L9499462 GLB3628-2 - 28.828gr

INSTRUCTION MANUAL Project No.
Page
Dept. C7250 Date: 2011-09-26 2/10045.02LMW 1(6)
TABLE OF CONTENTS
No. of manuals 6 pcs + 1 pc CD-Rom
Certificate for
crane issued by: BV
Certificate for
foundation issued by: BV
IMO No. L9499462
Name of ship -
Newbuilding No. DY3071
Shipyard DAYANG
Owners CROWN
Project No. 2/10045.02LMW
Mfg. No. 62512129 Crane-1, 62512130 Crane-2, 62512131 Crane-3, 62512132 Crane-4
Type of crane GLB3628-2/28.828gr
Order specification 490 8565-801 - 804 /D
Mechanical spec. 490 8566-801 - 804 /-
Hydraulic spec. 490 8568-801 - 804 /A
Electrical spec. 490 8567-801 - 804 /C
Slewing spec. 490 8567-801 /B
SAFETY DOCUMENTS
Document names written with bold letters are documents with safety aspects.
INSTRUCTION NO. REV NAME OF INSTRUCTION
GENERAL 1 1.000.4 E d SAFETY INSTRUCTIONS

1.005 E e PREFACE
1.009 E a GENERAL INSTRUCTIONS, CLEANLINESS IN HYDRAULIC SYSTEMS
1.102 E c CONVERSION FACTORS
1.518.3 ED d HYDRAULIC AND ELECTRIC SYMBOLS
TECHN. DESCRIP. 2 2/10045.02LMW - TECHNICAL DATA

2.007.91 E - TECHNICAL DESCRIPTION
FUNCTION 3 3.110.122 E - HYDRAULIC FUNCTION

3.131.29 E a STARTING AND STOPPING, ELECTRIC SAFETY FUNCTIONS, SINGLE CRANES
3.142.35 E b CRANE CONTROL SYSTEM CC3000
3.155.3 E - THERMOSTATIC CONTROLLED VENTILATION FAN
OPERATION 4 PM40 1879-E00 - CREW CHECKLIST BEFORE AND AFTER OPERATION

PM40 5500-E00 b OPERATING INSTRUCTION
PM40 6491-E00 - OPERATION, START AND STOP
PM40 6495-E00 - SWITCH FUNCTIONS, GRAB HANDL RIGG AND PARK POWER CABLE AND S
PM40 7090-E00 - CONTROLS AND INDICATORS
PM41 0001-E - EMERGENCY ESCAPE INSTRUCTIONS
PM41 0014-E00 a EMERGENCY ESCAPE INSTRUCTIONS, ROPE LADDER/FIXED LADDERS
4.620.26 E a PARKING THE CRANE, SEA STOWING, GENERAL INSTRUCTION
4.630 E - HANDLING HATCHES BY DECK CRANE
MAINTENANCE 5 5.005.55 E g MAINTENANCE CHART

INSTRUCTION MANUAL Project No. Page
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TABLE OF CONTENTS
MAINTENANCE 5 5.018 E b INSPECTION OF STRESSED COMPONENTS AND STRUCTURES

5.025.3 E - CONTAMINATION SWITCH - CHIP DETECTOR
PM51 1730-E00 a LUBRICATING CHART
PM51 4200-E00 - LUBRICATING CHART FOR CABLE WINCH
PM51 4300-E00 - LUBRICATING CHART FOR STABILIZING WINCH
5.150.4 E - LUBRICATING AND MAINTENANCE, CRANES TYPE GLB
5.301.13 E a FILTERS
5.302.24 E - HYDRAULIC OIL TANK
5.315 E b SAMPLING OF OIL TO VERIFY THE CLEANLINESS IN HYDRAULIC SYSTEM
5.421.40 E d LUBRICANTS FOR DECK MACHINERY
SERVICE 6
6.0 6.000 E e HOW TO ORDER SPARE PARTS

6.000.1 E c STATEMENT REGARDING DELIVERY OF SPARE PARTS TO SWIVELS, LIFTING B
6.000.2 E d RETURN FORM
6.004.1 E bc WORLDWIDE SERVICE NETWORK
6.005.7 E - INTRODUCTION
6.1 6.100 E b MEASURES BEFORE STARTING, DURING AND AFTER COMPLETED SERVICE/M
6.106.4 E - TROUBLE-SHOOTING CHART, OVERHEATING
6.117 E b TROUBLE SHOOTING, PUMPS
6.120.18 E a SLEWING GEARSET
6.120.64 E o HYDRAULIC MOTORS, HOISTING, LUFFING, AND SLEWING CIRCUITS
6.120.108 E b WINCHES, HOISTING/LUFFING
6.121.3 E a TROUBLE-SHOOTING CHART, HYDRAULIC HIGH SPEED MOTORS
6.127.50 E b HIGH PRESSURE PUMPS
6.132.18 E a REPLACEMENT OF VANE PUMP, CRANE TYPE GLB
6.142.5 E a RECOMMENDATION FOR INSPECTION AND REPLACEMENT OF HYDRAULIC HO
6.189 E f HYDRAULIC PISTON ACCUMULATORS
6.2 6.209.15 E - INSPECTION OF CLIMB PROTECTION, JIB AND CRANE HOUSE TOP
6.214 E i TIGHTENING TORQUES STUDS/SCREWS AND BOLTS
6.215.21 E b SERVICE DOOR (OPENING AND CLOSING), SERVICE AND LUBRICATION OF DO
6.216.83 E a ROPE REEVING DIAGRAM FOR CRANES TYPE GLB-2
6.216.101 E - PARKING AND RIGGING OF CABLE WINCH CABLE AND STABILIZING WINCH WI
6.222.1 E a HANDLING, INSTALLATION AND MAINTENANCE OF STEEL WIRE ROPES
6.223.20 E c REPLACEMENT OF WIRES, ONE OR TWO FALL RIGGING
625/1473 E c INDENTATION AND WEAR ON WIRE SHEAVES
625/1560 E f LIFTING BLOCK/BEAM
625/1579 E i MEASURING PROCEDURE FOR WEAR IN SLEWING BEARINGS FOR ROPE LUFF
625/1651 E - SLEWING BEARING GREASE SAMPLING PROCEDURE
6.3 6.303.49 E e TROUBLESHOOTING, CRANE CONTROL SYSTEM CC3000, GLB-CRANE

6.303.61 E c CARD FRONT MENUS CT2, CC3000
6.303.68 E - ABSOLUTE ENCODER CALIBRATION, CC3000
424 0738 c SIGNAL OVERVIEW, CRANE CONTROL SYSTEM CC3000
424 0739 d ERROR MESSAGES, CRANE CONTROL SYSTEM CC3000
6.305.16 E - ELECTRICAL EQUIPMENT, GENERAL MAINTENANCE
6.307.14 E - SLIP-RING UNIT
6.311.12 E - OIL LEVEL FLOAT SWITCH AND OVERHEATING PROTECTOR
INSTRUCTION MANUAL Project No. Page
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TABLE OF CONTENTS
6.3 6.320.367 E b LIMIT SWITCHES IN HOISTING AND LUFFING WINCH SYSTEMS, CC3000
6.321.13 E a SLACK WIRE SAFETY SWITCH HOISTING AND LUFFING WINCHES
6.324.1 E b PREPARATION FOR OVERLOAD (OL) TEST MODE
6.324.2 E - PREPARATION FOR RIG MODE
6.324.3 E - PREVENT OPERATION IN HIGH SPEED
6.990.56 E - EMERGENCY LOWERING IN CASE OF COMPLETE POWER FAILURE, OPERA
EXTRA EQUIPMENT 7 7.003.2 E c CABLE WINCH, TYPE KFM

7.026.6 E - ELECTRIC STABILIZING WINCH, FUNCTION AND RIGGING OF WINCH WIRE
7.075.11 E - MacHEAVYVISOR, RELEASE 3.3
7.076.2 E c USER MANUAL DISPLAY, CC PILOT XS
APPENDICES 8
SPARE PARTS 9 SEE SEPARATE TABLE OF CONTENTS

PARTS MANUAL Project No. Page
Dept. C7250 Date: 2011-09-26 2/10045.02LMW 4(6)
TABLE OF CONTENTS
GROUP DESCRIPTION PART NUMBER FIG
9.0 HOW TO ORDER SPARE PARTS e 6.000 E
9.1 HOISTING WINCH COMPLETE 189 6696-801 C/ 625-1440.147A

HOISTING WINCH 189 6675-801 B/ 625-1450.147A
GEAR, COMPLETE 875 13019-122 -/ 625-1451.155
DRIVE IN, COMPLETE 875 13004-133 -/ 625-1451.156A
PRESSURE ROLLER, COMPLETE 875 13030-006 -/ 625-1451.010
OIL PIPE, COMPLETE 875 13009-071 -/ 625-1451.072A
HYDRAULIC MOTOR 391 0458-801 A/ 625-2205.037
LUFFING WINCH, C 189 1625-801 B/ 625-1440.046A
LUFFING WINCH 189 1622-801 C/ 625-1450.056A
HYDRAULIC MOTOR 188 1221-801 B/ 625-2205.009A
WINCH MOUNTING SET 289 5365-801 -/ 625-2250.022
SLEWING GEAR ASSEMBLY SET 391 0247-801 C/ 625-3254.024A
SLEWING GEAR ASSEMBLY 391 0279-801 A/ 625-3254.022A
SLEWING GEAR 289 1855-801 B/ 625-3255.034
DRIVE IN, COMPLETE 875 13004-127 -/ 625-3256.007B
HYDRAULIC MOTOR 188 1223-801 B/ 625-2205.010
9.2 PUMP UNIT 1196654 A/ 625-4935.213

GEAR BOX 391 0431-801 B/ 625-4940.033
TANDEM PUMP 391 0807-801 A/ 625-4944.001
TANDEM PUMP 391 0808-801 B/ 625-4944.002
PUMP 289 5330-801 D/ 625-4945.056A
SERVO VALVE 875 19801-001 -/ 625-4948.009
PUMP 289 5331-801 D/ 625-4945.057A
PUMP 289 5879-801 B/ 625-4945.055A
VANE PUMP 391 0571-801 -/ 625-4945.058
DISTANCE PIECE 391 0469-801 A/ 625-4963.014
DISTANCE PIECE 391 0470-801 B/ 625-4963.015
OIL COOLER 289 6815-801 A/ 625-5740.031
OIL COOLER ASSEMBLY SET 391 0300-801 -/ 625-5740.022
OIL COOLER ASSEMBLY 391 2766-801 -/ 625-5740.032
9.3 OIL TANK ASSEMBLY 189 3870-801 -/ 625-5865.033A

CRANE HOUSE ASSEMBLY 1190634 -/ 625-6102.520
SLEWING SPECIFICATION 490 6433-801 -/ 625-6122.030
PROTECTING CUP MOUNTING 391 1210-801 -/ 625-6125.001
COVER MOUNTING 390 3274-801 -/ 625-6169.005A
COVER ASSEMBLY 390 3282-801 -/ 625-6169.006
JIB BEARING MOUNTING 391 0467-801 -/ 625-6170.068
BEARING HOUSING ASSEMBLY 391 0468-801 A/ 625-6170.069
JIB TOP ASSEMBLY 1195437 -/ 625-6244.073
LIMIT SWITCHES BOX 289 5323-801 -/ 625-6245.635A
LIMIT SWITCHES BOX 289 5449-801 -/ 625-6245.643
LIMIT SWITCHES BOX, MOUNT. 489 6415-801 C/ 625-6248.001B
SLACK WIRE DEVICE 289 3396-801 B/ 625-6250.023
CRANE JIB, YARD MOUNTING 489 5409-801 C/ 625-6275.004C
CRANE JIB ASSEMBLY 1195436 -/ 625-6408.115
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TABLE OF CONTENTS
9.3 CRANE TOP ASSEMBLY 1195407 -/ 625-6459.071

PROTECTIVE PLATE MOUNT. 390 7581-801 -/ 625-6459.051
INCLINOMETER, C 388 0176-801 B/ 625-6509A
CAB INSTALLATION 289 6809-801 -/ 625-6540.040
CAB ASSEMBLY 190 0115-801 -/ 625-6545.068
CAB CUPOLA ASSEMBLY 289 2251-801 A/ 625-6560.007A
CAB DOOR ASSEMBLY 390 8573-801 A/ 625-6546.008
EMERGENCY DOOR ASSY 390 4053-801 A/ 625-6546.001
WINDSCREEN CLEANER 387 6227-802 F/ 625-6561.001C
VENTILATION FAN ASSEMBLY SET 289 4601-801 -/ 625-6625.022
VENTILATION FAN 388 9464-801 -/ 625-6625.015A
LIFTING BLOCK 289 5332-802 B/ 625-7013.096A
SLEWING BEARING 289 5664-801 -/ 289 5664
SLEWING BEARING MOUNTING 391 0452-801 A/ 391 0452
SLEWING BEARING YARD MOUNTING 391 0453-801 A/ 391 0453
LOAD WIRE ROPE 391 1870-801 -/ -
LUFFING WIRE ROPE 390 3376-805 F/ -
9.4 VALVE UNIT 289 1639-801 A/ 625-7207.006

VALVE UNIT 289 2557-801 -/ 625-7207.007
FLUSHING VALVE 388 3579-801 F/ 625-7287C
UNLOADING UNIT 388 3576-801 B/ 625-7291C
FILTER UNIT, INLET 189 1558-801 A/ 625-7314.007A
FILTER UNIT OUTLET 189 1559-801 A/ 625-7314.008A
DIRECTION VALVE 289 1597-801 C/ 625-7322.047
DIRECTION VALVE 289 1598-801 B/ 625-7322.048
FLUSH AND UNLOADING UNIT 388 3580-801 C/ 625-7449B
UNLOADING UNIT 388 3576-803 B/ 625-7802.004
ACCUMULATOR 388 0362-803 F/ 625-7951.005
HYDRAULIC HOSES 625-7970G
PRES. SWITCHES EXTRA OVERLOAD 288 1436-801 -/ 625-7994.001
FILTER ELEMENT 489 3104-801 C/ -
HYDRAULIC SYSTEM SPEC. 1000005178 -/ 1000005178
9.5 DRIVERS DESK 124 0827-801 A/ 625-8563.059

EL. INST. JIB LIGHT (CRANE) 124 0760-801 A/ 625-8567.049
EL. INST. JIB LIGHT (PACKING) 124 0761-801 A/ 625-8567.050
CONTROLLER, HOISTING 314 2005-802 D/ 625-8591C
CONTROLLER, LUFFING/SLEWING 314 2006-802 D/ 625-8592C
CONTROLLER 414 6792-801 A/ 625-8596
CONTROL PANEL RIGHT CT3 224 0483-801 -/ 625-8597.041
EL. INST JIB LIGHT (CABIN) 324 2043-801 A/ 625-8597.061
EL. INST. FORCE LIMIT GRAB (CABIN) 324 1724-801 A/ 625-8597.063
EL. INST. PMS (CABIN) 324 1723-801 A/ 625-8597.064
EL. INST. DECK LIGHT (CABIN) 324 1777-801 A/ 625-8597.070
EL. INST. RESET EMERG.STOP 324 1819-801 -/ 625-8597.071
ELECTRICAL VENT. FAN ASSY. 1202310 -/ 625-8597.072
EL.INST.HOIST/LUFF LIMIT (CAB) 1205863 A/ 625-8597.073
EL. INST. AIR CIRCULAT FAN (CAB) 324 1848-801 A/ 625-8597.074
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TABLE OF CONTENTS
9.5 EL.INST. EXTRA CABLE (CABIN) 324 1236-801 A/ 625-8597.075

EL. INST. CONTAM. SWITCH (CAB) 324 1864-801 -/ 625-8597.076
CONTROL PANEL, GRAB (CT23) 1214847 B/ 625-8597.089
EL. CABINET (CT1/CT2) 1198703 -/ 625-8598.121
EL. CABNET (CT19) 1215193 A/ 625-8598.132
RELAY CARD WITH LED'S 324 0089-801 A/ 625-8599.020
ASSEMBLY CT2 PLATE 324 1682-801 B/ 625-8607.011A
EL. INST. IMPULSE RELAY 224 0116-801 A/ 625-8650.001
EL. INST. PMS ELECTRIC CABINET 224 0119-801 D/ 625-8650.003
EL. INST. OIL TANK HEATER (CT1) 224 0474-801 B/ 625-8650.004
EL. INST. FORCE LIMIT GRAB CT1 224 0547-801 A/ 625-8650.005
EL. INST. POWER SUPPLY (CT1) 224 0506-801 A/ 625-8650.010
EL. INST. CARD RELAY (CT2) 224 0154-801 A/ 625-8650.011
EL. INST. SAFETY RELAY (CT1) 224 0249-801 A/ 625-8650.012
EL. INST. CONT. SWITCHES (CT1/CT2) 224 0429-801 A/ 625-8650.013
EL. INST. VENTILATION FAN (CT1) 224 0505-801 A/ 625-8650.014
EL. INST. AUX RELAY (CT1) 224 0548-801 -/ 625-8650.015
EL. INST. EXTRA CABLE (CT1/CT2) 124 0524-801 A/ 625-8650.016
CABIN DISPLAY 424 0715-801 C/ 625-8655.001
SLIPRING UNIT 314 3985-801 C/ 625-8750.005D
CABIN DISPLAY ASSEMBLY 1182879 -/ 625-9597.081
MC-CARD WITH SOFTWARE 324 2262-801 A/ -
CC-CARD WITH SOFTWARE 324 2261-801 A/ -
POWER / CABLE CONNECTION 1000004300 B/ 1000004300
ELECTRICAL SYSTEM SPEC. 1000006546 B/ 1000006546
ELECTRICAL SYSTEM SPEC. GRAB 1216175 B/ 1000012164
9.7 CABLE WINCH ASSEMBLY 324 1956-801 D/ 624-2145.009A

CABLE WINCH 387 7990-801 G/ 624-2158E
STABILIZATION WINCH 324 1401-801 -/ 624-2420.001B
MOUNT. STAB. AND CABLE WHEEL 189 7669-801 -/ 624-2435.010
HAND PUMP 189 1952-801 C/ 624-2492C
FIRE EXTINGUISHER, MOUNT 490 4074-801 A/ 624-2524A
STAB WIRE SHEAVE ASSY 189 7420-801 -/ 624-2162.011
EL. INST. HEAT. SLIPR. DEVICE 324 2274-801 -/ 624-2147.002
MOUNTING ENCODER 390 9851-801 A/ 624-2180.014
MOUNTING ENCODER 390 9852-801 A/ 624-2180.015
SENSOR ASSEMBLY 1196357 A/ 624-2195.013
EL. INST. EMERG. STOP PEDESTAL 124 0335-801 C/ 624-2196.006
LIFE LINE 388 0962-801 -/ -
GENERAL 1.000.4 E rev.: d 2010-10-07
Safety Instructions
Cargo Handling Equipment

The MacGREGOR crane is a cargo handling device. is not valid unless MacGREGOR authorized service
It is designed and manufactured to meet international is used.
cargo handling standards for quality, safety and
performance within capacity specifications and The use of proper Spares and Exchange details
outreach as per certificate.
MacGREGOR shall be contacted for ordering of ex-
change equipment and spares for this crane. Articles
The crane is designed for operation in harbour or shel-
supplied by MacGREGOR are designed and quality
tered water environments where there is no signifi-
tested for this application and are supplied with our
cant movement of the ship due to wave action.
warranty for correct function and safe working of the
crane.
Testing and examination
The crane shall be tested and thoroughly examined MacGREGOR accepts no liability for the functioning
and certified by a competent person after any of the crane systems, nor for the safe use of the crane,
substantial repair. unless original spare parts are used.
Supervision, Instructions, Signs and Warnings

Safe Operating Conditions, Proper Instructions and
Precautions Proper use of this crane and its equipment is possible
as long as the owners, users and operators maintain
The responsible officer on board shall ensure that the the crane to meet full operational standards. This in-
crane is operated under safe conditions, by personnel cludes the replacement of signs, instructions and
familiar with its functions and operating instructions. warnings as per delivery. MacGREGOR does not ac-
All safety and precautionary issues contained in this cept responsibility for any party who fails to ensure
manual must be observed. Proper instructions and that this manual, signs, instructions, and warnings are
precautions are prerequisites for proper use. legible and easily accessible to personnel.
Preparation for Use and Operation According to Improper Use

