - Frenos - Freios Riduttore - Gearbox - Getriebe

Rducteur - Reductor - Redutor
n1 max TB P Pmax F
Type
[rpm] [Nm. 10%] [bar] [bar] Kg. lt.
AD Integrated 5.000 397 24 300 M14 x 1,5 130 2
Length 14 mm.
00 FL350.6C 4.000 423 21 300 M12 x 1,5 138 2,5
Length 12 mm.
00 FL350.6C-OR/AO 3.500 423 21 300 M12 x 1,5 140 2
Length 12 mm.
Senza freni - Without brakes - Ohne Bremsen - Sans frein - Sin Frenos - Sem freios
00 SF 5.000 -- -- -- -- 120 2,5
34
N
18
x
20

R1
09
100
20
12
R1
F
19
15
1 5
10
10
160
300
300
R1
00
R
20
20
11
9
M12x25
N
N
M16x30
18
18
x2
x2
0
0
F
15
370
370
340
340
280 h8
280 h8
199
15.5
17
314
199
15.5
314
115
25
26
25
115
26
74
M16
15
93
82.5
75
150
176
195
74
M16
15
F
160 H7 135 H7
195 270 h8
270 h8
00 SF
330
330
35
186
AD
186
(*)
FL 5 + OR/AO
00
FL 5
AD
PWD3150
8.2.5 Slew drive SH01
MacGregor Item : 11015108
Position: SH01
SH11C
POMPE / MOTORI A CILINDRATA FISSA
FIXED DISPLACEMENT PUMPS / MOTORS
COD. 10-0015-A11 B/1

CARATTERISTICHE TECNICHE
TECHNICAL SPECIFICATIONS
Fluidi: Hydraulic fluids:

Utilizzare fluidi a base minerale con additivi anticorrosione, Use fluids with mineral oil basis and anticorrosive, antioxidant
antiossidanti e antiusura (HL o HM) con viscosit alla and wear preventing addition agents (HL or HM). Viscosity
temperatura di esercizio di 15 40 cSt. Una viscosit limite di range at operating temperature must be of 15 40 cSt. For
800 cSt ammissibile solo per brevi periodi in Condizione di short periods and upon cold start, a max. viscosity of 800 cSt
partenza a freddo, per valori superiori contattare S.A.M. is allowed, for different types of viscosity please contact
Hydraulik S.p.A. Non sono ammesse viscosit inferiori ai 10 S.A.M. Hydraulik S.p.A. Viscosities less then 10 cSt are not
cSt. Viscosit comprese tra i 10 e i 15 cSt sono tollerate solo allowed. A viscosity range of 10 15 cSt is allowed for
in casi eccezionali e per brevi periodi. extreme operating conditions and for short periods only.
Temperature: Temperature ranges:

Non ammesso il funzionamento dell'unit a pistoni con The operating temperature of the oil must be within -25C
temperature del fluido idraulico superiori a 115C e inferiori a 115C [-13F 239F]. For applications with lower
-25C. Per applicazioni con temperature inferiori contattare temperatures please contact S.A.M. Hydraulik S.p.A.
S.A.M. Hydraulik S.p.A.
Filtrazione: Filtering:
Una corretta filtrazione contribuisce a prolungare la durata in A correct filtering is essential for long and satisfactory life of
esercizio dell'unit a pistoni. Per un corretto impiego dell'unit axial piston units. In order to ensure a correct functioning of
a pistoni la classe di contaminazione massima ammessa the unit, the max. permissible contamination class is 21/19/16
21/19/16 secondo la ISO 4406:1999. according to ISO 4406:1999.
Pressione di esercizio: Operating pressure:

La pressione massima ammissibile sulle bocche in pressione The maximum permissible pressure on pressure ports is 430
430 bar continui e 480 bar di picco. Nel caso di due motori bar [6235 psi] continuous and 480 bar [6960 psi] peak. If two
collegati in serie limitare la pressione di esercizio totale motors are connected in series, total working pressure
P1+P2 a 700 bar massimi. P1+P2 has to be limited 700 bar max. [10150 psi].
Pressione in carcassa: Case drain pressure:

La pressione massima ammissibile in carcassa di 10 bar. Maximum permissible case drain pressure is 10 bar [145 psi].
Una pressione superiore pu compromettere la durata e la A higher pressure can damage the main shaft seal or reduce
funzionalit della guarnizione dellalbero di uscita. its life.
B/3
R
axial piston
Albero di uscita: Output shaft:
La tabella una guida per la determinazione dei carichi Table is a guide to determine max. permissible loads. Values
accettabili. I valori sono determinati in modo da garantire una are calculated in such a way to assure at least 80% of the
vita almeno pari all'80% della vita dei cuscinetti in assenza di bearing operating life where no external load is applied. The
carico esterno. I valori sono riferiti a carichi applicati nella published values are related to loads applied in the middle of
mezzeria dell'albero e nella direzione pi sfavorevole. shaft and in the least favourable direction.
Cilindrata / Displacement 055 063 075 090 108 125 160 180
(*) (*) (*) (*) (*) (*) (*)
Forza radiale (Fq max) N 9200 10300 11500 12900 13600 15900 18400 20600(*)
Radial load (Fq max) [lbf] [2068] [2317.5] [2587.5] [2902.5] [3060] [3577.5] [4140] [4635]
Carico N/bar 25 30 25.7 28.5 35 37 41 45