Manual
1. Elevation of persons.
The crane operator, authorized by the responsible of- 2. Exposing persons to the risks of falling cargo.
ficer on board, must be familiar with all safety issues 3. Overloading.
contained in this Chapter and with preparation for use 4. Unlocking the crane or crane jib or operating the
and operating instructions before work is started. equipment at sea without full acceptance and con-
trol of personnel and equipment safety.
5. Unprofessional, intended or unintended, adjustment
of safety locks, hydraulic or electric settings.
Maintenance and Service
6. Disregard of occupational and safety standards of
Prerequisite for proper use is regular maintenance (see
work.
Chapter 5) and service (see Chapter 6).
MacGREGOR are available for full service of this cargo

crane. MacGREGOR will take responsibility only for
its own professional services. Our product guarantee
1 (14)
GENERAL 1.000.4 E rev.: d 2010-10-07
Functions, Installations and Equipment Safety Functions and Equipment
General Specific safety equipment is installed and delivered

with this crane and must be available for its intended
The MacGREGOR crane has built-in safety functions
use. The owner/operator of the ship and its equipment
and installations to allow for safe normal use, opera-
is responsible to ensure that safety functions,
tion, care and control. This is applicable to instructed
installations and equipment are maintained to opera-
personnel without specific professional education or
tional standards and are not being removed, by-passed
certification, but working according to this manual.
or worn to non-working condition.
Specific service and repair of the electrical, hydraulic
This manual features important presentations of safety
and the mechanical functions, controls and settings
functions, installations and equipment. A summary is
require professional service personnel knowledgeable
presented below.
of risks involved.
1. Safety Functions
Regular Care and Control (Maintenance)
a. Maneuvring functions:
This manual contains checklists for regular care and
1. All the cranes working functions are stopped
control of crane equipment, wire ropes and hydraulic
and the brakes will automatically be activated
filters. These checklists routine contain inspections
when the emergency stop button is pressed.
and maintenance regularly prescribed for safe func-
The buttons are loacated in cabin and on the
tion, e.g.:
CT1-cabinet door. This action activates safety
stops and automatic lock positions.
Chapter 4 contains:
2. The crane has several fail-safe functions for
Safety Precautions Checklist for Single Cranes.
over-ruling or stopping the operators maneuvring
in the event that normal hydraulic or electrical
Chapter 5 contains, if applicable:
functions fail, a sudden uncontrolled movement
Inspection of Stressed Components and Structures.
occurs or during overspeed operation (see be-
Lubrication chart; Crane.
low).
Lubrication chart; Cable Winch and Stabilizing Equip-
3. There are limit switches for reducing speed of
ment.
or stopping all dangerous motions.
Lubrication chart; Power Swivel.
Filters. b. Hydraulic functions:
1. Hydraulic valve functions are set for exact pres-
Before maintenance and service work is started, cer- sure. Any change in the settings adversely af-
tain measures and procedures must be done. fects crane operation and must exclusively be
set by professional service personnel (see in-
Chapter 6 contains: structions Hydraulic function and High pressure
Measures before Starting, during and after completed pumps).
Service/Maintenance Work. 2. Hydraulic oil pressure sensor automatically in-
Handling, Installation and Maintenance of Steel Wire dicate an overload. For safe hoisting or lower-
Ropes. ing, the system automatically switch from a high-
Electrical Equipment, General Maintenance. speed movement to a lowspeed movement. If
Emergency Lowering in Case of Complete Power already in lowspeed the hoisting and luffing
Failure, Operation of Crane Using a Hand Pump crane movements stop.
(Optional). 3. In case of a ruptured high-pressure oil pipe/hose
or other feed pressure drops, the oil feed pres-
sure will collapse. A feed pressure switch stops
the crane and the mechanical brakes are auto-
matically applied.
2 (14)
GENERAL 1.000.4 E rev.: d 2010-10-07
4. If there is a multiple-disc failure caused by worn d. Mechanical functions:

out brake discs, sticking cylinder, brake pilot 1. Automatic sensors recognize dangerous wire
valve or valve spool, hydraulic braking by pumps slacks and stop hoisting and luffing movements
and motor is still available. that threaten safe control and the equipment
5. In case of overheating oil, a temperature sen- itself.
sor stops the control system, locking crane 2. Each working circuit has at least two independ-
operation. The electric motor continues in idling ent brake systems.
to maintain oil cooling. Dynamic braking, deceleration, is achieved by
6. Efficient oil filters protect the system from the regenerative function of motor and pump
harmful oil conditions. A warning light on the (hydraulic braking).
operator's panel indicates if the filter has to be True static braking (parking brakes) is pro-
changed. Dirty filter might cause mal function vided by multiple disc-brakes.
to the system. The mechanical brakes are automatically acti-
7. If the hydraulic oil tank oil level drops below the vated in the event of dangerous oil pressure.
minimum permissible level. Each winch is provided with one multiple disc-
A warning light on the operators panel is acti- brake.
vated. Each slewing gear unit is equipped with one
An indicator stops the main electric motor and multiple disc-brake.
crane functions are closed while all brake sys-
tems are automatically activated.
2. Safety Installations
a. Warning lights, measuring instruments and meters:
c. Electrical functions:
1. The operators panel is provided with warning
1. The crane control system protects the crane
lights which indicate clogged filters or low oil
from overload by using pressure sensors. See
level in the oil tank.
also section 3. Crane Control System ....
2. During crane start-up a warning light on the
2. During a complete power failure all solenoid
operators panel indicates that starting proce-
valves are de-energized, causing brakes to be
dures are still running and that working condi-
activated.
tions are not acceptable before the lamp goes
3. The electronic cabinets have power failure indi-
out. Maneuvres are not to be ordered before
cators. This function closes the electronic sig-
the warning light goes out.
nals down which automatically activates all
3. A pushbutton siren is located in the crane op-
mechanical brakes.
erators cabinet, allowing the operator to alert
4. Heat sensors located in the main electric motor
persons in the working area (e.g. against pro-
stop all crane operations and activate all brakes.
hibited riding on the load or against load move-
5. The overcurrent protections on all electric mo-
ments).
tors prevent the electric motors from overload-
4. Measuring instruments and meters (e.g. for
ing.
checking the crane functions, adjusting valve
The main electric motor overcurrent protection
positions, and setting functional positions) are
stops all crane operations and activates all
supplied as per agreement with the crane buyer/
brakes.
owner. Tools and equipment which are elimi-
6. A separate electrical feed for the crane house
nated from the original order to MacGREGOR
lights, operators cab and on jib, maintains func-
are delivered at the discretion of the owner.
tion of lights even during feed disruption to the
crane operating functions. As there is not a
b. Covers and houses:
separate emergency illuminating system for the
1. Unauthorized visitors in the crane house, es-
crane (this is dependent on the ships systems)
pecially during crane operation, is prohibited.
the owner of the crane must provide a battery
type flash-light for the operators cab.
3 (14)
GENERAL 1.000.4 E rev.: d 2010-10-07
The crane is a dangerous working area, and re- The fire extinguisher is for emergency use in-
quires special permission to enter. Instructions side the crane.
given by the superintendent or responsible of-
ficer must be followed. The equipment must be regularly inspected for
2. Covers for electric boxes must be opened only proper pressure reading at the meter and must
by authorized personnel. be serviced annually. This is to be supervised
by the responsible officer on board.
c. Alert and warning signs:
The crane is equipped with a system of danger, d. Test device:
warning, caution and notice signs. These signs At delivery, the MacGREGOR crane is
are presented on pages 6 - 15. equipped with two pressure gauges.
3. Safety Equipment
a. Locks, seals and keys:
1. Functions and equipment that are essential for
oil pressure settings, coordination of controls
and crane movements or expose dangerous
high-voltage electricity are locked. All keys to
locked positions and switches must be kept and
controlled by the responsible officer onboard and
are only to be used by qualified personnel.
2. Safety valves for hydraulic pressure settings
and switches for electric safety circuits are
sealed to secure correct position and trim.
Sealed equipment may be opened and positions
changed only after consulting the MacGREGOR
service organization for proper handling.
b. Safety belt, rescue line, safety chains:

1. For maintenance, service or entry to the open-
air outside the crane house, personnel must wear
a safety belt. The connector hook should be
anchored to rails and fixed position while staying
or working on crane top.
2. The rescue line and equipment for emergency
evacuation of the crane operator must always
be easily accessible on the interior wall-side of
the crane cabin. The equipment status and
completeness must be inspected regularly by
the responsible officer onboard.
3. The safety chains on the open-air crane top and
work platforms inside the crane, must be used
for attendants safety during stay and work.
c. Firefighting equipment:
A fire extinguisher shall be made available by
owner in the operators cabin.
4 (14)
GENERAL 1.000.4 E rev.: d 2010-10-07
Danger, Warning, Caution and Notice

Signs
Principles of Risk Classification

1. DANGER SIGNS are attached to equipment or are Replacement signs must follow international and
related to operations that will expose personnel to national standards. Signs of non-MacGREGOR de-
a life-threatening danger (e.g. high voltage electric- sign are not allowed. MacGREGOR does not ac-
ity). cept responsibility for unauthorized signs.
Safety installations, covers or houses prevent ex- Specific Presentation of Signs and Their Message
posure during normal working conditions, but can- All signs attached to the crane are illustrated on the
not eliminate the imminent risk for any unprofes- following pages. Each sign is given a specific number
sional/non-certificated person, should the danger to which it is referred.
sign not be followed.
Those risks classified as DANGER sign are pre-

sented and explained below with this presentation.
2. WARNING SIGNS are attached to equipment or

are related to operations that will expose personnel
to severe risk of physical injury. The injury is not
expected to be life-threatening. A warning sign is
also used to warn against misuse that risks severe
equipment and property damage.
The danger does not exist unless protection instal-

lations or devices are removed, providing proce-
dures are followed.
3. CAUTION SIGNS are attached to equipment or

related to operations that may produce a physical
risk to any person who is not cautious or aware of
the risk.
Any person should be able to avoid the danger.
4. NOTICE SIGNS are attached to equipment and

provide references to procedures, and instructions
or policies to follow to avoid danger to the function
and operation of the equipment or damage to the
equipment itself.
Responsible officers onboard must ensure that the

signs are in good condition and readable to any
person admitted to the crane area.
5 (14)
GENERAL 1.000.4 E rev.: d 2010-10-07
Alert / Warning signs
All signs used in MacGREGOR cargo handling cranes are presented below. Each sign in your specific crane has a
number on it, which can be found in the list and in the illustrations below.
PM40 7101-E00 REPORT TO SUPERINTENDENT OR OPERATORS ROOM FOR PERMIT TO ENTER

Any visitor to the crane must obtain a special permit from responsible officer on board. For
NOTICE SIGN authorized entry during crane operation, the operator must be fully knowledgeable of safety
precautions. The foundation, platform and crane are a dangerous working environment and
requiers that the authorized visitor understands relevant safety.
This sign is at the bottom entrance to the crane foundation.

PM40 7102-E00 DO NOT ENTER DURING CRANE OPERATION - MOVING CRANE HOUSE AND MACHINE
PARTS ...
WARNING SIGN Authorized entry requires that visitor is aware of the character of general risk and that visitor has
adequate Manual information about how to avoid the exposure.

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

PM40 7104-E00LADDER WILL ROTATE WITH CRANE - WATCH OUT!
This is specifically warn of exposure of the ladder leading up to the crane house. Upon crane
WARNING SIGN rotation, this ladder rotates and moves suddenly without warning.
This sign is at the bottom entrance to the crane (twin) platform.

PM40 7105-E00 RISK OF GETTING CAUGHT BETWEEN WIRE AND DRUM - WATCH OUT!
At start of and during winch operation there is a risk of getting caught and jammed by moving
WARNING SIGN wire. A safe distance from wire and drums must be maintained and adequate caution must be
regarded.
Attached to the crane wall surfaces close to winches.

PM40 7106-E00 RISK OF GETTING CAUGHT BETWEEN DRUM AND BRACKET - WATCH OUT!
This sign warns the visitor about the risk of getting jammed during drum rotation.
Adequate caution must be regarded.
WARNING SIGN
Attached to brackets and walls of work platforms inside crane
6 (14)
GENERAL 1.000.4 E rev.: d 2010-10-07
PM40 7108-E00 RISK OF GETTING CAUGHT BETWEEN WIRES DURING CRANE OPERATION - WATCH
OUT!
This sign warns about the risk of moving wires that may catch and jam personnel.
The authorized visitor must be aware of the risk and be cautious to avoid being seriously hurt.
WARNING SIGN
This sign is attached to the steel bracket side at the open-air crane top entry.
PM40 7109-E00 RISK OF FALLING DOWN - USE SAFETY BELT!
During any visit to the crane top (e.g. for service jobs), the authorizing officer and the person
entering to the area must fully understand the risks involved.
WARNING SIGN
The safety belt must be worn during any visit to the crane top.
This sign is attached to the steel bracket side at the open-air crane top entry.
PM40 7111-E00 ROTATING FAN - KEEP HANDS OFF!
The rotating fans are protected by grids and the risk is for anyone who sticks fingers or hand
inside. This can be avoided by sign information.
CAUTION SIGN
Attached to fan houses on the open-air crane top and to wall surfaces near the top roof of the
crane.
PM40 7112-E00 RIDING ON CARGO FORBIDDEN
For the attention of the crane operator, to observe that the crane is a Cargo Handling device.
DANGER SIGN The crane operator is obliged to stop operation and to alert any person riding to keep off. The
operators alarm bell, in the crane operators cabin, may be used, preferably.
Attached on the wall side of the crane operators cabin.

PM40 7113-E00 HOT OIL AND SURFACES - WATCH OUT!
During crane operation, surfaces of oil heated equipment are extemely hot.
Service personnel dismounting such equipment (e.g. checking and setting valves) must be
NOTICE SIGN aware of this exposure.
Attached to surfaces inside the crane house, close to pumps, valves, pipes and manifold blocks.
Also in the foundation close to oil tank and pipes.
PM40 7114-E00 DANGEROUS OIL PRESSURE - BE CAREFUL!
The oil pressure inside oil pressure pipes is 25 - 350 bar.
Under normal working conditions, this exposes no risk for personnel because of rigorous pipe
WARNING SIGN quality control and dimensions and specifications applied to the equipment. For specific ser-vice
work, exchange of parts or equipment, the exposure may be dangerous for unqualified or
uninformed personnel.
Instructions for service must be followed and must be restricted to qualified personnel only.
Attached to surfaces close to pipes inside the crane house.
7 (14)
GENERAL 1.000.4 E rev.: d 2010-10-07
PM40 7115-E00SLIPPERY SURFACES - WATCH OUT!

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

PM40 7116-E00 STARTS AUTOMATICALLY WITHOUT NOTICE, AT +10C (+50F)
Under normal working conditions, of risk is not exposed to any person near of fans. During
service or upon removal of covers, the risk must be recognized. Such operation is restricted to
NOTICE SIGN qualified personnel only.
Attached to cooling fans, at the open-air crane top, and at the inside top roof.
PM40 7117-E00 HIGH VOLTAGE INSIDE - DO NOT OPEN! AUTHORIZED PERSONNEL ONLY
High voltage equipment, couplings and boxes are covered and do not expose risk unless co-
vers or hoses are removed. Access is restricted to qualified and authorized personnel only.
DANGER SIGN
Attached to electrical equipment and boxes where 110 V or 440 V is exposed after covers are
removed.
PM40 7118-E00 RISK OF FALLING DOWN - APPLY SAFETY CHAIN!
During any visit to the work platforms, the authorizing officer and the person entering the area
must fully understand the risks involved.
WARNING SIGN The safety chains (at work platforms) must be used to prevent personnel from falling.
Attached to the steel bracket side at the open-air crane top platform, and at the crane work
platforms inside the crane house.
PM40 7119-E00 HIGH VOLTAGE INSIDE - DO NOT OPEN BEFORE MAIN SWITCH (Q1) IS SWITCHED OFF!
AUTHORIZED PERSONNEL ONLY
High voltage equipment, couplings and boxes are covered and do not expose risk unless
covers or hoses are removed. Access is restricted to qualified and authorized personnel only.
DANGER SIGN
Attached to electrical equipment e. g. electric main motor.
PM40 7122-E00 RISK OF BODILY INJURY - SUSPENDED LOAD - WATCH OUT!
The crane operator must ensure that the suspended load does not expose personnel below to
risks of falling material. The crane operator must stop operation and alert personnel.
DANGER SIGN The operators alarm bell in the crane operators cabin is preferably used.
Applied on the wall side of the crane operators cabin.

PM40 7123-E00 RISK OF GETTING CAUGHT BETWEEN WIRE AND WIRE SHEAVES - WATCH OUT!
This sign warns of the risk of moving wires that may catch and jam personnel.
The authorized visitor must be aware of the risk and be cautious to avoid being seriously hurt.
WARNING SIGN
This sign is attached to the steel bracket side of the open-air crane top entry.
8 (14)
GENERAL 1.000.4 E rev.: d 2010-10-07
PM40 7124-E00 RISK OF BODILY INJURY. EMERGENCY OPERATION, AUTHORIZED PERSONNEL ONLY
OPERATE WITH UTMOST CARE, SEE INSTRUCTION
Emergency operation of luffing and slewing, in the event of complete power failure or main
DANGER SIGN pump unit failure, is extremely difficult and dangerous.
This operation must be undertaken with great care and only by skilled personnel. Instructions
must be observed at all times.
Attached to the wall side of the crane operators cabin.
PM40 7125-E00 DANGER - KEEP OUT OF WORKING AREA!
The working area of the crane, over deck as well as over the deck-sides, is dangerous for
personnel, equipment or property. Items lifted or articles dropped may cause death, injury or
DANGER SIGN severe damage.
The crane operator must stop operation and alert personnel.
The operators alarm bell must also be used for attention.
Attached on both sides of the crane jib.
PM40 7127-E00 220V INSIDE. DO NOT OPEN! AUTHORIZED PERSONNEL ONLY
This high voltage equipment is covered and does not expose risk unless cover is removed.
The electrical equipment inside cover is powered even if the main switch has shut off other
DANGER SIGN electrical supply.
Access is restricted to qualified and authorized personnel only.
Attached outside and inside the cabin.

PM40 7129-E00 STARTS AUTOMATICALLY WITHOUT NOTICE AT +25C (+80F)
Under normal working conditions, of risk is not exposed to any person near of fans. During
service or upon removal of covers, the risk must be recognized. Such operation is restricted to
NOTICE SIGN qualified personnel only.
Attached to cooling fans, at the open-air crane top, and at the inside top roof.
PM40 7130-E00 DANGEROUS OIL PRESSURE. BE CAREFUL!
The oil pressure inside oil pressure pipes is 25 - 350 bar.
Under normal working conditions, this exposes no risk for personnel because of rigorous pipe
quality control and dimensions and specifications applied to the equipment. For specific service
WARNING SIGN work, exchange of parts or equipment, the exposure may be dangerous for unqualified or
uninformed personnel.
Instructions for service must be followed and must be restricted to qualified personnel only.
Attached to surfaces close to pipes inside the crane house.

PM40 7131-E00RISK OF GETTING CAUGHT BETWEEN DRUM AND BRACKET - WATCH OUT!
This sign warns the visitor about the risk of getting jammed when the drum is rotating.
WARNING SIGN Adequate caution must be exercised.
Attached to brackets and walls of work platforms inside the crane.

PM40 7132-E00 HOT OIL AND SURFACES - WATCH OUT!
Surfaces of equipment in which there is hot oil can be extremely hot when the crane is in
operation. When service personnel are working on such equipment (e.g. checking and setting
NOTICE SIGN valves) they must be aware of the danger.
Attached to surfaces inside the crane housing, close to pumps, valves, pipes, and manifold
blocks. Also in the foundation, close to oil tank and pipes.
9 (14)
GENERAL 1.000.4 E rev.: d 2010-10-07
PM40 7134-E00RISK OF GETTING CAUGHT BETWEEN WIRE AND DRUM. WATCH OUT!
When the winch is started and during operation, there is a risk of getting caught and jammed by
moving wire. A safe distance from wires and drums must be maintained and adequate caution
WARNING SIGN must be exercised.
Attached to the crane wall surfaces close to winches.

PM40 7135-E00 RISK OF GETTING CAUGHT BETWEEN DRUM AND BRACKET - WATCH OUT! This
sign warns the visitor about the risk of getting jammed when the drum is rotating.
WARNING SIGN Adequate caution must be exercised.
Attached to brackets and walls of work platforms inside the crane.