Load [lbf/psi] [0.375] [0.45] [0.386] [0.428] [0.525] [0.555] [0.615] [0.675]
250 bar 1920 2150 2300 2800 2900 3300 3800 4050
[3625 psi] [432] [484] [517.5] [630] [652.5] [742.5] [855] [911.2]
Forza assiale tirante (Fax max) N
Axial pulling load (Fax max) [lbf]
350 bar 2650 2990 3550 3800 4050 4550 5300 5800
[5075 psi] [596] [673] [798.75] [855] [911.25] [1023.7] [1192.5] [1305]
N < 100 bar 800 800 1000 1000 1250 1250 1600 1600
[lbf] [< 1450 psi] [180] [180] [225] [225] [281.25] [281.25] [360] [360]
Forza assiale spingente (Fax max)
Axial pushing load (Fax max)
N/bar > 100 bar 9 9 12 12 13 13 17 17
[lbf/psi] [ > 1450 psi] [0.135] [0.135] [0.18] [0.18] [0.195] [0.195] [0.255] [0.255]
(*) (*)
Massima forza radiale permessa per albero SAI (SH11C 055-063): Max permissibile radial force with SAI shaft (SH11C 055-063):
Fq max = 6500 N Fq max = 6500 N [1462.5 lbf]
Massima forza radiale permessa per albero SAM (SH11C 075-090): Max permissibile radial force with SAM shaft (SH11C 075-090):
Massima forza radiale permessa per albero SAO (SH11C 108-125): Max permissibile radial force with SAO shaft (SH11C 108-125):
Massima forza radiale permessa per albero SAP (SH11C 160-180): Max permissibile radial force with SAP shaft (SH11C 160-180):
Quando un carico radiale esterno applicato all'albero la vita When an external side (radial) load is applied to the drive
dei cuscinetti determinata dalla intensit, dalla posizione e shaft, the bearing life will vary accordingly to the magnitude,
dalla direzione della forza applicata. Il diagramma mostra come location and direction of the load. The diagram shows how the
la vita dei cuscinetti varia con la direzione del carico. Nel bearing operating life varies versus the direction of the load. In
diagramma il valore 100% rappresenta la vita dei cuscinetti in the diagram 100% represents the bearing operating life where
assenza di carico esterno. La direzione ottimale del carico no external side load is applied to the drive shaft. The
dipende dalla bocca dell'unit a pistoni in pressione. optimum direction is dependent on which port is pressurised.
Il diagramma mostra che per determinate direzioni di carico The bearing operating life increases up to 30% when the load is
possibile avere incrementi di durata della vita dei cuscinetti applied with some peculiar directions and the maximum
anche del 30%. L'aumento massimo di durata dipende dalla increase is dependent on the operating pressure and the
pressione di esercizio e dalla dimensione nominale dell'unit a nominal size of the unit.
pistoni. When considering the permissible axial force, the force -
Nel considerare la forza assiale permessa bisogna fare transfer direction must be taken in account:
attenzione alla direzione di trasferimento della forza: Pushing axial loads increase the bearing life.
Carichi assiali spingenti incrementano la vita dei cuscinetti. Pulling axial loads reduce the bearing life (if possible pulling
Carichi assiali tiranti riducono la vita dei cuscinetti (se axial loads should be avoided) .
possibile i carichi tiranti devono essere evitati).
B/4
R
axial piston
Guarnizioni: Seals:
Le guarnizioni utilizzate sulle unit a pistoni assiali SH11C Seals used on SH11C series are of FKM (Fluoroelastomer).
sono in FKM (Fluoroelastomer). Nel caso di impiego di fluidi In case of use of special fluids, contact S.A.M. Hydraulik
speciali contattare la S.A.M. Hydraulik S.p.A. S.p.A.
Regime minimo di rotazione: Minimum rotating speed:

Nessun limite minimo di velocit; se richiesta luniformit di No limit to Minimum speed; if uniformity of rotation is
rotazione, la velocit minima non pu essere minore di 50 required, speed must not be less than 50 rpm. In case of use
rpm. Per applicazioni particolari contattare la S.A.M. of special applications, contact S.A.M. Hydraulik S.p.A
Hydraulik S.p.A.
Installazione: Installation:
I motori possono essere installati in qualsiasi direzione e SH11C series motors can be installed in every position or
posizione. Queste unit a pistoni hanno le bocche separate direction. These axial piston units have separate ports and
dalla carcassa e devono essere obbligatoriamente drenate. drain chambers and so must be always drained. As for
Nel caso delle pompe l'installazione con albero verticale e al pumps, installation of the unit with shaft in vertical position
di sopra del serbatoio comporta alcune limitazioni. Per and above the tank involves some limitations. For further
maggiori dettagli consultare nel Catalogo Informazioni details see on the General Information Catalogue, the section
Generali la sezione Norme generali di installazione. General installation guidelines.
Valvole flangiabili: Flangeable valves:

Le valvole sono disponibili per i motori sia in circuito aperto Flangeable valves are available for motors both in open and
sia chiuso. Per maggiori informazioni consultare il catalogo closed loop. For more information see the catalogue Axial
Valvole Assiali. Valves.
Valvole di lavaggio: Flushing valves:

I motori possono essere forniti con la valvola di lavaggio. The motors can be equipped with flushing valves.
Per il montaggio diretto della valvola di lavaggio sui motori
The mount the flushing valve on motors, it is necessary to
necessario utilizzare un coperchio speciale. Per maggiori
use a special port cover. For more information see the
informazioni consultare il catalogo Valvole Assiali.
catalogue Axial Valves.
Relazione tra senso di rotazione e direzione di flusso: Relation between direction of rotation and direction of
La relazione tra il senso di rotazione dellalbero dellunit a flow:
pistoni SH11C e la direzione del flusso del fluido illustrata in The relation between direction of rotation of shaft and
figura. direction of flow in SH11C piston units is shown in the picture
Nota: nel caso di impiego come pompa la posizione di below.
montaggio del coperchio a determinare il senso di rotazione.
Note: for pump operation, the direction of rotation is
Normalmente linversione del senso di rotazione di una
determined by the port plate mounting position. Usually, in
pompa SH11C comporta lo smontaggio del coperchio ed il
order to change direction of rotation of a pump, port plate has
suo rimontaggio ruotato di 180.
to be removed, turned of 180 and reassembled.
Motore reversibile Motore reversibile Pompa rotazione destra Pompa rotazione sinistra
Reversible motor Reversible motor CW rotating pump CCW rotating pump
B/5
R
axial piston
DATI TECNICI
TECHNICAL DATA
Dimensione / Size 055 063 075 090 108 125 160 180
Cilindrata cm3/rev 56.35 63.26 77.82 86.23 108.4 124.8 163.9 178.1
Vg
Displacement [in3/rev] [3.437] [3.859] [4.747] [5.26] [6.612] [7.613] [9.998] [10.864]
bar 430 430 430 430 430 430 430 430
cont. pnom
Pressione max. [psi] [6235] [6235] [6235] [6235] [6235] [6235] [6235] [6235]
Max. pressure picco bar 480 480 480 480 480 480 480 480
pmax
peak [psi] [6960] [6960] [6960] [6960] [6960] [6960] [6960] [6960]
Motore (cont.)
n0 max rpm 5000 5000 4500 4500 4000 4000 3600 3600
Motor (cont.)
Velocit max.
n1 max cont. rpm 2000
Max. speed Pompa Non Disponibile
Pump Not Available
n1 max int.(1) rpm 3750
Motore l/min 282 316 350 388 433 500 590 641
qmax
Portata max. Motor [U.S. gpm] [74.45] [83.42] [92.4] [102.5] [114.31] [132] [155.76] [169.22]
Max. flow
Pompa (2) l/min 112 Non Disponibile
q1 max
Pump (2) [U.S. gpm] [29.5] Not Available
Motore kW 202 226 251 278 310 358 423 459