PM40 7136-E00 RISK OF GETTING CAUGHT BETWEEN WIRES DURING CRANE OPERATION - WATCH
OUT!
This sign warns about the risk of moving wires, that may catch and jam personnel.
Authorized visitors must be aware of the risk and be very cautious to avoid serious injury.
WARNING SIGN
This sign is attached to the steel bracket at the open-air crane top entry.
PM40 7140-E00 HIGH VOLTAGE, SEPARATE FEED, EVEN WHEN MAIN SWITCH (Q1) IS SWITCHED OFF.
AUTHORIZED PERSONNEL ONLY.
High voltage equipment, couplings and boxes are covered and do not expose risk unless co-vers
DANGER SIGN or hoses are removed.
Boxes with this sign are powered even if main switch has shut off other electrical power. Access
is restricted to qualified and authorized personnel only.
Attached to electric cabinet CT1.
PM40 7142-E00 HIGH VOLTAGE INSIDE. DO NOT OPEN! AUTHORIZED PERSONNEL ONLY
This high voltage equipment is covered and does not expose risk unless cover is removed.
The electrical equipment inside cover is powered even if the main switch has shut off other
DANGER SIGN electrical supply.
Access is restricted to qualified and authorized personnel only.
Attached to the cover of slipring device in the foundation.
10 (14)
GENERAL 1.000.4 E rev.: d 2010-10-07
Fig. 1. PM40 7101-E00 Fig. 2. PM40 7102-E00
Fig. 3. PM40 7103-E00 Fig. 4. PM40 7104-E00
Fig. 5. PM40 7105-E00 Fig. 6. PM40 7106-E00
Fig. 7. PM40 7108-E00 Fig. 8. PM40 7109-E00
11 (14)
GENERAL 1.000.4 E rev.: d 2010-10-07
Fig. 9. PM40 7111-E00 Fig. 10. PM40 7112-E00
Fig. 11. PM40 7113-E00 Fig. 12. PM40 7114-E00
Fig. 13. PM40 7115-E00 Fig. 14. PM40 7116-E00
Fig. 15. PM40 7117-E00 Fig. 16. PM40 7118-E00
12 (14)
GENERAL 1.000.4 E rev.: d 2010-10-07
Fig. 17. PM40 7119-E00. Fig. 18. PM40 7122-E00
Fig. 19. PM40 7123-E00 Fig. 20. PM40 7124-E00
Fig. 21. PM40 7125-E00 Fig. 22. PM40 7127-E00
Fig. 23. PM40 7129-E00 Fig. 24. PM40 7130-E00
13 (14)
GENERAL 1.000.4 E rev.: d 2010-10-07
Fig. 25. PM40 7131-E00 Fig. 26. PM40 7132-E00
Fig. 27. PM40 7134-E00 Fig. 28. PM40 7135-E00
Fig. 29. PM40 7136-E00 Fig. 30. PM40 7140-E00
Fig. 31. PM40 7142-E00
14 (14)
GENERAL 1.005 E rev.: e 2003-09-09
Preface
This instruction manual covers the MacGREGOR Spare parts

hydraulic deck crane. We hope that it will prove a General advice how to order spare parts; spare parts
valuable companion to everyone concerned with the lists and illustrations.
operation of the crane or otherwise in a responsible
position.
Every manual belongs to a specific crane or piece of

equipment. The identification can be found on the label
on the manuals back.
The manual contains nine sections. The various

sections cover the following subjects:
General
Contents list; Safety; Conversion tables; Hydraulic
and electric symbols.
Technical description
Technical data; description of crane design.
Function
Electric and hydraulic functions of the crane.
Operation
Operating instructions; crane operators checklist.
Maintenance
Lubricating chart and maintenance instructions.
Service
General service instructions for the hydraulic system,
mechanical, control system and electrical equipment.
Extra equipment
Extra equipment, if any; e.g. cargo handling equip-
ment.
Appendices
Other information, which cannot be referred to any of
the above mentioned sections.
1 (2)
GENERAL 1.005 E rev.: e 2003-09-09
THIS PAGE IS INTENTIONALLY LEFT BLANK
2 (2)
GENERAL 1.009 E rev.: a 1996-05-20
General Instructions
Cleanliness in Hydraulic Systems
General
The fundamental and foremost rule in all work with Use a brush for cleaning, wipe off with a non-
hydraulic systems and components is absolute linting rag, repeat the cleaning if necessary. Fin-
cleanliness. ish by spraying the area of operations - hose con-
nections etc. - with the solvent.
Many components, e.g. valves and pumps, have 4. Mount protective covers immediately after remov-
very narrow tolerances, therefore microscopic im- ing a component, a pipe or a hose. Components,
purities, invisible to the human eye, may have dis- shall also be fitted with covers and plugs in order
astrous effect on the function of a hydraulic sys- to prevent ingress of dirt.
tem. These covers must be kept in clean and closed
packages. After use, covers are to be cleaned in
The hydraulic system installation contains a cleaner the workshop.
with a cartridge designed to stop impurities pro- 5. Observe minute cleanliness when handling all
duced within the hydraulic system during operation. types of quick-release connectors. Spray both
Every care must be taken to prevent external im- connectors with solvent before making up a con-
purities from entering the system when servicing or nection. Clean all covers before reinstallation.
repairing it.
Storing and filling up of hydraulic oil
This also applies for components that have been
1. Store barrels, hoses and pump as clean as pos-
removed and or to be reinstalled. Sooner or later, a
sible and best of all in a warm room. The oil vis-
component that has been replaced will be inspected
cosity will then be considerably lower, which
in a test equipment somewhere. It is important that
make the filling through filter easier.
the component stays in the same condition as it was
2. Barrels, hoses and pump must be carefully han-
when it was removed, as it may otherwise be
dled and cleaned when necessary.
impossible to decide the real cause of a malfunction.
3. Store barrels horizontally, so plugs (or cocks) are
It may also be possible that a component sent in
below the liquid level and impurities (e.g., damped
for inspection is not defective at all, and will be
air) does not penetrate the barrels.
returned.
4. Observe minute cleanliness when filling up oil -
carelessness is one of the greatest sources when
Rules when working on the hydraulic system impurities penetrates the hydraulic system.
The following fast rules shall be observed during 5. Fill up hydraulic oil. See separate instruction.
working on the hydraulic system: 6. Never use the last drop in the barrel, as it often
consists of water and other impurities depend-
1. Carry out a rough general clean-up. ent on how many times the barrel has been
2. Protect the area where work shall be done. Use opened.
a sheet of plastic material or similar.
3. Clean well with white spirit or a similar solvent.
Remember that it is not enough to clean only the
parts immediately concerned, but also their sur-
roundings from where accumulated dirt may be
transferred in to the repair area. Do not forget to
clean the tools to be used.
1 (2)
GENERAL 1.009 E rev.: a 1996-05-20
2 (2)
GENERAL 1.102 E rev.: c 1999-09-14
Conversion Factors
Length Pressure
1 mm = 0,0393701 in (tum) 1 atm = 14,6959 lbf/in2 (psi)
1 m = 3,28084 ft (fot) 1 atm = 1,01325 bar
1 in = 25,4 mm 1 atm = 1,03323 at
1 ft (fot) = 304,8 mm 1 bar = 0,986923 atm
1 at = 14,2233 lbf/in2 (psi)
Volume 1 at = 0,980665 bar
10 lbf/in2 = 0,689476 bar
1 dm3 = 1 litre = 0,219969 gallon (UK)
10 lbf/in2 = 0,70307 at
1 dm3 = 1 litre = 0,264172 gallon (US)
1 bar = 1,01972 at
1 gallon (UK)= 4,54609 dm3
1 bar = 14,5038 lbf/in2 (psi)
1 gallon (US)= 3,78541 dm3 2
1 kp/cm = 14,2233 lbf/in2
1 bar = 100 kPa = 0,1 MPa
Mass 1 Pa = 1 N/m2
1 kg = 2,20463 lb 1 Pa = 10,2 10-6 kp/cm 2
1 lb = 0,45359 kg 1 Pa = 0,145 10 -6 lbf/in2
1 ton (metric) = 1000 kg 1 Pa = 7,5 10-3 mm Hg
1 ton (UK) = 1 longton (US) 1 kp/cm2 = 98,07 103 Pa
1 ton (UK) = 1016,05 kg
Power
Force 1 kW = 1,35962 hk
1 kp = 2,20462 lbf 1 kW = 1,34102 hp (UK, US)
1 kp = 9,80665 N 1 hk = 0,986320 hp (UK, US)
1 lbf = 4,44822 N 1 hp (UK, US) = 1,01387 hk
1 lbf = 0,453592 kp 1 hk = 0,735499 kW
1N = 0,101972 kp 1 hp (UK, US) = 0,745700 kW
1N = 0,224809 lbf
Temperature
Moment of force 0C = 32F
1 kpm= 9,80665 Nm 0C = 273,15 K
1 kpm= 7,23301 lbf ft 0F = -17,7778C
1 Nm = 0,737562 lbf ft 0F = 255,3722 K
1 lbf ft = 0,135582 daNm 0K = -273,15C
1 lbf ft = 1,35582 Nm 0K = -459,67F
1 lbf ft = 0,13825 kpm
1 daNm = 1,01972 kpm 1
C = (F - 32) F = 1,8 (K - 273,15) + 32
1 daNm = 7,37562 lbf ft 1,8
1
F = C 1,8 + 32 K= (F - 32) + 273,15
1,8
Moment of inertia
C = K - 273,15
1 kg m 2 = 3417,17 lb in2
1 lb in 2 = 0,00029264 kg m2 K = C + 273,15
1 (2)
1.102 E rev.: c 1999-09-14
2 (2)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
Hydraulic and Electric Symbols
Hydraulische und elektrische Bildzeichen
This section covers a part of the symbols and port markings commonly
used in MacGREGOR (SWE) AB, Service Division hydraulic and electric
circuits, divided into three parts:
Diese Sammlung umfat einen Teil der allgemeinen Bild- und

Anschluzeichen, die in MacGREGOR (SWE) AB, Service Division,
hydraulischen und elektrischen Schemas vorkommen, unterteilt in drei
Gruppen:
1. Hydraulic symbols, basic.
Hydraulische Bildzeichen, einfach.
2. Hydraulic symbols, composite.
Hydraulische Bildzeichen, kombiniert.
3. Electric symbols.
Elektrische Schaltzeichen.
1 (30)
Hydraulic symbols and valve assemblies
Hydraulische Bildzeichen und Ventil-

Baugruppen
1. Hydraulic Symbols
Hydraulische Bildzeichen
Working oil line.

Arbeitsdruckleitung.
Pilot line.
Steuerdruckleitung.
Drain line.
Lecklleitung .
Plug, plugged connection (alternative symbols).

Verschluchraube, Sperrung (wahlweise).
Fixed restriction.
Feste Blende, feste Drosselung.
Variable restriction.
Regelblende, regelbare Drosselung.
Restriction unaffected by viscosity.

Temperaturunabhngige Drosselung.
Flexible hose.
Schlauch, biegsame Leitung.
2 (30)
Pipe junction.
Leitungsverbindung.
Crossed pipes, no connection.

Kreuzende Leitungen, ohne Verbindung.
Rotary connection.
Dreh-Verbindung.
Tank line, tank.

Tankleitung, Tank.
Regulation or variability.
Regelbar oder nachstellbar.
Enclosure of component assembly.

Umri eines Mehrkomponentenblocks.
Mechanical connection.
Mechanische Verbindung.
Pump, fixed displacement, 1 direction of flow.

Pumpe, konstantes Deplacement, 1 Stromrichtung.
Pump, variable displacement, 2 directions of flow.

Pumpe, variables Deplacement, 2 Stromrichtungen.
3 (30)
Motor, fixed displacement, 2 directions of flow, exter-

nal drain.
Motor, konstantes Deplacement, 2 Stromrichtungen,
extern Drainierung.
Motor, 2 displacement, 2 directions of flow.

Motor, 2 Deplacement, 2 Stromrichtungen.
Motor, variable displacement, 2 directions of flow.

Motor, variables Deplacement, 2 Stromrichtungen.
Electric motor.
Elektromotor.
M
Filter.
Filter.
Filter with contamination indicator.

Filter mit Anzeiger.
Filter with by-pass valve.

Filter mit Rckschlagventil.
4 (30)
Air breather.
Luftreiniger.
Pressure electric switch, normally open.

Druckschalter, druckgesteuert, normal offen.
Pressure electric switch, normally closed, adjustable.

Druckschalter, druckgesteuert, normal geschlossen,
regelbar.
Non-return valve.
Rckschlagventil.
Non-return valve, spring loaded with certain opening

pressure difference.
Rckschlagventil, federvorbelastet mit gewisser
ffnungsdruckdifferenz.
Non-return valve, spring loaded with certain closing

pressure difference.
Rckschlagventil, federvorbelastet mit gewisser
Schlieungsdruckdifferenz.
5 (30)
Quick coupling or gauge connection.

Schnellkupplung oder Meanschlu.
Gauge connection.
1
Meanschlu.
Ventilation valve.
Entlftungsventil.
Non-return valve with variable restriction.

Drosselrckschlagventil, regelbar.
Shuttle valve.
Wechselventil.
Brake cylinder.
Bremszylinder.
Cylinder, double-acting with fixed cushion at one side.

Zylinder, doppelt wirkend mit konstanter Dmpfung
auf einer Seite.
Pressure gauge.
Manometer.
Thermometer.
Thermometer.
6 (30)
Oli cooler.
lkhler.
Accumulator.
Druckspeicher.
Shut-off valve.
Absperrventil.
Valve, basic symbol.

Schieber, Grundzeichen.
Electrically controlled valve.

Schieber, elektromagnetisch gesteuert.
Pressure controlled valve.

Schieber, druckgesteuert.
Pilot controlled valve, internal pressure supply.

Schieber, vorgesteuert, interner Steuerdruck.
Pilot controlled valve, external pressure supply.

Schieber, vorgesteuert, externer Steuerdruck.
Lever controlled valve.

Schieber, knppelgesteuert.
7 (30)
Mechanically controlled valve.

Schieber, mechanisch gesteuert.
Valve with spring return.

Schieber mit Feder-Rckfhrung.
Valve with detent.

Schieber mit Lagehalter.
4/2 direction valve

A B
Electrically controlled four-way, two-position valve,
spring return to neutral position.
4/2-Wegeventil
4-Wegeschieber mit 2 Arbeitsstellungen, Feder-
P T
Rckfhrung in die Nullstellung.
4/3 direction valve

Electrically controlled four-way, three-position valve,
spring centred.
4/3-Wegeventil
4-Wegeschieber mit 3 Arbeitsstellungen, feder-
zentriert.
Proportional valve.
Proportionalventil.
Servo valve.
Servoventil.
8 (30)
Balance valve (GP- and HH-cranes)

Ausgleichsventil(GP- und HH-Krne)
Flow regulator, adjustable.

Flu Regulator, regelbar.
Flow regulator with non-return valve.

Flu Regulator mit Rckschlagventil.
Cartridge valve.
Patronenventil.
Pressure limiting valve, adjustable.

Druckbegrenzungsventil, regelbar.
9 (30)
Pressure limiting valve with remote opening or clos-

ing.
Druckbegrenzungsventil mit ferngesteuerter ffnung
oder Schlieung.
Pressure reducing valve.

Druckreduzierventil.
Pressure reducing valve with T-port.

Druckreduzierventil mit T-Anschlu.
10 (30)
2. Valve Assemblies
Ventil-Baugruppen
Filter unit with by-pass valve.

Filtereinheit mit Shuntventil.
Filter unit with by-pass valve and electric filter indica-

tion.
Filtereinheit mit Shuntventil und Zustandsanzeige.
Filter unit with pressure limiting valve.

Filtereinheit mit Druckbegrenzungsventil.
11 (30)
Filter unit with pressure limiting valve.

Filtereinheit mit Druckbegrenzungsventil.
Filter unit with by-pass valve and electric filter indica-

tion.
Filtereinheit mit Shuntventil und Zustandsanzeige.
12 (30)
Pump for hoisting winch.

Pumpe fr Lastwinde.

Pumpe fr Lastwinde.
13 (30)

Pumpe fr Lastwinde.
Pump for luffing winch.

Pumpe fr Einziehwinde.
14 (30)
Pump for luffing winch.

Pumpe fr Einziehwinde.
Pump for luffing or slewing.

Pumpe fr Einziehwinde oder Schwenkantrieb.
15 (30)
Pump for slewing or luffing.

Pumpe fr Schwenkantrieb oder Einziehwinde.
Pump for slewing.

Pumpe fr Schwenkantrieb.
16 (30)
Hoisting winch with 84-series motor and motor valve.

Lastwinde mit Motor Typ 84 und Motor-
Umschaltventil.
Hoisting winch with 63/64-series motor and motor

valve.
Lastwinde mit Motor Typ 63/64 und Motor-Umschalt-
ventil.
17 (30)
Hoisting winch with variable high speed hydraulic mo-

tor.
Lastwinde mit variabel schnellaufendem hydrau-
lischem Motor.
Luffing winch with 63/64-series motor and motor valve.

Einziehwinde mit Motor Typ 63/64 und Motor-
Umschaltventil.
18 (30)
Unloading and flushing valve, slewing.

Entlastungs- und Splventil, Schwenkantrieb.
Unloading and flushing unit, hoisting and slewing.

Entlastungs- und Splventil, Lastwinde und Schwenk-
antrieb.
Flushing valve.
Splventil.
19 (30)
Valve unit for stabilizing winch.

Ventileinheit fr Stabilisierungswinde.
Unloading unit for feed pump.

Entlastungsventil fr Speisepumpe.
20 (30)
Valve unit, cylinder luffing.

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

Ventileinheit, Zylinder-Einziehung.
21 (30)
3. Electric Symbols
Elektrische Schaltzeichen
Conductor junction, permanent.

Leitungsverbindung, fest.
Conductor junction, separable.

Leitungsverbindung, trennbar.
Crossed conductor, no connection.

Kreuzende Leitungen, ohne Verbindung.
Slip ring with brush.

Schleifring mit Brste.
Fuse, supply side indicated.

Sicherung, Zufhrungsseite markiert.
Magnetic relay, contactor.

Steuergert, elektromagnetische Erregerwicklung.
Make contact.
Arbeitskontakt.
Break contact.
Schaltkontakt.
22 (30)
Main contact.
Hauptkontakt.
Contact, manually operated.

Kontakt, von Hand bettigt.
Contact, manually operated without automatic return.

Kontakt, von Hand bettigt, nicht selbstrckstellend.
Emergency stop.
Notschalter.
Contact with delayed opening.

Kontakt mit Ausschalt-Verzgerung.
Contact with delayed closing.

Kontakt mit Einschalt-Verzgerung.
Contact with delayed opening/closing.

Kontakt mit Ein- und Ausschalt-Verzgerung.
Limit switch.
Endschalter.
Contact, thermal controlled.

Kontakt, thermisch gesteuert.
23 (30)
Pressostat.
Pressostat. P
Level switch.
lstandswchter.
Temperature switch, thermostat.

Temperaturwchter, Thermostat.
Touch free contact.

Berhrungsfreier Geber.
Inductive contact.
Induktiver Geber.
Ammeter.
Strommesser.
A
Voltmeter.
Voltmesser. V
Hour counter.
Stundenzhler. h
Earth (hull) connection.

Massenverbindung (Rumpf).
24 (30)
Rectifier.
Gleichrichter.
Transformer with two windings.

Transformator mit zwei Wicklungen.
Transformer with several secondary windings, with

screen between primary and secondary windings.
Transformator mit mehreren Sekundrwicklungen, mit
Schirm zwischen den Primr- und Sekundr-Wicklungen.
Triple-pole thermal relay (overcurrent) circuit breaker.

Dreipoliges thermisches Relais (berstrom-Aus-
lsung).
Frequency converter.
Frequenzumformer.
25 (30)
Diode.
Diode.

Light emitting diode.
Leuchtdiode.
Pilot lamp.
Meldeleuchte.
Light.
Beleuchtung.
Flood light.
Scheinwerfer.
Alarm signal.
Alarmsignal.
Alarmsiren.
Alarmhupe.
Single-phase outlet.
Steckdose, einphasig.
26 (30)
Position encoder.
Drehfeldgeber.
Puls/speed encoder
Geschwindigkeitsgeber
Flexible lead connector.

Steckverbindung.
Resistor.
Widerstand.
Resistor, non-linear.
Widerstand, spannungsabhngig.
Variable resistor.
Widerstand, regelbar.
Potentiometer with slider and a fixed tap.

Potentiometer mit Schleifer und einer Festanzapfung.
Heater.
Heizkrper.
Motor.
Motor. M
27 (30)
Condenser.
Kondensator.
Heater, cabin.
Heizkrper in der Fahrerkabine.
Air condition.
Klimaanlageapparat.
VL . . . .
Solenoid valve.
Magnetventil.
Oil tank heater.

lbehlterheizer.
28 (30)
Controller, hoisting.
Steuerknppel, Lastwinde.
Controller, luffing and slewing.

Steuerknppel, Einziehwinde und Schwenkantrieb.
29 (30)
30 (30)
TECHNICAL DATA
(2.001 E) Project No.: 2/10045.02LMW rev: - 2011-09-15
TECHNICAL DATA
GENERAL
Type of crane GLB 3628-2/28.828gr
Work order 2/10045.02LMW
Serial number 62512129 - CRANE No. 1

62512130 - CRANE No. 2
62512131 - CRANE No. 3
62512132 - CRANE No. 4
Weight 43 ton
Ambient temp range -20 to +45 C
BASIC DATA
Lifting height H 8.5 m
Lifting height K 27.5 m
Hoisting Hoisting Jib radius Jib radius Hoisting Hoisting Luffing time Slewing speed
capacity capacity Minimum Maximum speed speed Max min radius
Part SWL low high
(ton) (ton) (m) (m) (m/min) (m/min) (sec) (rev/min)
36 18 4.0 28 23 36 65 0.8
25.8 14.4 4.0 28 23 36 65 0.8
1 (4)
TECHNICAL DATA
ELECTRIC MOTOR, Pump unit
Rated power, cont. 152 kW
Rated power, S6 15% int. 240 kW
Starting current 580 A
MAIN SUPPLY
Rated voltage 440 V
Type of frequency 3 ~ 60 Hz
Control voltage 220 V
OIL VOLUME / OIL FILLING (per unit)
Oil tank 450 liters
Slewing gear 14.0 liters
Hoisting winch 13.0 liters
Luffing winch 6.5 liters
Cable winch, hydraulic turbo coupling 1.9 liters
Cable winch, spur gear 5.0 liters
Stabilizing winch, hydraulic turbo coupling 2.0 liters
Stabilizing winch, spur gear 1.8 liters
2 (4)
TECHNICAL DATA
Limit Switches in Hoisting and Luffing Winch Systems
Basic limit switches - see instruction 6.320.367
Ton Min. jib Max. jib

outreach outreach
(m) (m)
36 4 28
28.8 4 28
Basic limit switches luffing winch
Cams Cam Jib Speed Max jib Force Speed Min jib Winch Limit values on Distanc
degrees parking reduce, outreach limitation reduce, outreach angle winch drum e
pos. - luffing out (m) for luffing position (mm) MV
Empty Approx.(m) parking in (m) degrees
Drum position Approx (mm)
Lu, Stop (m) (m)
degree)
A B spr B D C spr C AT BT MV
BL5 30 4 207,65 1008 743
BL4 30 7 200,47 977
BL2 90 26,5 72,88 428
BL3 60 28 45,08 308
BL6 100 28,2 39,76 285
BL1 30 -3,00 0,00 114
**)
**) Second layer
Dimension AT and AL to be measured from the drum flange on empty drum side.
Dimension BT and BL to be measured from the drum flange on full drum side, second layer.
Limit switches, high hook luffing winch
Cams Cam degrees Speed reduce Max jib stop limit Winch angle position Limit values on
luffing out (m) degrees winch drum
Approx. (m) (mm)
E spr E AT BT
NA
NA
Dimension AT and AL to be measured from the drum flange on empty drum side.
Dimension BT and BL to be measured from the drum flange on full drum side.
NA high hook not applicable.
3 (4)
TECHNICAL DATA
Limit switches - hoisting winch

Cams Cam Empty drum limit, Speed Speed Full drum Winch Limit
degrees stop position. At least reduce, empty reduce, full limit, angle values on
three locking turns or drum drum stop position position winch drum
tank top. (m) Approx. (m) Approx. (m) (m) degrees (mm)
K H spr H AL BL
K spr
BH1 30 27,5 123
BH2 40 2,5
BH3 40 2,5
BH4 30 8,5 1014
**)
**) Second layer
Limit switches, high hook - hoisting winch
Cams Cam degrees Speed reduce switch Preventing jib

towards jib top from touching
Approx. (m) lifting block
F spr F ds
NA
NA
NA high hook not applicable.
One Outreach
4 (4)
TECHNICAL DESCRIPTION 2.007.91 E rev.: - 2008-08-08
Technical Description
Jib top
Protective plate
Lifting block
Main electric motor
Pump unit
Crane operator's cab

Oil tank
Slack wire device
Luffing winch
Crane jib
Hoisting winch
Slewing gear
Fig. 1. Crane type GLB.
1 (4)
MacGREGOR hydraulic deck cranes are self- The hydraulic system is designed for start at a
contained units with all machinery enclosed in the temperature range of from high to lowest ambient
crane house and, thus, well protected against external working temperature for world wide trading according
abuse. to classification societies. For cranes operating in cold
environment an optional oil heater should be installed
When delivered, the cranes are mechanically, in the oil tank. The oil heater is started by using the
hydraulically, and electrically complete in every pushbutton in the CT1 cabinet.
respect and ready to be installed on a suitable
foundation fixed in the ships deck or on a crane An oil cooler removes heat developed in the oil during
carriage travelling on deck. its work cycle. If the oil temperature exceeds a certain
level, a thermostat operates a contactor to stop the
main drive electric motor.
Construction
All crane movements - hoisting, luffing, and slewing -
Filters on outlet and inlet to the oil tank ensure
are driven by hydraulic motors. These are supplied
continous cleaning of the oil flow. Two filter indicators,
with high pressure oil by a pump unit comprising
one electric activates a warning lamp in cabin and
separate pumps for each hydraulic circuit and a
one visual indicates when elements need to be
separate feed and control pressure pump. The high
changed.
pressure pumps are mounted in the same pump unit
and are geardriven by a flange mounted electric motor.
Various pressure limits are provided to protect the
Starting of the electric motor is affected by an Y/D
crane against overload. All moving parts in the
starter, giving low starting current.
hydraulic system are lubricated by the hydraulic oil
which minimises mechanical wear and ensures the
The hoisting winch is driven by a hydraulic motor via
added advantage of silent operation.
a planetary gear box. A brake is integrated in the winch
gear set. When the winch is running, the brake is
The crane house is an all-welded structure on a rigid
automatically released by a hydraulic unit. The
baseplate, and encloses all mechanical and
hoisting winch is also provided with a pressure roller
hydraulical machinery and associated electrical
and one layer of wire on the drum.
equipment for adequate protection against rain, sleet,
and waves breaking over the ship. Catwalks, ladders,
Limit switches operate if the wire slackens and to
platforms, and handrails facilitate maintenance of the
preclude the complete unwinding of the wire from the
crane.
wire drums.
The tops of the crane house and of the jib head are
The crane jib is raised and lowered by the luffing winch
fitted with sheaves for the hoisting and luffing wire
whose general design is similar to that of the hoisting
ropes. All sheaves have sealed roller bearings
winch.
mounted on shafts and secured by locking plates.
The slewing drive of the crane uses a high-speed

Various limit switches on slewing and luffing motions
hydraulic motor, installed onto a planetary gearbox
are provided.
and fitted with a drive pinion. The pinion meshes with
the internal gear teeth of the slewing ring which
The cranes are supplied with test certificates to the
supports the crane house. On customers order limit
requirements of National Swedish Board of Shipping
switches can be provided to define the slewing range
and Navigation. The design meets the requirements
of the crane.
of ILO and the relevant classification societies whose
certificates will be furnished if specially ordered.
2 (4)
Crane operators cabin Deck lights

The crane operators cabin, with a tilted front window Two deck lights are installed in front under the cabin
located on the service door, affords an allround view and are controlled from cabin and bridge. Optional extra
of the entire work area. The cabincontains crane deck lights can be fitted upon request.
operator's seat, ready access to the two control
levers, one controlling the hoisting winch, and the Crane control system CC3000
other, the luffing and slewing movements.
Control of the hydraulic equipment is servo assisted
with the electronic crane control system CC3000.
The cabin also contains control panels with various
Speed regulation is infinitely variable and involves no
switches, pushbuttons, and signal lamps. Electric
loss of energy. The regulating system employs spring-
windscreen wiper, heater and ventilator are provided
loaded units which automatically return to neutral
as standard. Air conditioning is available as an
position when the hydraulic pressure drops.The main
optional feature.
movements of the crane, hoisting, luffing and slewing
- can be operated simultaneously without any speed
Emergency exit is via the cabin's side window.
reduction as well as independent of each other.
Jib
Hydraulic hoses
The jib is made of two box girders, joined by transverse
The hydraulic hoses are high-pressure tested and
tubular steel struts. The foot of the jib mounts on two
carefully cleaned and inspected before assembly.
trunnion journals at the sides of the crane house skirt.
A halogen floodlight is mounted on the jib.
Cargo handling gear
Electrical equipment The swivel, hook, shackles, rings, and chains all have
Certain electric cables outside of the crane house, ample safety margins for the maximum load to be
e.g. on the jib, are carried in steel conduit. All cables handled by the crane. The non-rotatory, langs lay wire
and electrical accessories are specifically designed ropes are galvanised and oiled.
for marine use.
Surface treatment
The slip-ring unit linking the crane network with the
All surfaces of the crane are carefully prepared by
shipboard network is placed under the platform inside
sandblasting before being given a coat of Primer. As
the crane house.
standard the crane is painted with an anticorrosive
system basically based on two-component epoxy
The electric cabinet is placed on the inside wall of the
paint and an acrylic finishing coat.
crane house. The cabinet contains contactors, relays,
motor switch and various other components of the
electric installation. The main power switch (Q1) is
placed on the CT1-cabinet.
Lighting
Lighting is installed in both crane house and cabin.
Can also be installed in foundation and pedestal if
required.
3 (4)
4 (4)
FUNCTION 3.110.122 E rev.: - 2009-02-02
Hydraulic Function
General Component identification
The following description refers to the standard The main components are identified by four-digit
hydraulic system of MacGREGOR hydraulic deck numbers in the diagram and on the actual components
cranes, GLB version. in the crane. The first digit of each number signifies
the circuit to which the component belongs:
Minor variations in the hydraulic system may occur in
individual cranes of the same type, and the objective of 1... Hoisting circuit
this description is only to provide a general orientation 2... Luffing circuit
concerning the arrangement of the hydraulic system. 3... Slewing circuit
4... Feed and control pressure circuit
Note! 5... Additional programming equipment *)
For reference see hydraulic circuit diagram in section 9.4 6... Twin crane hydraulic equipment
in the parts manual. All hydraulic components mentioned 7... Other additional hydraulic equipment *)
in this instruction can be found in the diagram.
*) Equipment installed at request of customer
The crane drive system consists of three separate
hydraulic work circuits, i.e. hoisting, luffing, and Legend
slewing respectively. There is also a feed and control
pressure circuit, to assist the hydraulic work circuit. MHO Hydraulic motor, hoisting circuit
MLU Hydraulic motor, luffing circuit
Each of the work circuits may have one or more pumps MSL Hydraulic motor, slewing circuit
located in the pump unit, in Figure 1 marked PHO, PLU, PHO Pump, hoisting circuit
PSL. Pump PF for the feed and control pressure system PLU Pump, luffing circuit
is also located in the pump unit. PSL Pump, slewing circuit
PF Pump, feed circuit
Identifying circuits in the hydraulic

HOISTING LUFFING SLEWING
diagram CIRCUIT CIRCUIT CIRCUIT
Figure 1 shows the arrangement of the three work

MHO MLU MSL
circuits, hoisting, luffing, and slewing circuits, together
with the feed and control pressure circuit. The circuits
appear in the same order in the hydraulic diagram.
Symbols PHO PLU PSL
Every hydraulic component is represented by a

special symbol in the circuit diagram. The meaning
of the symbols is explained in section General in
the Manual. The symbol for the reservoir is shown in PF
several places in the diagram for greater simplicity of
drawing; but there is naturally only one reservoir in
FEED AND CONTROL CIRCUIT
actual fact.
Fig. 1. Identifying hydraulic circuits.
1 (6)
FUNCTION 3.110.122 E rev.: - 2009-02-02
Feed and control circuits
Feed pressure circuit

The function of this circuit is mainly to replace the hot
fluid leaking from the closed work circuits. The feed
fluid is introduced through non-return valves into the
low-pressure side of the system. The feed circuit
operates at a pressure (inlet/outlet) of approx. 3.0/
2.5 MPa (30/25 bar), which is set at valve 4148 and
is measured at test point 1 and 16 respectively. Test
point 1 is feed pressure inlet and 16 is feed pressure
outlet.
Control pressure circuit

The function of this circuit is to supply fluid to the brakes
and to the pump servos, that controls winch speed,
slewing speed and working direction. The system
operates at the same pressure as the feed pressure
and is measured at test point 1.
Note!
For exact pressure settings, see pressure list in the
hydraulic diagram.
2 (6)
FUNCTION 3.110.122 E rev.: - 2009-02-02
Hoisting winch circuit Lowering
Introduction
Low speed High speed
The hydrualic circuit diagram shows the following main
hoisting components:
Pumps 1111, 1112 Hoisting Control lever

Hydraulic motor 1141
Brake 1211 Fig. 2. Control lever in neutral, hoisting
The brake is mounted inside the winch gearbox.
Function Lowering
With the control lever in neutral, Figure 2 or 5, and
the pump running, the hoisting circuit performs no
actual work. A continuous supply of fluid from the
feed circuit, flushes the circuit.
Low-speed range, brake release Control lever Hoisting

When the control lever is moved to the left for low-
speed operation of the winch, Figure 3, valve 1221 Fig. 3. Control lever, hoisting, brake release position
and 1226 in the actuated mode, "b", (1226 slightly
delayed in relation to 1221) and connects full control
pressure to the brake valve 1226 which releases the
brake, and also to valve 1128-1 which shifts from its
unloading mode. Lowering
With no load on the cargo hook and the control lever

in brake release position, Figure 3, the hoisting winch Low speed High speed
should produce a slow hoisting movement, so called
plussing. See instruction "High pressure pumps" in
section 6.1.
Control lever Hoisting
Fig. 4. Control lever, hoisting, low-speed hoisting
3 (6)
FUNCTION 3.110.122 E rev.: - 2009-02-02
High speed range, brake release Safety functions

When the control lever is moved to the right, Figure 6, The hoisting winch circuit embodies three safety
valves 1221 (a) and 1226 (b) are actuated, (1226 features:
slightly delayed in relation to 1221). Control pressure
is connected to the brake valve 1226 which releases - Main pressure limiting valves 1111-2; 1111-3, 1112-
the brake, and also to valve 1128-1 which shifts from 2, 1112-3.
its unloading mode. - Pressure switch 1311 (overload valve) stops the
crane in the event of overloading at low speed.
The brakes are released and the motor assumes the Shifts to low-speed when running in the high-speed
high-speed position (min. displacement). The motor mode.
rotates at double speed, and the lifting capacity of - Pressure switch 1381 stops the crane in the event
the winch is reduced to approximately 50 - 60 % of of insufficient feed pressure.
its maximum rate.
Note! It is not allowed to adjust sealed safety valves
With no load on the cargo hook and the control lever without contacting MacGREGOR Cranes, Service
in brake release position, Figure 6, the hoisting winch Department.
should produce a slow hoisting movement in the same
way as in low speed operation. Lowering
High-speed range overload

If the load on the cargo hook is too heavy for handling
in the high-speed range, the pressure switch 1311
will cause valve 1221 to shift to low-speed range. Full
displacement on the hydraulic motor.
Hoisting Control lever
Hoisting and lowering, high speed or low speed Fig. 5. Control lever in neutral, hoisting.
Pulling the control lever backwards from the brake

Lowering
release position will start the winch to lift the load,
Figure 4 low speed and Figure 7 high speed. The servo
valves 1111-6 ,1111-7, 1112-6 and 1112-7 affect the
servo cylinders and thus the pump displacement. The
pumps 1111 and 1112 thereby produce a flow of fluid
that is proportional to deflection of the control lever.
If, instead, the control lever is moved forward, the load
will be lowered, ie, the function is the same as for hoisting, Fig. 6. Control lever, hoisting, brake release position.
except for the direction of flow.
Lowering
High speed lowering (optional)
If the crane is designed for high speed lowering the
motor will automatically assume high-speed position
when the control lever is moved forward for lowering,
even if the control lever is to the left, for low speed.
Valve 1221 (a) will be actuated.
Fig. 7. Control lever, hoisting, high-speed hoisting.
4 (6)
FUNCTION 3.110.122 E rev.: - 2009-02-02
Luffing winch circuit
Introduction
The hydrualic circuit diagram shows the following main Note!
luffing components: It is not allowed to adjust sealed safety valves without
contacting MacGREGOR Cranes, Service Department.
Variable displacement pump 2111
Hydraulic motor 2141
Brake 2211
The luffing and slewing movements are generally Luffing-out (lowering jib)
operated by a common control lever, Figure 8.
Brake release
Moving the control lever from neutral, eg. backwards
to raise the jib, causes the valves 2221 and 2226 (2226
slightly delayed in relation to 2221) to shift position
and control pressure is admitted to the brake 2211 Luffing-in (raising jib)
and to valve 2127 which shifts position from the
unloading mode.
Fig. 8. Control lever, luffing/slewing.
With the control lever in the brake release position,
the luffing winch should produce a slow movement of
the crane jib, so called plussing. See instruction "High
pressure pumps" in section 6.1.
Raising and lowering the jib

Moving the control lever further backwards starts
operation of the luffing winch. The servo valves 2111-
6 and 2111-7 affect the servo cylinder and thus the
pump displacement. The pump 2111 thereby produces
a flow of fluid at a rate that is proportional to the lever
deflection.
To lower the jib, move the lever forward from neutral.

The function is the same as for luffing-in, except for
the direction of the fluid flow.
Safety functions
The luffing winch circuit embodies two safety features:
- Pressure limiting valves 2111-2, 2111-3.

- Pressure switch 2481; stops the crane in the event
of insufficient feed pressure.
5 (6)
FUNCTION 3.110.122 E rev.: - 2009-02-02
Slewing circuit
Introduction
The hydrualic circuit diagram shows the following main
slewing components: Slewing left Slewing right
(Anti-clockwise) (Clockwise)
Variable displacement pump 3111
Hydraulic motors 3141, 3142
Flush unloading unit 3127
Brakes 3211, 3212
Fig. 9. Control lever, luffing/slewing.
The luffing and slewing movements are generally

operated by a common control lever, Figure 9.
Brake release
Moving the control lever, eg. to the left for slewing left
(anti-clockwise), will affect valve 3221. The brakes will
be released and the unloading valve 3127-1 will be
blocked.
Slewing left and right

By moving the control lever further to the side, the crane
will start to slew in the direction chosen. The servo
valves 3111-6 and 3111-7 affect the servo cylinder
and thus the pump displacement. The pump 3111
thereby produces a flow of fluid at a rate that is
proportional to lever deflection.
To slew to the right (clockwise), move the lever to the

right instead. The function is the same as for slewing
left, except for the direction of the fluid flow.
Safety functions
The slewing circuit embodies one safety feature:
- Main pressure limiting valves 3111-2 and 3111-3.
6 (6)
FUNCTION 3.131.29 E rev.: a 2009-02-13
Starting and Stopping, Electric Safety Functions

Single Cranes
Introduction
The following description refers to the starting and Note! If crane is equipped with PMS a starting per-
stopping, and electric safety functions, of a standard- mission is required. Read "OPERATING
type single crane. A complete electric circuit diagram INSTRUCTION START - STOP" and "Controls and
relating specifically to the particular crane will be found Indicators" to operate crane with PMS.
in the section SPARE PARTS of the Manual.
The purpose of the present description is to furnish a Start sequence

general idea of the design and function of the electric - Press button S13 "1" (start).
system. The crane is supplied with electric power via - Pilot light H1 "DO NOT OPERATE" goes on.
the slip-ring unit and the main switch in the crane
house. Cables lead from the main switch to: a trans- The feed circuit pressure build up its operating pres-
former supplying power for all control circuits; a switch sure. Pressostats BP1 - hoisting circuit, BP2 - luffing
for the oil cooler fan motor; a Y/D switch for the main circuit, close and start a delayed closing 8s time relay
electric motor; and a thermostat switch for the venti- K71.
lation fan in crane house.
- After 8s, Y contactor K2 switches on N contactor
All components are marked by symbols in the dia- K1; the main motor M1 starts in Y connection.
gram, making it easier to follow the various stages of - At the same time as the Y contactor was switched
the starting sequence, e.g. on, an 8s delayed-opening double relay K9 was
started.
- Contactors: K1 (N); K3 (D); K2 (Y). - After 8s, the Y contactor drops, and D contactor
- Time relays: K9; K71. K3 is switched on by double time relay K9 closing
after 0.1s.
The D contactor and self-holding N contactor switch
Before start main motor M1 to delta configuration.
- Push button "1" (start) closing prepares the ener-
Verify that the ambient temperature is not below -15C. gizing of motor switch Q5 of oil COOL FAN MO-
If the crane is operated in temperatures below -15C a TOR M3.
heater has to be installed in the oil tank. Motor M3 is started by thermostat BLT1 if the tem-
perature of the hydraulic oil exceeds +10oC.
- Warning light H1 goes out. The crane is operatio-
Starting and stopping the crane nal.
Note! Joysticks for hoisting or luffing/slewing motions Stop sequence

must be in neutral position when starting the crane. If - Press button S13 "0" (stop).
the joysticks have been moved in any direction when - All contactors of Y/D switches and all other motor
pressing the start button the motion is blocked. Move contactors are de-energized. All motors stop.
the joysticks to neutral position then operation is - The ventilation fan motor stops only when the main
possible. switch Q1 is switched OFF.
1 (2)
FUNCTION 3.131.29 E rev.: a 2009-02-13
Other electric functions