Pmax
Motor [hp] [270.68] [302.84] [336.34] [372] [415.4] [479.72] [566.82] [615.06]
Potenza max. a pnom
Max. power at pnom
Pompa (2) kW 80.5 Non Disponibile
P1 max
Pump (2) [hp] [107.87] Not Available
Costante di coppia Nm/bar 0.9 1 1.2 1.4 1.7 2 2.6 2.8

Tk
Torque costant [Ibfft/psi] [0.045] [0.05] [0.06] [0.07] [0.085] [0.1] [0.13] [0.14]
cont. Nm 386 433 533 590 742 855 1122 1219

Tnom
(pnom) [Ibfft] [284.48] [319.12] [392.82] [435.13] [546.85] [630.13] [826.91] [898.40]
Coppia max.
Max. torque picco
Nm 431 484 595 659 829 954 1253 1361
peak Tmax
[Ibfft] [317.65] [356.71] [438.51] [486.05] [610.97] [703.10] [923.46] [1003.06]
(pmax)
Momento di inerzia (3) kgm2 0.004 0.004 0.007 0.007 0.012 0.012 0.022 0.022
J
Moment of inertia (3) [Ibfft2] [0.094] [0.094] [0.1645] [0.1645] [0.2820] [0.2820] [0.5170] [0.5170]
Peso (3) kg 19 19 23.7 23.7 35 35 48 48

m
Weight (3) [Ibs] [41.876] [41.876] [52.23] [52.23] [77.14] [77.14] [105.79] [105.79]
Portata di drenaggio (4) l/min 1.2 1.2 2.5 2.5 3 3 3 3

qd
External drain flow (4) [U.S. gpm] [0.317] [0.317] [0.66] [0.66] [0.79] [0.79] [0.79] [0.79]
(Valori teorici, senza considerare hm e v; valori arrotondati). Le (Theorical values, without considering hm e v approximate values).
condizioni di picco non devono durare pi dell1% di ogni minuto. Peak operations must not exceed 1% of every minute. A
Evitare il funzionamento contemporaneo alla massima velocit e alla simultaneous maximum pressure and maximum speed not
massima pressione. recommended.
* I valori relativi alle pompe si riferiscono allimpiego in circuito aperto. * Pump values refer to open circuit operation.
Note: Determinazione della velocit ammissibile Determinazione della velocit limite / Speed limits calculation
(1)
La velocit di rotazione della pompa pu essere aumentata
aumentando la pressione sulla bocca di aspirazione. La velocit di
rotazione massima della pompa non deve superare in ogni caso il
valore n0 max indicato in tabella. Per la determinazione della velocit
massima di rotazione ammissibile in funzione della pressione sulla
bocca di aspirazione utilizzare il diagramma a lato. (2) Valori validi per
un regime di rotazione pari ad n1 max. (3) Valori indicativi. (4) Valori
medi a 250 bar con olio minerale a 45C e viscosit 35 cSt.
Notes: Calculation of permissible speed
(1)
The pump rotation speed my be increased by increasing the
suction pressure. The max. pump speed must be always less then
value n0 max shown in table. To calculate the max. permissible speed
related to the pump suction pressure see the diagram at side. (2) The
values are valid for a rotating speed of n1 max. (3) Approximate
values. (4) Average values at 250 bar [3600 psi] with mineral oil at
45C [113F] and 35 cSt of viscosity.
B/6
R
axial piston
DIMENSIONI FLANGIA ISO 4 FORI (OC)
DIMENSIONS ISO 4 BOLTS FLANGE (OC) SH11C 055-063 ME
S1, S2: Drenaggi (1 tappato) / Drain ports (1 plugged) - 1/2 G (BSPP)
A, B: Utenze / Service line ports
R: Spurgo (tappato) / Air bleed (plugged) - 1/8 G (BSPP)
LM2 Per funzionamento come motore
For motor operation
FM3-LM3 Per funzionamento come motore

For motor operation FM2 Per funzionamento come motore
For motor operation
VM2 Per funzionamento come motore

For motor operation FP2 Per funzionamento come pompa
For pump operation
CAW Albero cilindico

Parallel keyed shaft SAM Albero scanalato
Splined shaft SAI Albero scanalato
Splined shaft
B/11
R
axial piston
8.2.6 Slew gear SG01
Position: SG01Art no: 10009536
HYDRAMARINE Data sheet Page 1 / 6
Gear box RPR3065

Spare parts list
Reduction Stage Reduction Stage
Intermed. Flange
Output Support Reduction Stage Intermed. Flange Brake
Pinion
Art no: 10009536
Brake FL-635 00-3333
Part list Brake FL-635

Pos. Qty Description Notes
001 1 Casing
003 1 Piston
005 14 Spring
007 1 Shaft
009 1 Cover
011 6 Disk
012 6 Disk
013 1 Disk
015 1 O-ring Part of seal kit
019 1 Backup-Ring Part of seal kit
020 1 Backup-Ring Part of seal kit
022 1 Oil Seal Part of seal kit
024 1 Bearing
025 1 Bearing
027 1 Circlip
028 1 Circlip
029 1 Circlip
030 1 Circlip
040 6 Screw
041 6 Screw
043 6 Washer
15-22 1 Seal kit Part no.: 11006404
Art no: 10009536
Reduction Stage 00-4013
Pos Qty Description Note

001 1 Ring-Gear
003-007 1 Sun Pinion
031 2 O-ring
A Cogwheel
B Flange
C Bolt
D Sun Pinion
E Washer
F Ring
G Circlip
H Ring
Intermediate Flange 00-3005

001 1 Flange
003 8 Screw
009 8 Washer
011 3 Washer
013 3 Plug
Art no: 10009536

001 1 Ring-Gear
037 2 O-ring
047 1 Circlip
A Cogwheel
B Flange
C Bolt
D Washer
E Ring
F Washer
G Sun Pinion
H Screw
Art no: 10009536
Intermediate Flange 00-3008

001 1 Flange
003 10 Screw
005 10 Washer
007 4 Spring Pin
009 3 Washer
011 3 Plug

001 1 Ring-Gear
032 1 Circlip
035 2 O-ring
A Cogwheel
B Flange / Housing
C Bolt
D Washer
E Ring
F Washer
G Sun Pinion
H Circlip
I Washer
Art no: 10009536
Output Support 36-1100

001 1 Support
004 1 Circlip
005 1 Lock Nut
006 1 Spacer
007 1 Tab Washer
008 1 Washer
010 1 Bearing
011 1 Bearing
013 1 Nilos Ring
015 2 Oil Seal
016 1 Disk
018 4 Pin
020 1 Magnetic Plug
021 1 Washer
023 1 Nipple
024 1 Pipe
025 1 Nipple
026 1 Nipple
027 1 Grease Nipple
See also LSS03,01-04,01 for lubrication

8.2.7 Diesel HPU EH01
Position: EH01
8.2.8 Filter with element MH05/MH10
MacGregor item s: 10007275, 10009400
Positions: MH05, MH10
8.2.9 Electromotor M01
Position: -M01
DATA SHEET
CARGOTEC NORWAY AS your order............ 365210

Andyveien 27 mark..................................:
4623 Kristiansand
motortype..........................: 14BG 208-4AA66-Z200L our order............................: 1096049

mounting...........................: B3B5 date....................................: 14.02.12
protection class..................: IP 56 certificate no......................: 24447-AB.OIK
insulation class...................: F
duty...................................: S1-100% moment of inertia J (kgm2).: 0,245
mass (kg)...........................: 230 no load current (A)..............: 17,1/29,5-25,2
starting torque d.o.l. (%)......: 250-243 temp.rise surface (K).........: 33-32,8
starting current d.o.l. (%)....: 689-687 temp.rise windings (K)......: 81,2-73,9
frequency (Hz)...................: 50 frequency (Hz)...................: 60
output (kw)......................: 37 output (kw)......................: 42,5
speed (min-1)...................: C-CW - 1465 speed (min-1)...................: C-CW - 1765
voltage (Vac)....................: / 690/400 voltage (Vac)....................: 440-480
nominal current (A)..........: 40/69 nominal current (A)..........: 69
power factor cos.phi..........: 4/4 load 0,84 power factor cos.phi..........: 4/4 load 0,84
efficiency (%)....................: 4/4 load 92,1 efficiency (%)....................... 4/4 load 92
S1-100%: Y 690V 60Hz 37kW 40,7Amp Cos 0,82 efficiency(%)93,2 /1773rpm

anti condensation heating : consumption (W).: 2x40 voltage(v)..... : 230
marine classification.: amb.temp............: 45 C
high voltage dielectric test between phases and earth during 1 min (Vac)...........: 2000
overload test during 15 seconds overload torque (% FLT).......................................: 160
vibration severity according EN 34-14 (half key)........................: class "N" or as specified below.
bearings DE/NDE...: 6312-C3 6312-C3

spesial features 3 X PTC-THERMISTORS 130C
motor serial numbers...: 1008-1388377-003-1

9 CERTIFICATES
9.1 Declaration of Conformity
9.2 Third party approval
9.3 Certificates for lifting equipment
9.3.1 Wire certificate
9.3.2 Hook & Shackle certificates
For prving og underskelse av kjettinger,ringer,kroker,sjakler, svivler,
FORM. NR. 4
blokker og andre lfteredskaper, fr de tas ibruk og etter de har vrt
forlenget, forstrukket, forandret eller reparert ved sveising.
Certificate of test and examination of chains, rings, hooks, shackles, swivels and
pulley blocks, before being taken into use, and of such gear after it has been
lengthened, overstrained, altered or repaired by welding.
Sertifikat nr. : 0000312061/170/2012

Test Certificate No.
Mottaker : CARGOTEC NORWAY AS Kundens ordrenr.: 365436

Receiver : Customer Order No.:
Kjenningnr. eller Angivelse av det som er prvet Antall av det Datum da prven Anvendt Tillatt
merke som er prvet ble utfrt prvevekt (last) arbeidsbelastning
tonn tonn
Distingushing Description of gear Number tested Date of test Proof load applied Working load limit
number or mark ton ton
AD1, AD2 BSS KROK M/SVIVEL 16-8 8.0 T 3 * 16 8,0
SF : 4
Levert i hht./according to: Forskrift best.nr. 522 Maskiner

Referanse til standard/ref standard: EN-1677
* Av produsent/by producer
M IKKE VARMEBEHANDLES
NOT TO BE HEAT-TREATED
Navn og adresse til fabrikanten eller forhandlerne. CERTEX NORGE AS

Name and address of makers or suppliers.
Navn og adresse til den institusjon det selskap eller firma som utfrte prven og underskelsen. CERTEX NORGE AS
Name and address of public service. association, company or firm performing the test and examination.
Undertegnedes stilling i ovennevnte institusjon, selskap eller firma. Verkstedleder/Kontrollr