Overheating protection Control system error
A thermostat BT2 in the hydraulic system of the crane If an error is detected by the crane control system in
opens the control circuits of the main electric motor the CT2-cabinet pilot light H4 illuminates. Check the
and the oil cooler fan motor when the oil temperature CT2-cabinet according to instruction "Crane Control
exceeds +85oC. Pilot light (H5) "High oil temperature" System CC3000" under Section 6.3.
illuminates.
Restart the crane by use of pushbutton S13 "1/0"

(start/stop). Pilot light H1 "DO NOT OPERATE"
illuminates. Crane and cooler fans start, but the crane
control system CC3000 is still blocked.
Pilot light H5 goes out when the crane's working oil

temperature is back below +85C. The crane control
system CC3000 returns to normal and pilot light H1
goes out.
Oil level switch

If the oil level in the hydraulic oil tank drops below the
minimum permissible level, an alarm system is swit-
ched on by a float type oil level switch BLT1. Warning
light H2 goes on.
If the oil level sinks further, level switch BLT1 opens

the control circuit of main motor M1.
Siren
A pushbutton "SIREN" in the cabin allows the opera-
tor to warn people on deck.
Ventilation fan
For all cranes a ventilation fan is fitted in the crane
house. This is controlled by a +25C thermostat BT1
which is located in the CT1-cabinet.
Lighting and heating

Electric power is supplied by separate slip-rings for
lighting in the crane house, in the operators cabin,
and on the jib and heating in the cabin.
The crane house lighting is operated by a switch un-

der the bottom plate. The cabin lighting is operated by
a switch and the jib light is operated by a pushbutton
in the cabin.
2 (2)
FUNCTION 3.142.35 E rev.: b 2009-07-10
Crane Control System CC3000
General
The following description refers to the microcomputer For detailed information about the control system a
based crane control system CC3000 for complete electric circuit diagram, relating specifically
MacGREGOR Cranes hydraulic deck cranes, single to your crane, will be found in the instruction manual,
crane versions. section "Spare Parts", Group 9.5. Also for detailed
information about the hydraulic system a complete
Minor variations in the use of control system input hydraulic circuit diagram can be found in section
and output signals due to differences in hydraulic and "Spare Parts", Group 9.4.
electric system may occur. The objective of this
description is only to provide a general orientation
concerning the principles of the control system.
Control lever Unloading/displacement

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

Brake valve
Slewing gear
SLEWING
MC Hydraulic Hydr.
"SL" pump motor
Unloading valve Limit switch box
Fig. 1. Crane control system with interfaces to control levers and hydraulic system.
1 (4)
FUNCTION 3.142.35 E rev.: b 2009-07-10
Crane control system - interfaces and

principle of operation
Control levers (joysticks)

The right control lever controls the hoisting winch. The
signals from the control lever are connected to the
MC card, "Ho" for hoisting winch.
The left joystick controls the luffing and slewing
movements. Both digital and analouge signals are
connected to MC card "Lu" for luffing and "SL" for
slewing.
The joystick linear potentiometers are fed with 0V,

+6V, and +12V. The output level is approximately +6V
with the joystick in neutral. The output signal is
controlled by the joystick and is decreased to
approximately +1.5V and increased to approximately
+10.5V, depending on the joystick movement.
The joystick for hoisting also gives 24V signals for

selection of low speed/high speed and hoisting/
lowering. The joystick for luffing/slewing also gives Fig. 2. Crane control system CC3000 in CT2
24V signals for selecting luffing in/luffing out and cabinet.
slewing left/slewing right. The voltage to current amplifier feeds the hydraulic
pump solenoids.
Crane control system

The Crane control system consists mainly of four CT2 cabinet
micro processor cards. One Communication Card CT2-cabinet containing the crane control system is
(CC) is used for internal communication between the protected against humidity by a casing with protection
cards and a parameter memory card. Three Motion class IP54 (dust and splash water proof).
Control cards (MC) are controlling all input and out-
put signals for each crane movement hoisting, luffing 19" subrack with electronic cards
and slewing. Each MC card feeds a potentiometer in All electronic cards are mounted in a standard 19"
the control lever for the crane movement in control.
aluminium subrack. A backplane card is used for
Potentiometer and control lever direction signals go
connecting power, 24V to the CC and MC cards. It
to a microprocessor with a software control program also provides communication lines between CC and
that handles brake release logic, overload logic and
MC cards and between CC card and the parameter
rampforming. The output from the microprocessor is
memory card.
fed to a voltage to current amplifier on the card.
The rampformer gives smooth acceleration and re- Hydraulic pumps

tardation to the crane movements.
The hydraulic pumps are variable displacement
pumps (e.g., the flow is steplessly variable from zero
The brake release logic circuit releases and applies
to max. rated flow). The pump oil flow is controlled by
the brake in the correct sequence with the displace-
a 24V pulse width modulated (PWM) current signal.
ment/unloading signals when the hydraulic motor is
The direction of the oil flow is dependent on which
started and stopped.
one of the two solenoid valves is activated.
2 (4)
FUNCTION 3.142.35 E rev.: b 2009-07-10
The speed of the winch, the pump displacement, the Micro Processor Cards - CC and MC
current through the solenoid coil and the lever
movement are proportional to each other.
Hardware
The control system consists mainly of one CC card
Hydraulic motors
and three MC cards. All MC cards are identical and
The hydraulic motors may be reversed by changing interchangeable.
the direction of the hydraulic pump oil flow. Each mo-
tor also having a low and a high speed range selected Each MC card is a complete stand-alone
by the operator's control lever. microprocessor system with processors, several types
of memories and communication channels, analogue
Overload protection and digital inputs as well as analogue and digital out-
To prevent the crane from being overloaded, i.e. lifting put current drivers. Each card can fully handle all in-
a too heavy load, the hydraulic system is equipped put and output signals needed for one hydraulic circuit,
with an electro-hydraulic overload system. Pressure i.e. one crane movement.
sensing switches, which normally enable the opera-
tion, stop the hoisting movement if a too heavy load A safety system consists of a secondary micro pro-
is lifted at the current jib outreach. The pressure switch cessor, which monitors the behavior of the primary
gives a signal to the control system overload logic, processor in critical situations such as hazardous ope-
which senses the overload input signal and switches ration at low feed pressure and overload pressure.
over from high speed to low speed or from low speed This system will stop the crane movement due to
to stop. activated limit.
Limit switch box, hoisting winch Software
The limit switch box contains cams with limit switches All cards, CC and MC are programmed with the same
and encoders. It controls the movements of the crane control software. Each card senses which rack-
hoisting block. position and therefore which function/crane movement
it is controlling.
Limit switch box, luffing winch

All cards identify themselves by showing a two-
The limit switch box contains cams, limit switches and character abbreviation of the function/movement
encoders. It controls the movements and outreaches name on the front panel display:
of the jib. - Sc - supervisor
- Ho - hoisting
Limit switches, slackwire - Lu - luffing
The limit switch for hoisting slackwire stops the - Sl - slewing.
lowering movement, and the limit switch luffing slack-
wire stops the luffing out movement when a wire is The leftmost card, the CC "Sc", is only used for
slack. supervisory functions such as communication with
other cards and distribution of control system para-
meters from the parameter memory card.
Luffing / slewing limits
If installed, luffing/slewing limits prevent collisions New versions of the crane control software can be
between the jib and other cranes, or other objects on loaded/programmed into the cards by using a stan-
the vessel. For more information about luffing/slewing dard notebook PC.
limits see section 4 and 6.3.
3 (4)
FUNCTION 3.142.35 E rev.: b 2009-07-10
Parameter memory card The system checks itself and external input and out-
All parameter values are stored in the parameter put signals. Internal problems such as loss of
memory card. The information is stored in electronic communications are continuously checked. Loose
memories on the card. Stored parameter values are connections to pumps and valves are detected when
not dependent on power supply or battery. There is, the output is activated. Signal levels that do not
however, a battery on the card used for a calendar, correspond to normal levels, i. e. the potentiometer
giving all cards date and time information. The card is input from the operator's handle, are also detected.
located inside the rack and is mounted on the
backplane card that also holds all the card connectors. When any type of malfunction is detected, the card
The lifetime of the battery is 10 years. flashes with its error LED, no. 28. All card error LEDs
are wired together to an error lamp in the operator's
cabin, the "control system error" lamp. To get the
Anti-condensation heating
corresponding error message number, push the
To avoid condensation on the electronic cards, the Select/Info push-button on the card with the flashing
temperature inside the cabinet is more then the LED.
temperature outside. Heating elements are therefore
mounted behind the row of plinths. They are powered If there are several errors, they are shown one at a
with 24V AC when the control system is switched off time for each push on the Select/Info push-button.
or when the crane is not operational. When there are no more error messages to read, the
display shows two hyphens "- -". The error LED is
now either on or off.
Signal overview CC3000
- If it is on, the error is still present but has been
Coloured LEDs acknowledged.
Signals to and from each card are indicated by green,
yellow and red LEDs (Light-Emitting Diodes) on the - If it is off, the errors are no longer present.
front panel of each card. When a new error is detected the error LED starts
flashing again to indicate that a new error exists.
Green LEDs are used for normal input and outputs.
Yellow LEDs indicate that the crane motion concerned Error message sign
is driven with slower speed. The corresponding error message text can be found
Red LEDs indicate that the motion is stopped. on the ERROR MESSAGES sign in the cabinet, see
section "Service", Group 6.3.
Signal overview sign
All signals indicated with LEDs are listed on the SIG-
NAL OVERVIEW sign inside the cabinet, see section
"Service", Group 6.3.
Error messages
Built-in diagnostics system

The CC3000 control system has its own built-in
diagnostics system. The system is capable of
detecting several types of malfunctions.
4 (4)
FUNCTION 3.155.3 E rev.: - 2001-08-23
Thermostatic Controlled Ventilation Fan
General
The ventilation fan is thermostatic controlled and

situated inside the crane house top, see Fig. 1.
Function
With the main switch in position "1" (on-position)
the ventialtion fan starts via a thermostat, positioned
in the CT1-cabinet, see Fig. 2. The thermostat bulb
is situated outside the cabinet.
The thermostat is activated at +25C. The thermo-

stat can be adjusted, see Fig. 3.
Thermostat
Fig. 2. Thermostat installed in CT1-cabinet

Fan
Fig. 1. Crane house Fig. 3. Thermostat
1 (2)
FUNCTION 3.155.3 E rev.: - 2001-08-23
2 (2)
OPERATION PM40 1879-E00 rev.: - 2011-04-01
Crew Checklist Before and After Operation
Before operation Heater fans in crane house

Start the heater fans up to 24 hours before operation.
General
To start the heater fans, set switch Heater Fan S49
Read sections 4 "Operation" and 5 "Maintenance" in
on the CT1 cabinet to "1" and turn main switch Q1 to
the instruction manual.
"1". The fans automatically goes off when the crane
Make sure that maintenance is done.
house temperature is +25C. Refer to "Controls and
Make sure that control levers are in neutral. If not, tell
Indicators" in section 4. See Fig. 1.
responsible officer.
Refer to Technical Data in section 2 for operating
temperature for your crane.
Oil level S50

Make sure that the oil level in tank is sufficient.
Make sure that the oil level in winches and slewing HOUR
METER
gears are sufficient.
S49
Oil temperature
The oil temperature in the oil tank must be at least
+10C before operation.
Start oil heater and heater fans to increase the oil

temperature before operation. Q1
If the oil is colder than +10C, you can start the crane S51
and let it idle to increase the temperature of the hy-
draulic oil until it is +10C.
Oil heater
Start the oil heater up to 24 hours before operation. Fig 1. CT1 cabinet
To start the oil heater, set switch Summer/Winter
switch S50 on the CT1 cabinet to "2", winter. Turn
main switch Q1 to "1". The heater automatically goes
off at oil temperature +10C. Refer to "Controls and
Indicators" in section 4.
1 (2)
Release jib and lifting gear After operation

Release jib and loose gear from its parking position.
Park the crane
Refer to Parking the cranein section 4. See Fig 2.
Park the crane, refer to Parking the cranein section 4.
Anti-condensation heating
Make sure that the heating elements in the electric
cabinet CT2 are warm. Refer to Crane control system
CC3000 in section 3. See Fig 4.
Fig. 2. Lifting gear
Wires and sheaves

Make sure that the wires run correctly in the sheaves
and that the wire ends are securely clamped.
Fig. 4. Heating elements in CT2 cabinet
Fig. 3. Wires and sheaves
2 (2)
OPERATION PM40 5500-E00 rev.: b 1996-08-08
OPERATING INSTRUCTION
Handling of dangerous cargo

- Dangerous substances shall be handled in accordance with the
relevant requirements of National or Local Regulations and ap-
plicable National and International standard, only under the su-
pervision of a competent person who is familiar with the risks
and the precautions to be taken.
- Further requirements are stated in ILO Codes of Practice, Safety

and health in dock work.
The crane is not designed for transport of passengers.
1 (2)
OPERATION PM40 5500-E00 rev.: b 1996-08-08
2 (2)
Operation, Start and Stop
Operation
Safety precautions for crane operation Max. 2
MacGregor cranes are designed for operation in har-
bour or sheltered water environments where there is
no significant movement of the ship due to wave action.
Fig. 2. Trim
Only ship's crew is allowed to operate key switches.

When the crane is rigged for operation, all keys must Control lever slewing and luffing
be stored in a safe place by responsible officer. With the slewing/luffing control lever in neutral, the
brakes are engaged. Move the lever a short distance
Tell responsible officer onboard before you operate from neutral to release the brakes. Move the lever left
the crane. or right to slew in that direction. Move the lever forward
or backward to operate the luffing winch.
Do not operate crane if someone is in the crane house When the luffing winch operates, the hoisting winch
without permission. brake is released and it can hoist slowly. Refer to
"Controls and Indicators".
When operating with grab or magnet, handling log or
palletized cargo the lifting capacity must be reduced
to 80% of SWL if there is no GRAB switch in cabin.
It is not permitted to drag loads, you must lift them.
List and trim

Make sure that the ship does not list more than five
degrees. See Fig. 1.
Max 5
Fig. 3. Control lever slewing and luffing
Control lever Hoisting and lowering

With the hoisting winch control lever in neutral, the
winch brake is engaged. Move the hoisting winch lever
to high or low speed position to release the winch brake.
Maximum lifting capacity at high speed is approximately
40% of maximum SWL. The winch starts hoisting at a
slow speed when the brake is released if there is no
load in the hook. Move the lever forward to lower or
Fig. 1. List backward to hoist. Refer to "Controls and Indicators".
Make sure the ship does not trim more than two de-
grees. See Fig. 2.
Fig. 4. Control lever hoisting and lowering
1 (2)
Start and stop Trouble shooting if the crane stops

If the "HIGH OIL TEMP" pilot lamp is on:
Start
1. Push the start button "1" (S13, start/stop) to start
Joysticks for hoisting or luffing/slewing motions must
the main motor and oil cooler fan. The crane cannot
be in neutral position when starting the crane.
be operated.
Press pushbutton START PERMISSION CRANE to ask
2. Pilot lamp "HIGH OIL TEMP" goes out when the oil
for start permission. The crane is ready to start when
temperature is less than +85C.
the green pilot light comes on. Press pushbutton 1
3. Pilot lamp "DO NOT OPERATE" goes out when the
(START) to start the crane. The crane will start within
crane is ready for operation.
20 seconds and is operational when the red warning
light goes out. Do not operate on red light.
If the "LOW OIL LEVEL" pilot lamp is on:
1. Make sure that the hydraulic oil level is sufficient.
Note!
If the "CHECK OIL FILTER" pilot lamp is on
If the joysticks have been moved in any direction when
1. Replace filter and make sure that the hydraulic
pressing the start button the motion is blocked. Move the
system operates correctly.
joysticks to neutral position then operation is possible.
Broken circuit in cabinet CT1
1. Make sure that the motor switches and overcurrent
relays are not opened. Refer to the settings list inside
the cabinet.
STOP
Fig. 5. Start and stop
Stop
Press pushbutton 0 (STOP). See Fig 5.
Short stop in operation

When you take a short stop in operation or in case of
technical problems:
1.Raise swivel to approx. 1.5 m below jib head, if pos-
sible.
2.Return control levers to neutral.
3.Press STOP button.
Emergency stop
If the crane gets out of control:
- Let go of both control levers; they will return automati-
cally to their neutral positions.
- Press Emergency Stop button on the control panel!
2 (2)
Switch Functions, Grab Handling

Rigging and Parking of Power Cable and Stabilizing Wire
CAUTION!
Do not pull out power cable against the closed brake.
The cable winch and stabilizing winch stops in RIGG
position (brake closed).
Switch functions
CARGO / GRAB HANDLING 1 2
Key switch with two positions,1 / 2.
1 - Cargo
Normal SWL.
Fig. 1. CARGO/GRAB HANDLING key switch in cabin.
2 - Grab
- Reduced SWL for operation with grab.
- Interlock connection of "grab control equipment".
See instruction "Installation of Power Supply Cable
", section 6.3.on top of the control levers. 0
1
CABLE WINCH PAY OUT
Key switch with two positions, 0 / 1, automatic return.

To be used to pay out the power cable when
rigging the cable to grab equipment. The switch is only Fig. 2. CABLE WINCH PAY OUT key switch in cabin.
activated when the "MANUAL / AUTO GRAB " switch
is in position "0" for rigging.
0
1
STAB WINCH PAY OUT
Key switch with two positions, 0 / 1, automatic return.

To be used to pay out the stabilizing wire when rig-
ging the wire to grab equipment. The switch is only
activated when the "MANUAL / AUTO GRAB " switch
Fig. 3. STAB WINCH PAY OUT key switch in cabin.
is in position "0" for rigging.
1 (4)
MANUAL / AUTO GRAB K81: Time relay for closing the grab automatically.
Switch with three positions, 1 / 0 / 2: Setting time: Grab closing time plus one (1)
second or more.
1 - Manual
The manual position is used when the grab is to be
manually operated, using the pushbutton on top of
the control levers. The open and close movement
continues as long as the button is pressed and stops 0
1 2
when the button is released.
0 - Rigging
The rigging position is used when connecting or dis-
connecting the power cable and stabilizing wire from Fig. 4. MANUAL / AUTO GRAB, switch in cabin.
its parking position to or from the grab. Cable winch
and stabilizing winch motors are stopped.
2 - Auto
The auto position is used when the grab is to be ope-
rated automatically. The open and close movement is
started by touching the pushbutton on top of the control
lever. The movement then continues automatically until Fig. 5. GRAB CLOSED pushbutton in cabin.
the grab is completely opened or closed. To stop the
grab, press the "STOP GRAB" button.
GRAB CLOSED
Pushbutton with indicator light. When button is pushed,
the indicator light comes on and grab is closed.
Fig 6. GRAB OPEN pushbutton in cabin
GRAB OPEN
Pushbutton with indicator light. When button is pushed,
the indicator light comes on and grab is opened.
STOP GRAB STOP
Pushbutton. Stops the opening and closing move-

ments of the grab. The grab can then be operated
using the buttons on the controller levers. Fig. 7. STOP GRAB, pushbutton in cabin.
Adjustment of time relays in CT19

There are two time relays in the CT19-cabinet that
control the grab opening and closing sequences in
AUTO-mode. They have to be adjusted as follows:
K80: Time relay for opening the grab automatically.