Name and address of makers or suppliers.
Vi attesterer at utstyret tilfredstiller kravene i <<Forskrift best. nr. 522 Vedlegg 1 Maskiner og best. nr 555 Bruk av arbeidsutstyr>>/ We certify that the
compliance with rules and regulations given in << Forskrift best. nr- 522 Machinery>> and <<best nr. 555 Use of Working Equipment>>
08/03/2012
Certex Norge AS
Underskrift/Signature
9.4 FAT report
10 Radio Remote Control User Manual
Position: -RCC97.1
InstructionManual
MC3Series
RadioRemoteControlSystems
MC35
MC36
MC3200
MC3300
Cavotec Micro-control as
Wesselsv2,7500Stjrdal,NorwayEmail:mc@cavotec.com
Tel.:+4774839860www.cavotec.com
MC3Seriesinstructionmanual
Contents
SAFETYNOTES 4
1 INTRODUCTION 5
1.1 ABBREVIATIONS 5
1.2 MARKING 5
1.2.1 TERMINALUNITS 5
1.2.2 BASEUNIT 5
2 SYSTEMDESCRIPTION 6
2.1 TERMINAL 6
2.2 BASEUNIT 6
2.3 CABLE(OPTIONAL) 6
2.4 ANTENNA 6
2.5 CARRYINGBELT/NECKSTRAP 7
3 FUNCTIONALDESCRIPTION 7
3.1 SIGNALENCODING 7
3.2 FEEDBACK 7
3.3 OPERATINGRANGE 7
4 MAINDATA 8
5 INSTALLATION 9
5.1 INSTALLINGTHEBASEUNIT 9
5.2 INSTALLINGTHEANTENNA 9
6 OPERATION 10
6.1 OPERATIONOFTERMINAL 10
6.1.1 START 10
6.1.2 STOPANDEMERGENCYSTOP 10
6.1.3 TIMEOUT 10
6.1.4 ACTIVITYCHECK 10
6.1.5 FREQUENCYSELECTION 10
6.1.6 MIN/MAXPROGRAMMING 11
6.1.7 STATUSINDICATIONSONTHETERMINAL 11
6.2 OPERATIONOFBASEUNIT 12
6.2.1 IRXSYSTEMS 12
6.2.2 FIELDBUSDISPLAYS 13
6.2.3 MCLINKCANDISPLAY 14
7 BATTERYCHARGERANDBATTERIES 15
7.1 CHANGINGTHEBATTERY 15
7.2 BATTERYCHARGERINSTALLATIONANDUSE 15
7.3 DISPOSINGTHEBATTERIES 16
7.4 POWERSUPPLY 16
8 MAINTENANCE 16
8.1 SPARE/REPLACEMENT 16
8.2 SERVICE 17
9 SAFETYOFMACHINERY 17
9.1 HARMONIZATION 17
9.2 SAFETYDATA 17
9.2.1 SAFETYFUNCTIONS 17
9.2.2 ESTOP 17
10 WARRANTY 18
Safetynotes
InspecttheMC3seriesequipmentbeforeusingit.
Checkforanydamagethatmaybeincurredduringshipping.
Donotopentheterminalunit.Therearenouserserviceableparts.
Donotusethedeviceifitappearstobedamaged.
UseonlyoriginalbatteriesfromCMC.
Avoidshockandvibrationsifpossible.
Donotuseoutsidetemperaturerange.
Donotimmerseinwater.
ENSURETHATTHESUPPLYVOLTAGEISCORRECT.
INSTALLATIONSHOULDONLYBECARRIEDOUTBYQUALIFIEDPERSONNEL.
CavotecMicrocontrolASreservestherighttomakeimprovementsand/orchangesinthe
productsand/orspecificationsdescribedinthisinformationatanytimewithoutnotice.
1 Introduction
TheequipmentoftheMC3seriesisdesignedforuseinharshindustrialenvironmenttocontrol
machinerysuchasoverheadcranes,hoists,recoveryvehicles,concretepumps,sludgetrucksetc.
Theremotecontrolsusejoysticks,pushbuttonsandtoggleswitchestocontrolthedesignated
equipment.
Asthedifferentremotecontrolmodelsvaryaccordingtocustomerrequirements,thismanual
describesonlyfunctionsthatarecommonforallMC3seriesdeliveries.Forcustomerspecific
systemspleaserefertoprojectdocumentation.
1.1 Abbreviations
CMC CavotecMicrocontrolas
PSD Projectspecificdocuments
1.2 Marking
1.2.1 Terminalunits
Theserialnumberandotherrelevantdatasuchasfrequency,projectnumberetc.isfoundonthe
backsideoftherespectiveunit.
1.2.2 Baseunit
Theserialnumberandotherrelevantdatasuchasfrequency,projectnumberetc.isfoundonthe
righthandsideoftherespectiveunit.
2 Systemdescription
Thesystemconsistsof
terminal(remotecontrolunit),withacarrying
beltorneckstrap
baseunitwithantenna
(batterychargerandbatteries)
Theterminalandthebaseunitareconnectedviaa
radiolink.Somesystemsarealsodeliveredwitha
cableforcommunicationbetweenterminalandbase
unitastheonlywayofcommunicationorasabackup
fortheradiolink.Whencommunicatingonlyby
cable,batterychargerandbatteriesarenotpartofdelivery.
Thesystemmayalsoconsistofmorethanoneterminal/baseunitoperatingtogether.
Ascustomerspecificationsvarygreatly,theterminalcomesindifferentmodelswhichdifferin
configuration,sizeandweight.
2.1 Terminal
TheterminalcontainstheEstopswitch,pushbuttons,joysticks,toggleswitchesandLEDindicator
lamps.Theterminaliscarriedbytheoperatorwithabeltoraneckstrap.
Models
MC3200
MC3300
MC35
MC36
2.2 Baseunit
ThepartofthesystemconnectedtothemachineorPLC.CMCdeliversoutputsignalstocontrol
machinery,andhasnoresponsibilityforcontrolelementsthatarepartsofmachinery.CMCcanonly
providecorrectoutputsignalsbasedoncustomersinformation.
2.3 Cable(optional)
Connectstheterminalwiththebaseunitandservesbothaspowersupplyandcommunicationline.
Cablecanbeusedasbackuporinsteadofradiocommunication.Whencableisconnectedsystem
willautomaticallycommunicateoncableandradiowillbedisabled.
2.4 Antenna
Locatedonorconnectedtothebaseunitwithacoaxialcable.Theantennacanbeofinternalor
externaltype.Externalantennacanbemountedonthebaseunitorsomedistanceawaywithan
extensioncablesuppliedbyCavotecMicrocontrol.
Themaximumlengthoftheantennaextensioncableis50m.
2.5 Carryingbelt/neckstrap
Beltorstraptocarrytheterminalsafelyandkeeptheoperatorshandsfree.Shouldbeused
whenevertheterminalisbeingoperatedforsafetyandcomfort.
Failuretousethebeltorstrapmaycauseinjuryasyouwillnothavepropercontrolofthe
terminal.
3 Functionaldescription
Theremotecontrolcommunicatesbyradiosignalsorbycable,withthebaseunitwhichisinstalled
atthedesignatedequipment.
3.1 Signalencoding
Uniqueencodingoftheradiosignalpreventsunintentionaloperationcausedbyinterferencefrom
otherradiosystems.
3.2 Feedback
Iffeedbackisconfiguredtheoperatorcanreadinformationfromthemachineattheoperator
terminal,viaadisplayorLEDS.Theinformationcouldincludee.g.%ofload,rpm,torque,speed,text
instruction,etc.Iffeedbackisadirectinputfrommachinery,customerisresponsibleforthe
informationbeingpresented.
3.3 Operatingrange
Dependingontheinstallationtheoperatingrangecanbefrom1001000m.Therangemaychange
accordingtothesurroundingsandotherequipment.Toachieveoptimalrange,careshouldbetaken
wheninstallingtheantenna(Chapter5.2).
4 Maindata
Terminal Base unit
Dimensions MC-3-5 230x175x160mm Physical size and weight of the housing

(LWH) will vary for each delivery. Please refer
MC-3-6 330x220x200mm to system specific drawings and order
specific documentation.
MC-3200 280x180x180mm
MC-3300 340x230x185mm
Weight 2-4kg (the weight will vary with the terminals

equipment)
IP class IP 65,optional IP66 or IP67, depending on configuration.
(Battery charger: IP-40)

Operating Temperature Between -25C and +50C
(Battery charger: between +10C and +40C)

Radio frequency AUTO/Selectable 418-870MHz. For guidelines on national regulations, contact CMC
Radio power <10mW, according to regulations
Operating range 100-1000m
Batteries Rechargeable Li-ion, 7.2V, 1600-1800mAh Power 12-24VDC

supply
Use only MC-3-series batteries from Cavotec. 85-265VAC 50/60Hz
Operating time Approx. 12 hours continuous operation with fully Input Refer to system specific
charged batteries. Range between 8 hours and 16 data.
hours depending on configuration
Time out Adjustable, 0-99 min. 30 min. default. Output Refer to system specific
data.
Defined in SW, must be configured before delivery
5 Installation
INSTALLATIONSHOULDONLYBECARRIEDOUTBYQUALIFIEDPERSONNEL.
ENSURETHESUPPLYVOLTAGEISCORRECT.
ConsidertheambienttemperatureandIPrating.
Iftheinstallationissubjecttoharshvibrations,usevibrationdampersavailablefromCMC.
5.1 InstallingtheBaseunit
1) Fastenthebaseunitsecurelyontoasuitablepartofthemachineorequipmentbeingcontrolled.
a) Installthebaseunitinaprotectedareanotbeingexposedtodamage
b) Ensurethatthebaseunitisinstalledwhereitwillnotbeconflictingwithmovingpartsin
operation
2) Reservespacearoundtheunittoensureeasyremovalofthelid/openingofthedoorandeasy
accesstotheconnectorsandbuttonsinthebaseunit.
Systemspecificschematicforconnectionsisgivenintheprojectspecificdocumentation.
5.2 InstallingtheAntenna
Mounttheantennasothereislineofsightbetweentheantennaonthebaseunitandtheterminal
carriedbytheoperator.Largemetalobjectsbetweentheterminalandantennaonbaseunitmay
stopthesignalandpreventoperation.
Takecarethattheantennawillnotbedamagedbymovingmachinery.
Donotmounttheantennainsideametalenclosure.Thereshouldbenometalobjectswithina
radiusof1mfromthecentreoftheantenna
Theantennamustbemountedvertically
Otherwirelessequipmentmayinterferewiththeradioremotesystem.Frequencyplanningis
importanttoavoidthis.ContactCMCforguidance
Ifmorethanoneantennaismountedatthesamesite,particularcareshouldbetakenwith
regardstosufficientchannelspacinganddistancebetweenantennas.Rangemaybedegradedif
thesearenotconsidered.ContactCMCforguidance
6 Operation
6.1 OperationofTerminal
MC3seriesterminalsareproducedtocontrolavarietyofequipment.Specificinstructionsarenot
givenhere,butarefoundintheprojectspecificdocumentation.Itisimportantthattheoperatoris
familiarwiththemachinebeingcontrolled,andhasbeengiventhenecessarytraining.
6.1.1 Start
Checkthatafullychargedbatteryisintheterminal.Pullout/twisttheEmergencyStopbuttonand
turntheterminalON.PresstheStartbuttoniffitted.
Afteraselftest(approx.1sec.)theterminalwillestablishcontactwiththebaseunit.
6.1.2 StopandEmergencyStop
PresstheEmergencyStopbuttontoactivateEmergencystop.Twistandpulltorelease.
ThesystemmaybeequippedwithStop/StandbyinsteadofEmergencystop;thisisindicatedbycolor
andlabelofStopbutton.
CorrectlabelandcoloronEmergencystop/Stop/Standbyinaccordancewithmachineryiscustomer
responsibility.CMCcanonlyprovidecorrectmarkinginaccordancewithcustomersinformation.
EmergencyStop/Stopbuttonisdefaultplacedontherighthandsideofterminal.
6.1.3 Timeout
Ifthesystemisnotusedforatimeitcanbeconfiguredtogointopowersavemodetoconservethe
battery.Timeoutcanbeadjustedfrom099minutesorturnedoff.Defaulttimeoutis30min.
6.1.4 Activitycheck
Forsafetyreasons,activitycheckmaybeaddedforallorforarangeoffunctions.Thiswillforcethe
switch/joysticktobesetinneutralpositionbeforetheoperatorisallowedtostartupterminal.
Asdefaultallfunctionshaveactivitycheck.
6.1.5 Frequencyselection
MC3seriessystemscanbedeliveredwithautomaticormanualfrequencyselection.
Ifautomatically,thesystemwillscanasetof2to8predefinedfrequenciesandfindanavailable
frequency(notoccupied/withlownoise).
10
Ifthesystemisequippedwithmanualselectiontherewillbeafrequencyselectbuttononthe
terminalorarotaryswitchtoselectthenextfrequencyprogrammedintothesystem.Thebaseunit
willautomaticallyscantofindthefrequencytheterminalissetto.Thefunctionshouldbeusedif
thereisbadlinktobaseunit,eithernoconnectionorofteninterrupting.Whenchangingfrequency,
alloutputswillgotoneutralpositionforashorttime.Thesystemstartsagainaswritteninchapter
6.1.1.Dependingonthesystemsetup,thesystemwill,afterpoweroffandon,startwitha
predefinedfrequencyorwiththelastselectedone.
6.1.6 MIN/MAXprogramming
Optionalthereisaneasy,quickandexactpossibilitytoprogramanalogueoutputfromtheterminal
side.
Ifsoyouwillfindtwobuttonsfor(min/max)ontheterminal.FordetailspleaserefertothePSD.
6.1.7 Statusindicationsontheterminal
TheterminalisdeliveredwithaLEDforstatusindications;thisisusuallymarkedwithSTATUSor
BAT.OnsystemsdeliveredwithLCDscreen,errorcodesandexplanationsarealsofoundthere.
Flashingpattern Description Action
Steadylight Normalcondition.Terminalis None

turnedon,batteryvoltageis
OK,nofaultisdetected
Slowflashinglightw/ostop(1 Lowbatteryvoltage Replacebatterywithafully

flash/sec.) chargedone.
Shortflashes(2flashes/sec.) Programmingmode Turnterminaloffandonagain

tostartnormaloperation.
1flashwithlongstop(every Processorfaultortestmode. Ensurethattheprocessor

2ndsec.) Indicatesaprocessormodule moduleBOOTjumperisnot
faultand/oraprocessorfault. turnedon.Replaceprocessor
moduleand/orprocessor.
2flasheswithastop Activityatstartup.Ajoystickis Setallswitches/joysticksto

outofcentreposition,ora OFFpositionand/orneutral
switchisinONposition. position.
3flasheswithastop Radiofault Change/replaceradiomodule.
4flasheswithastop Shutdownduetolowbattery Replacebatterywithafully

voltage chargedone.
5flasheswithastop Keyboardfault.Terminalisnot Thereisafaultattheinput

abletoreadswitches, module.
joysticksetc.
6flasheswithastop Shutdownduetoinactivity.The Turnterminaloffandonagain
11
terminalwillsoonturnitself tostartnormaloperation.
offsincenoswitches,joysticks
etc.havebeenactivated.
7flasheswithastop Prioritystop.Stopbuttonor Ensurestopbuttonisoutand

shockdetectorhavebeen turnterminalOFFandONagain
activated. tostartnormaloperation.
Shortflashesatthebattery Terminalinprogrammingmode Min/Maxprogrammingof