Setting time: Grab opening time plus one (1)
second or more.
Fig.8. Pushbuttons on top of the control levers in cabin.
2 (4)
Rigging of power cable to grab Procedure in crane

Lower the grab to the deck. Set the CARGO/GRAB
- Start the crane. HANDLING switch in position "2". See Fig 1. If neces-
- Set the MANUAL / AUTO GRAB switch in position sary, pay out some cable, using the CABLE WINCH
"0" for rigging, see Fig. 4. PAY OUT switch, before loosening the cable. Make
- Remove power cable and cable laying from their sure that the CARGO/GRAB HANDLING switch is in
respective parking positions. If necessary, pay out position "2" before going on to the next step.
the power cable by holding the CABLE WINCH
PAY OUT switch in position "1", see Fig. 2, and by
pulling the rope until required length is paid out. Procedure on deck
- Attach a rope to the cable laying. Loosen the cable connector and cable laying from the
- Drop the rope to the deck. grab. Fasten the rope to the cable laying.
- Pay out the power cable by holding the CABLE
WINCH PAY OUT switch in position "1" and by Procedure on platform
pulling the rope until required length is paid out. Pull the rope and power cable up to the platform.
- Connect power cable and cable laying to grab. Connect the cable and cable laying to their respective
parking ears on the jib top. See Fig. 9 and 10.
Parking of power cable

Procedure in crane
After attaching the power cable and cable laying to
Park the crane jib in its parking support, see separate
the parking ears, tighten the cable carefully by swit-
instruction.
ching the CARGO/GRAB HANDLING switch between
position "2" and position "1". After parking the power
Procedure on platform cable put the CARGO/GRAB HANDLING switch in
Secure one end of a rope to the protective handrail. position "1".
Drop the other end of the rope down to deck.
1. Stabilizing wire.
2. Power cable from cable winch
1 2
Fig. 9. Parking of power cable and stabilizing wire at the jib extension.
3 (4)
Rigging of stabilizing winch wire to Parking of stabilizing wire

grab or hook block
Park the crane jib in its parking support, see separate
- Start the crane. instruction.
- Set the MANUAL / AUTO GRAB switch in position
"0" for rigging, see Fig. 4. Procedure on platform
- Remove stabilizing wire and cable laying from their Secure one end of a rope to the protective handrail.
respective parking positions. If necessary, pay out Drop the other end of the rope down to deck.
the wire by holding the STAB WINCH PAY OUT
switch in position "1", see Fig. 2, and by pulling the
rope until required length is paid out. Procedure in crane
- Attach a rope to the wire. Lower the grab to the deck. Set the MANUAL / AUTO
- Drop the rope to deck. GRAB switch in position "0". If necessary, pay out
- Pay out the wire by holding the STAB WINCH PAY some wire by using the STAB WINCH PAY OUT switch
OUT switch in position "1" and by pulling the rope before lowering the wire.
until required length is paid out.
- Connect the wire to grab or hook block. Procedure on deck
Loosen the stabilizing wire from the grab. Fasten the
rope to the stabilizing wire.
Procedure on platform
Pull the rope end up to the platform. Connect the
stabilizing wire to its parking ear on the jib top. See
Fig. 9 and 10.
Procedure in crane
After attaching the stabilizing wire to the parking ears,
tighten the wire carefully by switching the CARGO/
GRAB HANDLING switch between "2" and "1" posi-
tions. After parking the wire put the CARGO/GRAB
HANDLING switch in "1" position.
Fig.10. Crane jib parked in jib support.
4 (4)
Controls and Indicators

CT3 Display CT3
Luffing out
32 31
Lowering
Slew Slew
left Low High
right
Luffing in speed speed
Hoisting
Fig. 1. Controls and indicators in the crane cabin.

WARNING!
Only ship's crew is allowed to operate key switches. H3 CHECK OIL FILTER
Indicator light. Comes on when the oil pressure over
WARNING! the oil filter is more than five bar. The crane will stop
Store Keys Safely five minutes after the light has come on. Note! Replace
When the crane is rigged ready for operation, all keys the oil filter or do a check of the hydraulic system.
for all lockable switches must be stored in a safe place
by the responsible officer on board. !
H4 CONTROL SYSTEM ERROR
Indicator light. Comes on when an error is sensed by
the crane control system in the electronic cabinet CT2.
H1 DO NOT OPERATE
Indicator light. Comes on during starting sequence
H5 HIGH OIL TEMP
of the crane (main electric motor and supply to elec-
tronics). Indicator light. Comes on when the oil tempe-
rature in the hydraulic system is more than 85C.
Note! The crane stops when the oil temperature is
H2 LOW OIL LEVEL more than 85C.
Indicator light. Comes on as a pre-warning for low oil
level in crane and the siren, which is installed under !
H6 OVERLOAD
the crane cabin, will sound. The indicator light and the
Indicator light. Comes on at overload.
siren can be switched off by selecting the key "FLOAT
SWITCH" in position "1". Note! Refill oil tank.
1 (8)
F14 RESET WIPER

H7 LUFFING LIMIT Pushbutton. Resets the wiper motor (automatic fuse),
Indicator light. Comes on when permitted jib outreach when the wiper motor has stopped due to a surge in
for actual load is reached. current.
- The light flashes when jib is in speed reduce area.
- Continuous light when jib has stopped.
RGENC
ME Y
E
S15 EMERGENCY STOP
H8 MAIN MOTOR OVERHEATED Pushbutton. Stops the complete crane in case of
Indicator light. Comes on when the main motor (M1) emergency. The pushbutton has to be reset, otherwise
temperature exceeds 150. the crane cannot be started again.
Note! The crane stops when the motor temperature
is more than 150C.
D
S16 DECK LIGHT
Pushbutton. Switches on/off the deck light placed
H9 HOISTING LIMIT under the cabin.
Indicator light.
- The light flashes when the hook is in speed reduce
area.
- Continuous light when hook has stopped at full drum
limit position or empty drum limit position. S17 SIREN
Pushbutton. Starts the siren.
R
S11 RESET EMERGENCY STOP J
Pushbutton with indicator light. The indicator light S18 JIB LIGHT
comes on when the emergency stop button(s) is/are Pushbutton. Switches on/off the jib light.
pushed. When all emergency stop buttons are reset
push the button to switch off the indicator light.
0
1 2
? S19 FLOAT SWITCH

H12 START PERMISSION CRANE
Pushbutton/Indicator light. Before starting the crane Key switch with three positions, 0/1/2. Normal oil level
push the pushbutton to ask for start permission. The is between MIN and MAX. If the oil level drops the
crane is ready to start when the green indicator light indicator light LOW OIL LEVEL comes on and the
comes on. alarm will sound. Select position "1" or "2". Examine
why oil level has dropped!
0 - Normal position
1
1 - Siren off
0 Use the Siren off position in an emergency. The siren
S13 START / STOP will be silent and the indicator light LOW OIL LEVEL
Pushbutton with two positions, 1 / 0. goes off. The operation of the crane may be continued
for a short time.
1 - Start
Position 1 starts the complete crane. During the
2 - By-pass
starting sequence the DO NOT OPERATE indicator
The by-pass position is used in extreme emer-
light comes on.
gency to lower a load which is hanging on
the hook. The LOW OIL LEVEL light conti-
0 - Stop
nues to illuminate and the crane siren sounds.
Position 0 stops the complete crane.The power supply
See separate instruction "Oil level float switch and
to the main electric motor and electronics will be
overheating protector".
broken.
2 (8)
0 0
1 1
S20 PARKING OF JIB S27 AIR CIRCULATING FAN 0/1 ON

Key switch with two positions, 0/1. CABIN CEILING
Switch. 0/1. Starts and stops the ventilation fan on
0 - Normal position the cabin ceiling.
1 - Parking
The parking position is used when maximum outreach
is reached for the jib. Further lowering is possible for
parking of the jib when switch is in parking position "1". S28 BUZZER (CONTAMINATION)
Sounds to indicate contamination in the hydraulic
system.
0
1
S22 WIPER H30 CONTAMINATION

Switch. 0/1. Starts and stops the window wiper. Indicator light. Comes on and indicates contamina-
tion in the hydraulic system. See instruction "Conta-
mination switch - chip detector" in section 5.
0
1
S23 CAB LIGHT

Switch. 0/1 (On/Off). Operates the cabin light.
0
1
S24 CAB HEATER

Switch. 0/1. Starts and stops the cabin heater.
0
1
S25 CIRCULATING FAN ON CABIN WALL

Switch. 0/1. Starts and stops the ventilation fan on
the cabin wall.
1 2
S26 CARGO / GRAB HANDLING

Key switch with two positions,1 / 2.
1 - Cargo
Normal SWL.
2 - Grab
- Reduced SWL for operation with grab.
- Interlock connection of "grab control equipment".
See instruction "Installation of Power Supply Cable
", section 6.3.
3 (8)
S31 CONTROL LEVER, HOISTING/LOWERING S32 CONTROL LEVER, LUFFING/SLEWING
Note! Joystick for hoisting/lowering motion must be in Note! Joystick for luffing/slewing motion must be in
neutral position when starting the crane. If the joystick neutral position when starting the crane. If the joystick
has been moved in any direction when pressing the has been moved in any direction when pressing the
start button the motion is blocked. start button the motion is blocked.
Move the joystick to neutral position then operation is Move the joystick to neutral position then operation is
possible. When the control lever is in neutral position possible. With the control lever in neutral position the
the brake is engaged and holds the load. brakes are engaged.
Moving control lever in low speed or high speed posi- Moving the control lever short distance from neutral
tion releases the winch brake. releases the brake for luffing winch or/and slewing
Moving control lever in hoisting or lowering direction machinery.
means continued speed increase from zero to maxi- Moving the control lever furthermore in luffing or sle-
mum speed. wing direction means continued speed increase from
To give a smooth acceleration and retardation to the zero to maximum speed.
winch movement the control system is fitted with a To give a smooth acceleration and retardation to the
ramp former with a special ramp time. luffing winch movement and the slewing movement
The ramp time is the time it takes to increase the winch the control system is fitted with a ramp former with a
speed from standstill to maximum speed, when the special ramp time.
control lever is moved rapidly from zero to maximum The ramp time is the same as it takes the luffing winch
speed position. In the same way it also takes the cor- speed or the slewing machinery to increase from
responding ramp time to decrease the winch speed standstill to maximum speed when the control lever
from maximum speed to standstill, if the control lever is moved rapidly from zero to maximum speed posi-
will be dropped. tion. In the same way it also takes the corresponding
The ramp time for the hoisting system is 2 seconds. ramp time to decrease the winch speed from max. to
See Fig. 2 standstill if the control lever will be dropped.
The ramp time for luffing is 2 seconds and for slewing
PUSHBUTTON 4 seconds. See Fig. 3 and 4.
Pushbutton on top of the control lever to be used only
when operating extra equipment e. g. grab.
PUSHBUTTON
Pushbutton on top of the control lever to be used only
when operating extra equipment e. g. grab.
Control lever movement Control lever movement
Start - acceleration Retardation - stop Start - acceleration Retardation - stop
Speed Speed
max. max.
Time
Time
2 sec. 2 sec.
2 sec. 2 sec.
Acceleration Retardation
Fig. 2. Hoisting/lowering.
Fig. 3. Luffing.
4 (8)
Control lever movement 0 - Rigging

The rigging position is used when connecting or dis-
connecting the power cable and stabilizing wire from
its parking position to or from the grab. Cable winch
and stabilizing winch motors are stopped.
Start - acceleration Retardation - stop
2 - Auto Grab
Speed
The auto position is used when the grab is to be ope-
max. rated automatically. The open and close movement is
started by touching the pushbutton on top of the control
lever.The movement then continues automatically until
the grab is completely opened or closed. To stop the
Time grab, press the "STOP GRAB" button.
4 sec. 4 sec.
0 1
Fig. 4. Slewing.
SG3 CABLE WINCH PAYOUT
Key switch. Automatic return. 0/1.
To be used to pay out the power cable when rigging
the cable to grab. The switch is only activated when
the "GRAB" switch is in position "1" for rigging.
See also separate instruction "Switch Functions, Grab

Handling, Rigging and Parking of Power Cable and
Stabilizing Wire" in section 4.
CT23 Panel
STOP
SG6 STOP GRAB

0
1 Pushbutton. Stops the opening and closing movements
of the grab. The grab can then be operated using the
SG1 STAB WINCH PAYOUT buttons on the controller levers. See separate instruc-
Key switch. Automatic return. 0/1. tion "Switch Functions, Grab Handling, Rigging and
Parking of Power Cable and Stabilizing Wire".
To be used to pay out the stabilizing wire when rigging
the wire to grab equipment. This switch can only be
operated when the "GRAB" switch is in position "1"
for rigging. See also separate instruction "Switch Fun- SG8 GRAB OPEN
ctions, Grab Handling, Rigging and Parking of Power Indicator light. Comes on when grab is open.
Cable and Stabilizing Wire" in section 4.
SG9 GRAB CLOSED

0
Indicator light. Comes on when grab is closed.
1 2
SG2 GRAB MANUAL / RIGGING / AUTO

Switch with three positions, 1 / 0 / 2:
1 - Manual Grab
The manual position is used when the grab is to be
manually operated, using the pushbutton on top of
the control levers. The open and close movement
continues as long as the button is pressed and stops
when the button is released.
5 (8)
Cabin Display
The display gives information about the status of the
crane during its operation. What information that can
be presented depends of the crane's configuration. CONTROL LEVER INDICATOR, (S31)
The information on the display is supplied by the soft- The right circle with four green arrows and a small
ware Macheavyvisor, refer to section 7 of this manual. white ball represents the right control lever and the
four motions it controls.
Note! If there is no communication with the CC3000 (Hoisting/lowering in both high/low speed)
system, the message "Disconnected" shows on the
screen. During operation of the hoisting winch, the white ball
will move along the circle to indicate the direction and
In case of overload indicated by CC3000 an audible speed during hoisting and lowering. Clockwise rota-
alarm and a text warning come on. tion means hoisting and counterclockwise rotation
means lowering.
LOAD DIAGRAM
Note! If an arrow goes yellow the motion is speed
reduced by CC3000. If an arrow is crossed with a
The default view includes a load diagram with a white
white cross, the motion is not permitted by CC3000.
marker, that shows the current load and outreach.
The specific diagram for this crane can be found in

Technical Data in section 2 of this manual.
CONTROL LEVER INDICATOR, (S32)

LOAD
The current load in the hook in ton. If the value equals The left circle with four green arrows represents the
or exceeds the limit, the box flashes in red. left control lever and the four motions it controls.
(Luffing in/out and slewing left/right)
Note! If an arrow goes yellow the motion is speed

reduced by CC3000. If an arrow is crossed with a
JIB RADIUS
white cross, the motion is not permitted by CC3000.
The current jib radius in meter. If the value gets close
to the limit, the box goes yellow.
HOISTING/LOWERING SPEED
The current hoisting/lowering speed in m/min.
JACK-KNIFE
This icon appears on the screen when the Jack-knife
limit is reached.
6 (8)
Electric Cabinet CT1
1 2 S50
S50 SUMMER/WINTER
Switch with two positions, 1/2, that controls the oil
heater in the oil tank.
1 - Summer
When the crane house temperature is more than +10C
set switch to "1" - summer position. Set main switch Hour meter
(Q1) to position "1".
2 - Winter
When the crane house temperature is less than +10C
set switch to "2" - winter position. Set main switch (Q1)
to position "1" approximately 24 hours before operation.
RGENC
ME Y
E
S51 EMERGENCY STOP

Pushbutton. Stops the complete crane in case of
emergency. The pushbutton has to be reset, otherwise
the crane cannot be started again.
Q1 S51 Emergency stop

Q1 MAIN POWER SWITCH
Switch with two positions 0/1 (OFF/ON). Fig. 5. Electric cabinet CT1/CT2.
0 - OFF
Stops the power supply to the electric cabinet CT1.
1 - ON
Starts the power supply to the electric cabinet CT1. 0
S52 CRANE HOUSE LIGHT

WARNING! Switch. Turns on and off the crane house light. Switch
Some components in the crane are still energized is installed on the roof of the pedestal.
when the main power switch is off. Refer to electric
diagram for information about energized components.
RGENC
ME Y
E
S71 EMERGENCY STOP

Pushbutton. Stops the complete crane in case of
emergency. Positioned inside the foundation at deck
level near the access door. The pushbutton has to be
reset, otherwise the crane cannot be started again.
7 (8)
8 (8)
OPERATION PM41 0001-E rev.: - 1994-06-16
EMERGENCY ESCAPE INSTRUCTIONS

Leaving Crane Operator's Cabin
Using Escape Line and Safety Belt
1. Make sure that the loop at the upper end of the
escape rope is securely fastened in the dee-eye
on the cranehouse wall.
2. Put on the safety belt and pull tight.
3. Drop the reel out of the cabin window so that the

rope uncoils and hangs down.
Take care that the reel does not hit anybody or

cause other damage.
4. Exit through the window on the escape ladder on

the outside of the cabin and grip the rope firmly
just below the brake buckle. Adjust the speed of
descent by alternately holding the rope tight and
letting go by degrees.
Braking of the lowering speed may also be con-

trolled by a person on deck by alternately tight-
ening and slackening the rope.
If more than one person is to descend by the rope,

reverse it after each lowering operation.
1 (2)
OPERATION PM41 0001-E rev.: - 1994-06-16
2 (2)
OPERATION PM41 0014-E00 rev.: a 2010-02-03
EMERGENCY ESCAPE INSTRUCTIONS

Rope Ladder / Fixed Ladders
Leaving Crane Operator's Cabin Using
Rope Ladder 1
1. Exit through the window to the escape ladder on

the outside of the cabin. See Fig.1 pos.1.
2. Release the rope ladder from the bracket by remo- Rotating
ladder
ving the straps and pull the rope ladder out and let Emergency
it fall towards the deck. See Fig.1 pos. 2. ladder
Hand rail
1
Fixed ladder Foot rail
Deck level
Strops
Fig. 2. Fixed emergency ladders.
Emergency rope ladder attached to bracket

After the emergency rope ladder has been used it is
important that the emergency rope ladder is put back
correctly, see Fig. 3.
Fig. 1. Emergency rope ladder.
Leaving Crane Operator's Cabin Using

Emergency Ladders
1. Exit through the window to the emergency ladder

on the outside of the cabin. See Fig. 2 pos. 1. Fig. 3. Emergency rope ladder attachment.
1 (2)
OPERATION PM41 0014-E00 rev.: a 2010-02-03
2 (2)
OPERATION 4.620.26 E rev.: a 2008-08-20
Parking the Crane, Sea Stowing

General Instruction
Introduction
Prior to sea voyage, the jib/jib extension should be put When the jib enters the parking area the function "Force
on its parking support, see Fig. 2. The hook is to be Limitation" is automatically activated. This function
stowed to deck, fibrestrops with low ultimate load or limits the pull in the hoisting wire rope to reduce stress
manual stretching screw must be used. If the hook is in the steel structure of the crane and parking
not secured to deck a jib safety lock is recommended to arrangement. See also instruction "Limit Switches in
lock the crane jib in the parking support. See Fig. 3. ..." in section 6.3.
Parking the crane Sea stowing with cargo hook secured

to deck
When parking, the jib is driven to maximum outreach
and then the key switch "PARKING OF JIB" is put in 1. Lower the jib into parking support, using the key
position "1", see Fig. 1. The key switch must be switch "PARKING OF JIB", see Fig. 1.
held in this position until the jib reaches its parking 2. Run the block up to suitable height.
position. 3. Secure hook to deck as shown in Fig. 2.
PARKING OF JIB
0 0
1 1
Fig. 1. Switch in cabin, Parking of jib.
Rope connection
Stretching screw
Notice! Hand-tighten
turnbuckle
only to the extent that
Deck the tightening gear is
not slack.
Fig. 2. Jib/jib extension on parking support, hook secured to deck.
1 (4)
OPERATION 4.620.26 E rev.: a 2008-08-20
Sea stowing with cargo hook/block Prior to cargo handling

hoisted to jib top
1. Release the hook from sea stowing position.
1. Lower the jib into parking support, using the key 2. Release the crane jib from parking parking
switch "PARKING OF JIB". See Fig. 1. support.
2. Run the block up against the jib. Do NOT tighten 3. Luff the crane in to working area (e.g. within max.
too hard. (The jib must still be resting on the support). outreach).
3. We recommend to secure the hook to the deck with
a rope otherwise the hook will be swinging during Note! Release the hook manually from sea stowing
sea voyage. See Fig. 4. position before starting the crane since the hook will
start hoisting when the brake is released.
When parking the jib with the hook block hoisted to jib Crane jib
top it is important that the parking support is provided Locking bar
with an arrangement to lock the crane jib/jib extension.
See Fig. 3.
Important!
The wire ropes must not be tightened too hard. The Chain
crane structure, wire ropes, sheaves, and winches
are subject to heavy stress during sea voyage.
Jib
support
Locking bar position with

crane in operation
Fig. 3. Locking arrangement on parking support.
Rope
Fig. 4. Block secured to deck by using a rope.
2 (4)
OPERATION 4.620.26 E rev.: a 2008-08-20
Crane jib parked on next crane

housing or foundation (If no electrical
interlocking.)
Example:
Before operating crane No. 1 carefully check that crane
No. 2's jib has been removed from its parking support,
see Fig. 5.
Crane No. 2 Crane No. 1
Fig. 5. Jib parked on crane housing.
Example:
Jibs parked in their jib supports on the foundation Before operating the crane carefully check that the
towards each other. Hook secured to deck, see crane jib has been removed from its parking
Fig. 6. support.
Crane No. 2 Crane No. 3
Fig. 6. Jib parked on foundation, hook secured to deck.
3 (4)
OPERATION 4.620.26 E rev.: a 2008-08-20
Parking suggestions of extra equipment
Example: Important!
The grab should be lowered to the deck when the Power cable and stabilizing cable should be parked
crane is parked, this to avoid load on the wires. on jib top during sea voyage. Parking on hook block
is for temporary use only.
Turnbuckle
Support Support
SIDE VIEW TOP VIEW
Fig. 7. Grab lowered to deck, fixed with suitable tightening equipment.
Example: Example:
Fix block
with wire
ropes
Deck Deck
Angle bar Angle bar
Fig. 8. Power swivel with lifting block secured to deck. Fig. 9. Power swivel secured to deck.
4 (4)
OPERATION 4.630 E rev.: - 1994-02-04
Handling Hatches by Deck Crane
Handling hatches
When pulling hatch covers by means of deck Always check that the pulley blocks are correctly
cranes, it is very important that the pulley blocks are positioned, so that the hoisting ropes cannot deviate
so placed that the hoisting wire can be maintained more than 5, at the most, from the crane house
very nearly vertical during operation. The crane jib centre line.
should be set at an angle where it will not require
any subsequent shifting in order to achieve the N.B. The capacity of the wire pulling the hatch cover
required lifting height. may limit the force which can be applied by the
crane.
The included angle between the hoisting wire and
the vertical centre line of the crane house must not
exceed 5.
Fig. 1. Fig. 2.
1 (2)
OPERATION 4.630 E rev.: - 1994-02-04
2 (2)
MAINTENANCE 5.005.55 E rev.:g 2010-07-08
Maintenance Chart
Lubricate crane according to LUBRICATING Loose gear