light analogfunctions
NoLED Terminaloff Ensureterminalcontainsa

chargedbatteryandisturned
on.Iftheterminalhasturned
itselfoffduetoinactivity,turn
itoffandonagaintostart
normaloperation.
6.2 OperationofBaseunit
AlltheMC3seriesbaseunitsareproducedaccordingtocustomerspecifications,thewiringdiagram
showshowthebaseunitisconnected.
Ifthebaseunitdoesnotoperatecorrectly,checkthedisplayformessages.Seebelow.
AllrepairsmustbecarriedoutbyarepresentativefromCMC.
6.2.1 IRXsystems
ThedisplayonIRXsystemsisamenusystemallowingviewingofalloperationalparametersand
serviceinformation.
Duringnormaloperation,thedisplayisdividedintothreefields,anupperline,thestatusandthe
timer.
Baseunitdisplaywhenthereisnocommunicationwiththe
terminal.
Normaloperation.Baseunitcommunicateswithterminaland
relay1and7areactivated.
Afatal(nonrecoverable)errorhasoccurred.
<msg>isatextdescribingthecause.TurnthesupplyOffandOn.
Ifthemessagereappears,themainboardisfaultyandneeds
replacing.
12
Thetimerfieldshowsthetimeelapsedsincethelastchangeofoperationalmode
(online/passive/idle/locked/blocked)inhours,minutesandseconds: 01:43:12
Indicationsintheupperline
[Error:E003] Failureinradiomodule.
[Error:E010] Auxportcommunicationerror.
[Error:E011] MUSbuscommunicationerror.
[Microcontrolas] Nocommunicationwithaterminalandnoonboard
relaysactive.
[..3......0......] Showsactivatedrelays,inthiscaserelays#3and#10.
Indicationsinthestatusfield
A4:30% Mostactiveanalogoutput.Inthiscasechannel4withoutputvalueof30%.
Online Normaloperation,baseunitcommunicateswithaterminal.
Passive Baseunitcommunicateswithaterminal,butEstoprelayisdeenergized.Maybe
causedbytoolowsupplyvoltage.Itisnotpossibletooperateequipmentwhenin
passivemode.
Idle Baseunitdoesnotcommunicatewithaterminal.
Locked Ifseveralterminalsareconfiguredforonebaseunit,thebaseunitcommunicates
withselectedterminalanddoesnotsearchforadditionalterminals(firstcomefirst
servemode).
Blocked Baseunitcommunicateswithaterminal,butisinactiveduetosoftplcfunction(e.g.
startbuttonisnotactivated).
6.2.2 Fieldbusdisplays
Fieldbusreceiversarealwaysdeliveredwitha4digitsegmentdisplay.Thisdisplayindicates
differentfaultstatusesaswellaswhatterminalisonlineatanygiventime.Onstartupthedisplay
alsoshowtheterminalIDssupportedinthisbaseunit.
13
Possibleindicationsindisplay
Display Comment
E001 CPUinPMfaulty
E003 Radioerrorornoradiopresent
E010 NocommunicationwithPLC
E011 NocommunicationwithslavePM
6.2.3 MCLINKCANdisplay
TheMCLINKCANisequippedwitha3digitsegmentdisplay.Thisdisplayindicatesoperationstatus
anderrormessages.Thedisplayisfoundontheupperrightcornerofthemodule.
Digit1 Indication
2 Remotestatus
3 CanOpenstatus
Digit2 Indication
0 Noterminalcommunication
Communicatingwithterminal
E Emergencystopfunctionisactivatedontheterminal
Digit3 Indication
P Preoperational
operational
S Stopped
U Unknownstate
Possibleindicationsindisplay
Display Comment
Normaloperation
E01 Waitingforsetupfiletobedownloaded
E03 Radioerrorornoradiopresent
E10 NocommunicationonCANbus
Fxx Fatalerror,powercycleisrequiredtoresumenormal
operation
14
7 Batterychargerandbatteries
Chargingbatterytakesupto3hours.Therechargeablebatteryhasalifetimeofapproximately1000
chargingcyclesor23years.Thesetimescanvaryaccordingtousage,systemspecificationsand
ambienttemperature.
Riskofelectricshockifusedincorrectly.
Donotusethedeviceifitappearstobedamaged.
Thebatterychargerisintendedforindooruseonly.Keepawayfromhighhumidityandheat.
7.1 Changingthebattery
UseonlybatteriesprovidedbyCMC.
1. Putthemachinebeingcontrolledintoasafeposition.
2. TurntheterminalOFF.
3. Removethebatteryandinsertafullychargedone.
4. TurntheterminalON.
5. Hotswap
Terminalswith2batteriesfittedcancontinuetooperatewithoutbeingswitchedoff.
Replaceonlyonebatteryatatime.