CHART. - Check that block, beam, hook, swivel and shackle
are intact. Check according to instruction "Lifting
Daily or before taking crane into Block/Beam", section 6.2.
operation
Hydraulic oil tank

- Check oil level.
After 50 operating hours (running-in
Slewing gear case period)
- Check oil level. See instruction in section 6.1. The
oil quantity is marked on the name plate and in Power swivel oil tank (optional)
instruction "Technical Data", section 2. - The first oil change see instruction in section 7.
Winches, hoisting and luffing

- Check oil level. See instruction in section 6.1. The
oil quantity is marked on the name plate and in Every month
instruction "Technical Data", section 2.
Escape device
Filter service indicator - Visual inspections should be carried out with
- Check filter service indicator particular attention being paid to the condition of
- If necessary change filter cartridges, see instruction the rope.
"Filters", section 5.
Filter guard (CT1)

- When the pilot light "Check Oil Filter" illuminates
Every 200 operating hours or every two
red the filter guard will stop the crane within 5
months
minutes.
- Replace oil filter. See instruction "Filters", section 5. Pumps
- Check for leaks.
Limit switches; compare section 6.3 instruction
for stop position
Multiple-disc brake, slewing gearset/winches
- Testrun all functions and check that they are - The drain plug shall be taken out every 200 hours
working properly. of operation, to drain off oil that may have been
collected.
Slack wire switch

- Function test, see instruction in section 6.3.
1 (4)
Slewing bearing studs/screws - Wire ropes are inspected according to stipulations

- Inspect visually the slewing bearing studs/screws issued by Classification Associations and National
from deck and inside pedestal. If any stud/screw Bodies.
shows a tendency to slacken, tighten all studs/ - Check that wire rope clamps on wire drums are
screws. Tightening torque, see drawing "Slewing safely secured.
bearing, yard mounting" and "Slewing bearing,
mounting", section 9.3. Wire sheaves
- Inspect for wear
Wire rope sockets (thimbles) - Check that shafts are safely secured.
- Make sure that wire rope thimbles are safely
secured Climb protection, jib top
- Inspect for wear and damage. - Inspect climb protection for wear and damage
- Check play between wire sheave and climb
Ventilation filter unit (optional) protection. See instruction in section 6.2.
- Make sure the coarse filter is clean.
- Clean or replace if necessary. See separate Slack wire device
instruction. - Inspect rollers for wear or damage.
Pressure roller (hoisting winch)

After 200 operating hours - Check roller and springs for wear and damage
- Check function.
Slewing gear case Electrical equipment including slip-ring unit

- The first oil change. (Running-in period 200 hours.) - Inspect according to Electrical Equipment, General
See instruction in section 6.1. Maintenance in section 6.3.
Winches, hoisting and luffing Heating elements, cabinet CT2

- The first oil change (Running-in period 200 hours). - Check that the elements in cabinet CT2 is working
See instruction in section 6.1. i.e. get warm.
Crane house, foundation and jib welding joints
Every 500 operating hours or every six - Inspect for any sign of crack
months See "Inspection of Stressed Components and
Structures", section 5.
Oil cooler Hydraulic system

- Inspect oil cooler externally. Clean when required. - Check the following pressures:
- Feed pressure inlet, at guage connection 1
Wire ropes, wire rope clamps - Control pressure, at guage connection 2
- Pressure cut-off (overload) valve/valves 1311,

- Inspect for wear. See instruction "Handling,
1312 etc., at connection 3.1
Installation, and Maintenance of Steel Wire Ropes"
in section 6.2 Pressures should be according to the Hydraulic
Component Specification, part of Hydraulic Circuit
diagram in section 9.4.
- Adjust if required.
2 (4)
Oil analysis (oil tank) Winches

- Sample oil and analyse every six months. - Oil analysis. See instruction "Winch", section 6.1
- Change oil. See instruction in section 6.1.
Pump servo
- Check plussing Air breather, hydraulic oil tank
- If necessary adjust. - Check and replace air breather on top of the tank.
Slewing gear, pinion Hydraulic accumulators

- Check backlash. - Check pressure, re-charge as required. See
instruction Hydraulic Accumulators, section 6.1.
Slewing bearing
- Measurement to be taken according to instruction Cable winch (optional)
"Measuring Procedure for Wear in Slewing - V-belt, check tension
Bearings for Rope Luffing Cranes" in section 6.2 - Slipring unit, check
- Check seals. - Brake discs, check
- Brush holders, check.
Filter service indicator See instruction in section 7.
- Replace filter cartridge. See instruction "Filters",

section 5. Service door
- Open service door, see instruction in section 6,
Slip-ring unit and check hinges for damage and corrosion.
- Check brush holders, wire brushes and slip-rings

according to instruction in section 6.3. Slewing bearing studs/screws/nuts
- Inspect visually and by hammer test.
External access ways
- Inspect for wear and damage.
Every 2000 operating hours or every two

Emergency escape ladder (optional) years
- Inspect for wear or damage.
Hydraulic oil tank

Ventilation filter unit (optional) - Take out the drain plug
- Make sure the filter bags are clean. - Drain oil and clean the reservoir. (See Hydraulic
- Replace if necessary. See separate instruction. Oil Tank, section 5.)
- Verify that the oil level float switch is working
properly. This inspection is verified when changing
oil or cleaning of oil tank
Every 1000 operating hours or at least - Check air breather cap
every year - Top up with fresh oil according to Lubricants for
Deck Machinery, section 5
- Change all oil filter cartridges.
Slewing gear case
- Change oil. See instruction in section 6.1.
3 (4)
Multiple-disc brake, winch Every ten years

- Check for leaks
- Check braking torque - Replace all hydraulic hoses. See instruction in
- Check according to instruction "Winch" in section 6.1. section 6.1.
Multiple-disc brake, slewing gearset

- Check for leaks
- Check braking torque
- Check discs
- Check according to instruction "Slewing Gearset,
section 6.1.
Oil tank in cable winch (optional)

- Drain oil, turbo coupling
- Drain oil, spur gear.
See instruction in section 7.
Oil tank in power swivel (optional)

- Drain oil and clean the reservoir. See instruction,
in section 7.
At dry docking or at maximum 5 years

interval
Slewing bearing studs/screws

- Tighten all studs or screws. Tightening torque, see
separate drawing, "Slewing bearing, yard
mounting" and "Slewing bearing, mounting", section
9.3
- Consult MacGREGOR before replacing studs or
screws with any other specifications than
recommended.
Every five years
Hydraulic hoses inside crane house

- Check hydraulic hoses for damage. See
instruction in section 6.1.
4 (4)
MAINTENANCE 5.018 E rev.: b 2004-05-24
Inspection of Stressed Components and Structures
Introduction
Stressed parts of the crane structure subjected to This inspection should be performed at intervals ac-
high loads require inspection for signs of cracks and cording to the Maintenance Chart.
other damage at regular intervals.
Note!
Cracks detected at an early stage do not generally Rust on a painted surface does not necessarily
impair the handling safety of the crane unless they mean that there is a crack in the underlying mate-
are not repaired. rial.
For safety reasons, service routines should include

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

A thorough visual inspection is fairly easy to carry ways contact MacGREGOR Cranes, Service De-
out as cracks will generally show by cracking or partment for advice.
flaking of the paint followed by a brownish discol-
oration by rust.
(Inspect welds and surrounding material.)
Example:
Fig. 1. Crane structure. Fig. 2. Parking support.
1 (2)
2 (2)
MAINTENANCE 5.025.3 E rev.: - 2009-01-26
Contamination Switch - Chip Detector
General
The crane hydraulic system is fitted with contamination The switches are used for early detection of wear in
switches/chip detectors in all main hydraulic circuits. the axial piston units as hydraulic pumps and motors
e.g. in the bearings of axial piston units.
The switches are connected to the housing of all main
pumps i.e. hoisting circuit pumps, luffing circuit pump,
and slewing circuit pump, see Fig. 1.
Slewing
Contamination switch
Luffing
Contamination switch
Hoisting
Fig. 1. Pumps in crane.
1 (4)
Function
The contamination switch, see Fig. 2, has a perma-

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

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

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

9.5.
LED
Fig. 3. CT2 cabinet.
2 (4)
Maintenance
When contamination is indicated the ALARM sounds ALARM

(Buzzer)
and the CONTAMINATION pilot light illuminates on
the control panel, see Fig. 4, the crane has to be
stopped and the contamination switch has to be
identified, removed from the pump, and checked.
The ferromagnetic dirt particles have to be removed

from the switch, and the switch reassembled into the
pump.
Operate the crane for another 8-12 hours, and check CONTAMINATION
for contamination indication. (Pilot light)
If contamination is indicated in the same circuit during

this operation period, the pump/pumps in the circuit
has/have to be checked.
Check the leakage condition of the pump. Fig. 4. Symbols on the control panel.
3 (4)
4 (4)
LUBRICATING CHART PM51 1730-E00 rev.: a 2009-11-09
Item Part of crane (see page 2 for location) a b c d e f

1 Wire sheaves, Crane house top: 1 nipple/sheave (4-6 nipples) *
2 Wire sheaves, Jib top: 1 nipple/sheave (4-7 nipples); Wire rope thimble: 1 nipple *
3 Wire sheave, Lifting block: 1 nipple
4 Wire rope socket (thimble): 1-2 nipple(s), Crane top
5 Swivel, Lifting block: 1 nipple. (Not on all cranes)
6 All wire ropes
7 Electric motor: 2 nipples
8 Door hinges: 3 nipples, see instruction manual, section 6.2.
9 Jib bearings: 2 nipples
10 Oil tank
11 Air breather cap
12 Oil filters
13 Slewing gear case
14 Slewing bearing teeth
15 Slewing bearing - See drwg. section 9.3 for nipples **
16 Hoisting + Luffing winches, bearing: 1 nipple/winch
17 Hoisting + Luffing winches, oil change
* Check what number of nipples that apply to your Key to symbols

crane. It is of utmost importance that all nipples
are greased. a Daily
b Every 100 working hours (or before taking
** Relubrication should be performed under
slewing motion. If that is not possible relubricate winch into operation, item 17)
bearing through all grease fittings, than turn c Every 200 working hours or every two months
bearing approx. 200 mm and relubricate again. d Every 500 working hours or every six months
Repeat this procedure until overlap of greasing e Every 1000 working hours or every year
is achieved and the whole bearing f Every 2000 working hours or every two years
circumference is filled with new grease at the
gaps and seals. (Five rotations/greasings
should be sufficient.) Key to symbols
Grease for ball and roller bearings
Before greasing proceed as follows
Crane jib parked on parking support: Grease for sleeve bearings
Park the crane and slack the luffing and hoisting Grease for wire ropes
wire. Grease for open spur gears
Grease for jib bearings
Oil level, check
Oil filters, check
Oil filters, replace
Air breather cap, check
Hydraulic oil, oil change
Gear case oil, oil change
The first oil change to be done after 200
working hours (running-in period)
Gear case oil, oil change
The first oil change to be done after 200
working hours (running-in period)
Slip-rings to be treated according to

separate instruction, see section 6.3.
Documents with supplementary data:

Oil quantity required: "Technical data", Section 2.
Maintenance intervals: "Maintenance chart", Section 5.
Location of nipples etc: "Lubricating and maintenance", Section 5.
Lubricants: "Lubricants for deck machinery", Section 5.
1 (2)
LUBRICATING CHART PM51 1730-E00 rev.: a 2009-11-09
Red lamp on right control panel in operators cab Jib top with lifting block for single crane
CHECK
OIL FILTER
6. Wire ropes
3. Wire sheave
CAUTION!
Renew all filter cartridges 5. Swivel
when this lamp is lit.
Example: Wire sheaves crane top and wire rope

thimble, manual greased.
1, 4 Example: Wire sheaves jib top and wire rope
1
thimble, central greased.
1, 4 1
Hoisting winch oil level

1. Wire sheaves
CAUTION!
Remove the pressure relief valve before measuring
oil level with oil dipstick.
The oil level will not be correct until the pressure is
released.
See instruction 6.120.108 E in section 6.1.
Pressure relief valve
Oil dipstick / Oil filler inlet
17 8. Door hinges
Filter service 7. Electric motor

indicator
12. Oil filters
12
Filter
4135 10. Oil tank
11. Air breather cap
16, 17. Luffing winch
12 Oil filling 13. Slewing gear case

16, 17. Hoisting winch
Filter
4136
15. Slewing bearing 9. Jib bearings
14. Slewing bearing teeth
2 (2)
LUBRICATING CHART PM51 4200-E00 rev.: - 2008-05-14
Lubrication Chart for Cable Winch
Parts a b Key to symbols

1 Electric motor, bearing a Every 5000 working hours or every two years
2 Turbo coupling, oil change b Every 12 months
3 Gearbox, oil change
Turbo coupling, oil change
Gearbox, oil change

- Oil quantity required: "Technical data", section 2.
- Maintenance intervals: "Maintenance chart", section 5.
- Lubricants: "Lubricants for deck machinery", section 5.
1 (2)
2 (2)
Lubrication Chart for Stabilizing Winch
Parts a b c Key to symbols

1 Electric motor, bearing a Every 10000 working hours or every two years
2 Turbo coupling, oil change b Every 5000 working hours or every two years
3 Gearbox, oil change c Every 12 months

Turbo coupling, oil change
Gearbox, oil change

- Oil quantity required: "Technical data", section 2.
- Maintenance intervals: "Maintenance chart", section 5.
- Lubricants: "Lubricants for deck machinery", section 5.
1 (2)
2 (2)
Lubricating and Maintenance

Cranes type GLB
Contents
Door hinges ................................................................. 2

Electric motor .............................................................. 3
Slewing bearing ........................................................... 4
Jib bearing ................................................................... 5
Wire sheaves Jib and Wire rope socket ...................... 6
Wire sheaves Crane house ......................................... 7
Wire rope socket Crane top ......................................... 8
Slewing gear case ....................................................... 9
Lifting equipment ....................................................... 10
Oil tank ....................................................................... 11
Oil filter ...................................................................... 12
Oil filter change .......................................................... 13
Wire ropes ................................................................. 14
Winch with high speed motors ................................... 15
Cable winch (optional) ............................................... 16
Power swivel (optional) .............................................. 17
1 (17)
Door hinges
Grease nipple;
Service door
2 (17)
Electric motor
Grease nipple;
Upper bearing
Grease nipple;
Lower bearing
3 (17)
Slewing bearing
Grease nipple; Grease;

Slewing bearing Slewing bearing teeth
4 (17)
Jib bearing
Grease nipple;
Inside crane house
5 (17)
Wire sheaves Jib and Wire rope socket
Grease nipples; Jib top, Central lubricating
6 (17)
Wire sheaves Crane house
Grease nipple
7 (17)
Wire rope socket Crane top
The wire rope sockets can also be located on jib top

or lifting block.
Grease nipple
8 (17)
Slewing gear case
Oil change Air breather
Check oil level
Oil drain plug
9 (17)
Lifting equipment
Grease nipple, Lifting block
Grease nipple, Swivel
10 (17)
Oil tank
Check air breather

Check oil level (dipstick)
Drain oil tank
11 (17)
Oil filter
Filter unit, outlet Filter unit, inlet

Oil filling Electrical indicator, visual indicator
12 (17)
Oil filter change

Necessary equipment when changing filter cartridges:
- 2 new filter cartridges with O-rings.
- Spanner.
- Bucket.
Put the bucket Remove the

1 under the filter
2 drain-plug by
unit. hand and let the
Loosen the oil run into the
drain-plug at bucket. Make
the bottom of sure not to lose
the filter unit the
using the O-ring.
spanner.
(size 9/16"
or 15 mm)
Loosen the Unscrew the

3 filter cap using
4 filter cap by
the spanner. hand.
(size 1" or Be careful not
26 mm) to drop it.
Remove the old
O-ring between
the filter cap
and the filter
head.
Remove the Mount the filter cap and tighten it using

5 old filter
6 the spanner.
cartridge.
Install the new
O-ring Mount the drain-plug and the O-ring on the
7 filter cap and tighten it using the spanner.
between the
filter cap and
the filter head.
Install the new
filter cartridge.
13 (17)
Wire ropes
Relubricating of steel wire ropes, see instruction

6.222.1 E.
Grease
14 (17)
Winch with high speed motors
Grease nipple
Oil filler inlet

Oil dipstick
Oil outlet
15 (17)
Cable winch (optional)
Oil change; Spur gear

Grease nipples; Electric motor
Oil drain plug;

Spur gear
Oil change; Turbo coupling
16 (17)
Power swivel (optional)
Check oil level (dipstick)
Grease nipples, ball bearing
Drain oil tank (seen from below)
17 (17)
MAINTENANCE 5.301.13 E rev.: a 2009-04-20
Filters
Introduction
For cleaning hydraulic oil, the hydraulic system is The other indicator is visual (see Fig. 1) and should
equipped with two filters. The two filters are marked be read when the oil temperature is approximately
4135 and 4136. 45C. Upon reaching a certain degree of clogging, a
red indication can be seen on the top of the filter
Filter indicators indicator. Replace both filter cartridges in the system
when the red indication shows.
The filter indicators operate only when the crane
starts.
Replacement filter cartridges
Filter 4135 has two filter indicators. One indicator is You must replace both cartridges (see Fig. 3) in the
electric and operates a warning lamp placed on the crane at the same time. Flush all other parts of the
control panel in the cabin (see Fig. 4a and 4b). filters with white spirit when you replace the cartridges.
Use new seals. Reassemble the filters.
4101 4102
Electric indicator
Visual
indicator
Oil filling
Filter Filter
4135 4136
Fig. 1. Filter inlet. Fig. 2. Filter outlet.
Fig. 4a. Control panel.
Filter cartridge
Fig. 3. Filter cartridge. Fig. 4b. Control panel.
1 (2)
MAINTENANCE 5.301.13 E rev.: a 2009-04-20
2 (2)
Hydraulic Oil Tank
The hydraulic oil tank is placed on the wall inside the Oil level MIN
crane house. If the oil level drops to MIN, the oil and temperature
guard activates the lamp LOW OIL LEVEL on the
Checking oil level control panel in the operator's cab. At the same time
the siren sounds.
Check oil level by use of the dipstick. Check that oil
level is between min. and max on the dipstick.
Verify that the guard is working properly by starting the
crane. Loosen the nut that holds the guard and lift it up
slowly.
1
Oil filling
1. Outlet filter
2. Inlet filter
3. Air filter with dipstick
4. Oil level and temperature guard
2 5. Thermometer
6. Vedge valve (oil drain)
3
7. Quick coupling
8. Heater
4
Fig. 1. Hydraulic oil tank.
1 (2)
Filling oil
Oil is filled at an aero-quip type quick-release coupling,
placed on the filter unit, see Fig. 2. When filling oil the
hydraulic system must be at rest and the electric
power switched off.
Fill oil to just under the MAX mark on the dipstick. Use
oil according to the Lubricating Chart.
NOTE! Oil must not be filled directly into the tank.
Cleaning the oil tank