7.2 Batterychargerinstallationanduse
UseonlythebatterychargersuppliedwiththesystemorareplacementfromCMC.
1. Installthebatterychargerinacleananddryenvironment(+10Cto+40C).
2. Connectthechargertothecorrectsupplyvoltage.Usethecorrectpowercableforthe
countyyouusethecharger.IfyouchooseDCyoucanconnecton12VDCor24VDC.TheDC+
isinthecentre.Besuretheplugiscompletelyintheconnector.
3. Insertthebatterytobecharged.
4. Waittoseetheindicationthatchargingisnormal.Anindicatorshowswhenthebatteryis
charged.
15
RedLED:Batteryischarging
GreenLED:Batteryisfullycharged
YellowLED:Charger/Batteryisoutsidetemperaturelimits,chargingwillnottakeplace.
5. Batteriesnotinconstantuseshouldbechargedatleastonceevery6months.Optimal
storagetemperatureis510C.
7.3 Disposingthebatteries
Batteriesarehazardouswasteandmustnotbedisposedwithnormalrubbish.Youshould
disposethebatteriesaccordingtolocallawsandrules.
7.4 Powersupply
Someterminalmodelsareequippedwithacableandbatteries,andsomewithonlyacable.The
cableisconnectedtothebaseunit,andservesasbothpowersupplyfortheterminalunitand
communicationlinktothebaseunit.Formodelswithbothradiofunctionandcable,theradiomode
isdeactivatedassoonasthecableisconnected.Theterminalandthebaseunitthencommunicate
viathecable.Ifconnectingordisconnectingthecablethesystemsgetsashortcommunication
interruptandstartsagainautomatically.
Plugonthesideofterminal
8 Maintenance
Theterminalandbaseunitdonotneedanymaintenance.However,theunitsshouldbeinspected
fordamageandcleanedregularly,foralldisplays,labelsandsymbolstobereadproperly.
Forsafetyfunctionsthelifetimeofwearingpartsneedstobeconsidered.Thesepartsneedtobe
changedattheendoflifetimetofulfillthemachinerydirective.Limitationscouldbefoundinthe
PSD.Thecompanyowningthemachineneedstotakeresponsibilityforthis.
Donotopentheterminalhousing,itwilldegradethegasket.
Iftherubberbootsoftheterminalsjoysticks/switchesaredamaged,replacethematonce.
8.1 Spare/Replacement
Sparepartscanbeorderedthroughyourlocaldistributor.Youwillneedtheserialnumberfromthe
system,seesection1.1Marking,andthepartnumber.
Disposeofelectronicproductsaccordingtolocalrules.
16
8.2 Service
Servicecanbearrangedwithyourlocaldistributor.Youwillneedtheserialnumberfromthesystem
anddescriptionoftheservicerequired.
9 Safetyofmachinery
9.1 Harmonization
TheMC3seriesisdesignedinaccordancewith:
R&TTEDirective(99/5/EC)
o LowVoltageDirective(2006/95/EC)
o EMCDirective(2004/108/EC)
MachineryDirective(2006/42/EC)
Furtherstandardsandcertificatesmaybeincludeddependingontheapplication.
ThesystemiscertifiedaccordingtotheFederalCommunicationsCommissionrulesPart90sub
clause217.Tomaintainthedistanceof20cmfromthebodytotheantennaasrequiredintherules
theterminalshouldonlybeusedwiththecarryingbelt.
9.2 Safetydata
9.2.1 Safetyfunctions
TheMC3seriessystemshaveasetoffunctionsthatmaybeusedassafetyfunctions.Thesafety
functionsfulfilltherequirementstothemachinerydirective(2006/42/EC)
Thefunctionsthatmaybeusedassafetyfunctionsaretheemergencystopandpossibledigitaland
analogcontrolfunctionsusedfordangerousmovementfunctionsonthemachine.Thesafety
functionsendattheterminationpointsinbaseunit,whichistheinterfacetothecustomers
machine.
TheMC3seriesradioremotecontrolsystemisasubpartofacompletemachinery.Forthecomplete
machinerytofulfilltherequirementstothemachinedirectivethecustomerneedstoconsiderall
applicablesafetypartsofthemachinerytogetherwithoursystem.
LimitationsofoursystemcanbefoundinthePSD.
9.2.2 Estop
TheEstopinMC3seriessystemshastobepartofthemachinesEstoplooptobedefinedasE
stop.WhenevertheMC3seriesEstopisactivatedorthesystemisgoingintosafestate,theEstop
relayisdeenergized.
CustomerisresponsibleforcorrectconnectionoftheEstopintheEstoploop;CMCcanonly
providesufficientandcorrectinstallationandcommissioningdocumentation.
ThetablegivesanoverviewofwhichstandardstheCMCremotesystemandEstopcompliesto.
17
Compliesto System
ENISO13849 SafetyfunctionsCategoryBPLb
Allsystems
EN9541 EstopCat.3MCRLSsystems
EstopCat.4MCIRX2/MCIRX
LITE/MCLINKCANsystems
Tomaintainthespecifiedsafetylevels;theinstallation,operating,maintenanceandrepair
instructionsgiveninthismanualandinthePSDmustbefulfilled.
10 Warranty
AllthedeliveriesarethoroughlytestedandpackedbeforetheyleaveCMC.Ifthedeliveryisfoundto
bedamagedwhenitisopened,informthecarrierimmediately.CMCdoesnotcoveranydamages
causedduringtransport.
Allsystemsaredeliveredwarrantedagainstmaterialandmanufacturingfaults.Thewarrantycovers
repairsauthorizedbyCMCataCavotecpremises.ExpensesforserviceoutsideCMCarenot
included.
RepairsdonewithoutauthorityfromCMCmayinvalidateanywarranty.
Informationinthisdocumentissubjecttochangewithoutnotice.
2010CavotecMicrocontrolas
Allrightsreserved.
18
11 OTHER

MC Gregor Crane and 501-MOB-boat-davit - CARGOTEC - Manual SP2423-1-15 UM

Transféré par

Informations du document

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

MC Gregor Crane and 501-MOB-boat-davit - CARGOTEC - Manual SP2423-1-15 UM

Transféré par

Droits d'auteur :

Formats disponibles

PROJECT DOCUMENT Page 1 of 1

Customer Supplier Project number, supplier

P.O. number, customer

Equipment: MacGregor Crane

Type: HMC 1400 LK 30-18 (50-15) MOB27

Revision Reason for issue Date Author Checked by

2 MAIN DATA ........................................................................................................................................ 5

3 TECHNICAL DESCRIPTION .............................................................................................................. 6

4 PRESERVATION, STORAGE AND INSTALLATION ...................................................................... 13

5 OPERATING INSTRUCTIONS ......................................................................................................... 17

6.2.3 Electromotor ........................................................................................................................ 35

7 PARTS LIST ..................................................................................................................................... 41

8 DRAWINGS and DATA SHEETS .................................................................................................... 45

10 Radio Remote Control User Manual ............................................................................................ 63

1.2 Purchase information

1.3 If problems occur

+47 916 86 000

1.4 General security conditions

1.6 Restrictions in guarantee

1.7 After warranty period

1.8 Restrictions in use

1.9 HSE Health, Safety and Environment

Secure the maintenance work space!

When replacing heavier items, individual parts and/or heavy structural

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

Only authorized personnel may perform work on the electrical installation or

Whenever inspection, maintenance or repair work requires voltage free

Disconnection of live Warning!

Accidental Measures must be taken to prevent accidental activation of equipment

When in doubt ASK!

Environment Environmental considerations should be kept in mind when disposing of any

2.1 Technical data

2.2 Weight & outline dimensions

3.1 General technical description

3.2 Construction, main design

3.2.1 Crane pedestal

3.2.2 Crane king structure

3.2.3 Crane jib system

3.2.4 Jib / knuckle cylinder

3.2.5 Slew gear and slew bearing

3.2.6 Hydraulic system

3.2.7 Hydraulic winch

3.2.8 Hydraulic oil tank

3.2.9 Manual Overload Protection

3.2.10 Diesel HPU back-up (Option)

3.3 Electrical system

LOCATED BY CUSTOMER Radio Remote Cabinet

LOCATED INSIDE 3G1.5mm RESCUE BASKET

Electrical Block Diagram (typical layout)

The electrical system comprises the following main elements:

Starter Cabinet ES400

3.3.1 Starter Cabinet ES400

Start, stop and emergency stop of the HPU motor

Motor Motor Motor Power mller

-H4 -H3 -H2

3.3.2 Radio Remote Cabinet RRC97

Power available lamp

Power Radio Remote Rescue Basket Rescue Basket

-H1 -H2 -H3 -S6

START STOP Horn

-S1 -S2 -S4 -S5

3.3.3 Electromotor and slip ring

3.3.4 Radio Remote -Control Terminal RRC97.1