Oil filling
Before cleaning the oil tank, immobilise the crane jib
in a suitable manner, push the stop button and switch
off the power. Drain off the oil into clean empty barrels Fig. 2. Oil filter unit with filling.
or drums.
Remove the tank cover. Scrape off sediment, if any,

from the tank bottom and sides using a rubber scraper.
Flush the tank with white spirit.
Wipe the tank dry with clean rags. DO NOT USE

COTTON WASTE, or other linting material. Apply new
sealing compound and reinstall the tank cover.
If the drained oil is in good condition and can be used

anew, it should be filtered before refilling.
Pump and hoses used for filling must be perfectly

clean.
Fill oil to just under the MAX mark on the dipstick. Use
oil according to the Lubricating chart.
2 (2)
Sampling of Oil to Verify the Cleanliness in Hydraulic System
General Procedure for oil sampling

- Oil temperature in the system should be 40-50oC.
This instruction describes sampling oil from a hy- - Special oil sampling bottles should be used and
draulic crane system. can be purchased from oil companies.
- Connect a pressure gauge hose to gauge outlet
This procedure is general and there can be some 3.1 (hoisting circuit), see Fig. 1.
differences depending of crane type. - Start the crane and run the hosting winch in maxi-
mum speed hoisting.
Type of oil to be used in the system can be found - Bleed out 0.5 litre of oil in a bucket. This oil to be
in Section 5. disposed.
- Fill the oil sample bottle.
When to sample oil - Send the oil sample to an oil company for
analysis.
To verify the oil condition, an oil sample should be
The oil company will be able to recommend if the
taken every six months and sent for analysis. This
oil can be further used.
analysis is done by the oil companies and can be
Feedback on the oil analysis can also be obtained
of different levels. When the result is received, a
from MacGregor Cranes.
recommendation is normally given if the oil is ap-
proved or has to be changed.
For maximum practical contamination in the sys-

tem, see Table 1.
Pump Hose
Gauge outlet 3.1

Bottle
Fig. 1. Sampling hydraulic oil.
1 (2)
Analysis using automatic particle counter

ISO 4406
We recommend cleanliness code 19/17/14 or better,
according to ISO 4406:1999. Scale no. Number of particles per millilitre fluid
Number of particles equal to or larger than 4 m(c), ISO code More than Up to and including
not to exceed code 19. 26 320 000 640 000
Number of particles equal to or larger than 6 m(c), 25 160 000 320 000
Number of particles equal to or larger than 14 m(c), 23 40 000 80 000
21 10 000 20 000
Analysis using microscope sizing 20 5 000 10 000
We recommend cleanliness code -/17/14 or better, 19 2 500 5 000
according to ISO 4406:1999. 18 1 300 2 500
17 640 1 300
Number of particles equal to or larger than 5 m, 16 320 640
not to exceed code 17. 15 160 320
Number of particles equal to or larger than 15 m, 14 80 160
not to exceed code 14.
13 40 80
12 20 40
Procedure if oil sample is showing too high 11 10 20
contamination 10 5 10
9 2,5 5
If the oil analysis shows too high contamination, the 8 1,3 2,5
oil and the filters should be changed. The crane
7 0,64 1,3
should be driven for approximately 1 hr and a new
6 0,32 0,64
oil sample should be taken and sent for analysis.
Table 1. Cleanliness level correlation table.
2 (2)
MAINTENANCE 5.421.40 E rev.: d 2008-05-14
Lubricants for Deck Machinery

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

Synthetic oil (polyglycol type). Synthetic oil brand.
Viscosity 220 cSt/40C. Example: MOBILE Glygoyle 30.
Viscosity index (VI) 210.
Solidification point -30C or better.
The oil must fulfil specifications according to DIN Stabilizing winch, turbo coupling (if
51354, FZG stage 12. applicable)
Viscosity 22 cSt/40C (ISO VG 22).
CAUTION! The oil must not be mixed with mineral oil Example: SHELL TELLUS 22.
or synthetic gear oil on PAO-basis. The oil can also
dissolve paints and some seals. Stabilizing winch, gear box (if applicable)
Example: Shell Tivela S220 or similar.
Synthetic oil brand.
Example: Aral-Dego GS220.
Hoisting and luffing winches
Synthetic oil (polyglycol type).
Viscosity 220 cSt/40C.
Viscosity index (VI) 210.
Solidification point -30C or better.
The oil must fulfil specifications according to DIN
51354, FZG stage 12.
CAUTION! The oil must not be mixed with mineral oil

or synthetic gear oil on PAO-basis. The oil can also
dissolve paints and some seals.
Example: Shell Tivela S220 or similar.
Crane hydraulic system

For service in normal conditions:
Viscosity 68 cSt/40o C approx. (ISO VG 68 HV).
Viscosity index (VI) min. 150.
Solidification point -35o C or better.
Example: SHELL TELLUS T68.
For service in arctic climate:

Viscosity APPROX. 46 cSt/40o C (ISO VG 46 HV).
Viscosity index (VI) approx. 150.
Solidification point -45o C or better.
Example: SHELL TELLUS T46.
Load handling equipment, without oil heater

Viscosity 32 cSt/40oC approx. (ISO VG 32 HV).
Viscosity index (VI) min. 150.
Solidification point -45oC or better.
Example: SHELL Tellus T 32.
1 (2)
MAINTENANCE 5.421.40 E rev.: d 2008-05-14
B. GREASES
Plain bearings and wire rope sockets

Lithium grease with molybdenum disulphide.
Base oil viscosity 150 cSt/40C.
Dropping point 180C.
Example: MOBILGREASE Special 530303.
Crane jib bearing

Lithium/mineral oil-based grease.
NOTE: MUST NOT contain molybdenum disulphide.
Example:
SKF LGMT2 or SKF LGEP2. (-30C to +110C).
TEXACO MULTIFAC EP2. (-30C to +100C).
Roller/ball bearings
Grease with EP additives.
Must withstand wet conditions.
Example: SHELL Alvania EP (LF) 2 (-20 to +130C).
Arctic climate: SHELL Albida PPS2.
Ropes
Grease resistant to salt water and with antirust
properties. (Very thin.)
Temperature range -30 to +100C.
Viscosity 9.8 cSt/40C.
Example: FUCHS Cedracon.
Arctic climate: FUCHS Ceplattyn.
Open spur gear units

Grease with good adhesion properties.
Example: SHELL MALLEUS GL95 (-15 to +150C).
SHELL MALLEUS GL65 (-30 to +150C).
Slip-ring unit, signal slip-rings

Example: "Cramolin B".
Please contact MacGREGOR (SWE) when choosing

lubricants for extreme temperatures.
2 (2)
How to order
Cargotec Sweden AB
MacGregor Cranes spare parts 6.0
Sjgatan 4G
SE-891 85 RNSKLDSVIK, Sweden
Telephone: 46 - 660 - 29 40 00
Telefax: 46 - 660 - 139 77
www.cargotec.com
SERVICE
Hydraulic system 6.1
Mechanical
equipment 6.2
Electrical
6.3
equipment
SERVICE 6.000 E rev.: e 2010-09-08
How to Order Spare Parts
Important details when enquiring or ordering spare parts
Please send your inquiry or order to closest MacGregor global service station, see instruction "MacGregor Global
Services", 6.004.1 E.
To speed up the process we request you to provide us with below information:
State name of company as well as your name
Vessel's name and IMO number (and/or Lloyd's number)
Crane type (see manual or name plate in operator's cabin)
Crane place on the vessel. No. 1 counted from the fore
Crane serial number (see manual or name plate in operator's cabin)
Spare part figure or drawing number. To be found in section 9 in the manual
Part description
Item number from spare part figure or drawing respectively
Part number, if available, from spare part figure or drawing respectively
Quantity required
When you order a wire rope or lifting block, please specify which certificate is needed.
Deadline - when or where in the world do you need the parts?
Delivery details such as: consignee as well as phone and fax numbers
Terms of delivery: by DHL, air freight direct or consignment, by truck or shipping freight
The more you can provide us with above details the faster and more reliable replies and deliveries will be made.
Address:
Cargotec Sweden AB
MacGregor Cranes
Phone: 46 - 660 - 29 40 00
Telefax: 46 - 660 - 139 77
www.macgregor-group.com
1 (2)
6.000 E rev.: e 2010-09-08 page 2 (2)
Tel: 46 - 660 - 29 40 00
Direct: Fax: 46 - 660 - 139 77
Date: ................................................
Spare parts/Service specification

Please use this form whenever assistance is needed. Service request
Confirmation of
phone call/conv.
From: .. ............................................................. E-mail address: ................................................
.............................................................. Phone no.: ......................................................
.............................................................. Telefax no.: ......................................................
Re: M/V ........................................................ IMO /Lloyd's no.: ..............................................
Crane type: ............................................. Serial no: .........................................................
Crane place: ........................................... Our ref.: ..........................................................
For following spares we would like to: have your quotation
place order, deadline for arrival :................................
Part no. Qty Description Fig./Drwg. Item
1. .......................................... ..... ............................................ .............................. ..............
2. ........................................... ..... ............................................ .............................. ..............
3. ........................................... ..... ............................................ .............................. ..............
4. ........................................... ..... ............................................ .............................. ..............
5. ........................................... ..... ............................................ .............................. ..............
6. See enclosure
Delivery/Agent's address: ............................................................................................................
............................................................................................................
............................................................................................................
...................................................................................................................
Name/ Title/
SERVICE 6.000.1 E rev.: c 2007-01-08
Statement Regarding Delivery of Spare Parts to Swivels, Lifting

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

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

be considered sufficient to subject that part, Gunnar Tjrnstrm
by separate means, to the same stress as Quality Manager
would have been imposed on if it had been
tested in-situ during the testing of the
complete appliance.
Section B
Paragraph B.1.2 stipulates that every item of loose

gear, including cargo blocks, lifting beams and lifting
frames, should be tested:
(a) before it is taken in to use the first time

(b) after any renewal or repair of a stress-bearing
part.
1 (2)
SERVICE 6.000.1 E rev.: c 2007-01-08
2 (2)
SERVICE 6.000.2 E rev.: d 2009-03-05
RETURN FORM
How to return parts from deck crane manufacturing,
installation or guarantee exchange
Delivery address: MacGREGOR Cranes

Cargotec Sweden AB
Att.: Mr Daniel Lundberg
Bjrnavgen 2
SE-891 41 RNSKLDSVIK
SWEDEN
Transport means, if necessary: Advised by us on request.

Phone no.: 46-660-29 40 00
Fax no.: 46-660-124 55
E-mail: daniel.lundberg@macgregor-group.com
Identification: Absolutly necessary is a paper inside the return

shipment, shortly describing:
1) the part
2) from where it has been taken and
3) why it is returned.
Claim: Detailed claim can be sent separately and does not

have to be enclosed.
The above refers only to the return shipment as such.
1 (2)
SERVICE 6.000.2 E rev.: d 2009-03-05
RETURN FORM
To be packed inside return box or parcel
Date:
Sent by:
Newbuilding no.:
Ships name:
IMO no.:
Crane place on board:

Crane serial no.:
Returned parts
drawing or article
no, serial no.:
Part description:
Serial no. of unit

from which the part
is taken:
Unit description:
Reason for return: *
*) Please note: To be filled in with short but specific details. Faulty is not enough, a much better
description is leaking, not adjustable, cracked, earthing fault, short circuit if the reason is obvious,
or, a circumstantial evidence pointing to the returned part as the reason for malfunction, like luffing
movement too slow in one direction.
(Service/guarantee: 662 5000-706)
2 (2)
SERVICE & PARTS 6.004.1 E rev.: bc 2011-06-21
Worldwide Service Network

Marine Service: Worldwide Service Network
AUSTRALIA DENMARK INDIA
Sydney Office Copenhagen Office Mumbai Office

Tel: +61-2-464 741 49 Tel: +45-44-538 484 Tel: +91-22-2758 2222
Fax: +61-2-464 770 03 Fax: +45-44-538 410 Fax: +91-22-2758 2227
24 hrs: +61-408-494 777 24 hrs: +45-44-538 484
Esbjerg Office INDONESIA
BELGIUM Tel: +45-44-538 484
Fax: +45-44-538 410 Batam Office
Antwerpen Office 24 hrs: +45-44-538 484 Tel: +62-778-737 2207
Tel: +32-3-546 4640 Fax: +30-778-737 2210
Fax: +32-3-542 4772 ESTONIA
24 hrs: +32-3-546 4640 ITALY
Zeebrugge Office Tallinn Office
Tel: +32-50-84 05 50 Tel: +372-6 102 200 Genoa Office
Fax: +32-50-84 09 50 Fax: +372-6 102 400 Tel: +39-010-254 631
24 hrs: +372-53-018 716 Fax: +39-010-246 1194
BRAZIL 24 hrs: +39-335-139 4779
FINLAND
Rio de Janeiro Office JAPAN
Tel: +55-21-2516 1790 Turku Office
Fax: +55-21-2516 1743 Tel: +358-2-412 11 Kobe Office
24 hrs: +55-21-9121 1986 Fax: +358-2-412 1517 Tel: +81-78-846 3220
24 hrs: +358-400-824 414 Fax: +81-78-846 3221
CHINA 24 hrs: +81-90-4387 9992
FRANCE Kumozu Office
Hong Kong Office Tel: +81-59-234 4114
Tel: +852-2394 1008 Le Havre Office Fax: +81-59-234 0040
Fax: +852-2787 7652 Tel: +33-235-247 299 Tokyo Office
24 hrs: +852-9097 3165 Fax: +33-235-247 298 Tel: +81-3-5403 1966
Shanghai Office 24 hrs: +33-611-643 942 Fax: +81-3-5403 1953
Tel: +86-21-2606 3000 Marseilles Office 24 hrs: +81-90-7188 0377
Fax: +86-21-6391 2276 Tel: +33-491-095 252
24 hrs: +86-1350-1828 932 Fax: +33-491-609 020 KOREA
24 hrs: +33-679-826 544
CROATIA Busan Office
GERMANY Tel: +82-51-704 0844
Rijeka Office Fax: +82-51-704 0414
Tel: +385-51-289 717 Bremerhaven Office 24 hrs: +82-51-704 0844
Fax: +385-51-287 154 Tel: +49-471-780 41
24 hrs: +385-98-440 260 Fax: +49-471-740 80 MALAYSIA
Zagreb Office 24 hrs: +49-471-780 41
Tel: +385-1-3837 711 Hamburg Office Kemaman Office
Fax: +385-1-3835 563 Tel: +49-40-254 440 Tel: +60-985-92 129
Fax: +49-40-2544 4444 Fax: +60-985-82 272
CYPRUS 24 hrs: +49-40-2544 4120 24 hrs: +60-985-92 129
Kuala Lumpur Office
Limassol Office GREECE Tel: +60-377-828 136
Tel: +357-25-763 670 Fax: +60-377-852 131
Fax: +357-25-763 671 Piraeus Office 24 hrs: +60-122-786 889
24 hrs: +357-99-463 862 Tel: +30-210-428 3838 Miri Office
Fax: +30-210-428 3839 Tel/fax: +60-854-28 136
24 hrs: +30-6974-300 541 24 hrs: +60-122-786 889
MacGregor Cranes Address Telephone Telefax

Cargotec Sweden AB SE-891 85 RNSKLDSVIK (+46) 660-29 40 00 (+46) 660-139 77
www.macgregor-group.com/cranes Sweden
1 (2)
SERVICE & PARTS 6.004.1 E rev.: bc 2011-06-21
Worldwide Service Network

Marine Service: Worldwide Service Network
MEXICO SINGAPORE UNITED KINGDOM
Campeche Office Singapore Office Aberdeen Office

Tel/fax: +52-938-286-1528 Tel: + 65-6597 3888 Tel: +44-1224-347 050
24 hrs: +1-985-641-3853 Fax: + 65-6597 3799 Fax: +44-1224-347 051
24 hrs: +65- 6597 3777 24 hrs: +44-7850-313 733
THE NETHERLANDS Liverpool Office
SPAIN Tel/fax: +44-151-708 4177
Rotterdam Office Bilbao Office 24 hrs: +44-7768-334 419
Tel: +31-10-283 2121 Tel: +34-94-480 7339 Newcastle Office
Fax: +31-10-429 3219 Fax: +34-94-431 6945 Tel: +44-191-295 2180
24 hrs: +31-10-283 2121 24 hrs: +34-609-428 066 Fax: +44-191-295 2188
Cadiz Office 24 hrs: +44-7768-334 419
NORWAY Tel/fax: +34-956-877 611 Portsmouth Office
Ferrol Office Tel: +44-2392-210 703
Bergen Office Tel: +34-696-946 086 Fax: +44-2392-210 734
Tel: +47-56-313 300 Fax: +34-981-354 624 24 hrs: +44-7768-334 419
Fax: +47-56-313 070
24 hrs: +47-905-873 71 SWEDEN UNITED STATES
Kristiansand Office Fort Lauderdale Office
Tel: +47-91-68 60 00 Bjuv Office Tel: +1-954-600-4199
Fax: +47-38-01 87 01 Tel: +46-42-85 800 24 hrs: +1-757-558-4580
Oslo Office Fax: +46-42-85 899 Houston Office
Tel: +47-23-10 34 00 Enkping Office Tel: +1-713-681-5452
Fax: +47-23-10 34 01 Tel: +46-171-232 00 Fax: +1-713-681-8204
24 hrs: +47-905-873 71 Fax: +46-171-232 99 Jacksonville Office
Gothenburg Office Tel: +1-904-821 0340
PANAMA Tel: +46-31-721 50 00 Fax: +1-904-821 0850
Fax: +46-31-424 946 24 hrs: +1-757-558-4580
Balboa Office 24 hrs: +46-31-721 50 00 Lafayette Office
Tel: +506-603-45 032 rnskldsvik Office Tel: +1-337-231-5961
24 hrs: +1-757-558-4580 Tel: +46-660-29 40 00 Fax: +1-337-231-5966
Fax: +46-660-139 77 New Orleans Office
POLAND 24 hrs: +46-31-721 50 00 Tel: +1-985-892-9833
Fax: +1-995-892-9837
Gdynia Office THAILAND 24 hrs: +1-985-892-9833
Tel: +48-58-785 5110 New York Office
Fax: +48-58-785 5111 Bangkok Office Tel: +1-914-305-9091
24 hrs: +48-602-725 088 Tel: +660-2-726 9516 Fax: +1-914-305-9091
Fax: +660-2-726 9514 24 hrs: +1-914-305-9090
QATAR Norfolk Office
UNITED ARAB EMIRATES Tel: +1-757-558 4580
Doha Office Fax: +1-757-558 4581
Tel: +974-4460 7310 Abu Dhabi Office 24 hrs: +1-757-558-4580
Fax: +974-4460 7314 Tel: +971-2-5541 690 Slidell Office
24 hrs: +974-5507 1093 Fax: +971-2 5541 601 Tel: +1-985-641-3853
24 hrs: +971-50-4510 715 Fax: +1-985-641-3856
RUSSIA Dubai Office 24 hrs: +1-985-641-3853
Tel: +971-4-3213 933
St. Petersburg Office Fax: +971-4-3413 110
Tel: +7-812-493 4284 24 hrs: +971-50-651 0371
Fax: +7-812-493 4285
24 hrs: +7-812-938 0498
Vladivostok Office
Tel: +7-4232-24 34 63
Fax: +7-4232-24 34 62
MacGregor Cranes Address Telephone Telefax

Cargotec Sweden AB SE-891 85 RNSKLDSVIK (+46) 660-29 40 00 (+46) 660-139 77
www.macgregor-group.com/cranes Sweden
2 (2)
SERVICE 6.005.7 E rev.: - 2003-02-12
Introduction
Before proceeding to trouble-shooting, the crane ope-

rator and the service staff should familiarize
themselves with the construction and functions of the
crane. It is a bit late in the day to learn how to operate
the crane when it has already broken down.
Begin by learning the hydraulic and electric symbols

used in the circuit diagrams to facilitate tracing the
probable fault in the circuit diagrams, Fig. 1 and 2,
checking the findings afterwards in the crane proper.
Trouble-shooting may thus be divided into a theoreti-

cal and a practical part, each subdivided into hydrau-
lic, electric, and mechanical trouble-shooting. The
hydraulic and electric operations presuppose know-
ledge of the locations of various points of measure-
ment and checking.
Take care always to have correct circuit diagrams Fig. 1.

available on board. If a diagram has gone astray, a
new one can be had from MacGREGOR Cranes. Pro-
per measuring instruments must always be available, Hydraulic circuit diagram
e.g. pressure gauges and voltmeters.
The trouble-shooting method described here is only

intended as a general guide. Methods and practices
may vary, but the purpose is always the same: to
find the fault quickly and methodically in order to put
it right.
Fig. 2.
When a crane function ceases to operate properly, it

generally does so in actual operation. This means
that the crane operator will often be able to give Electric circuit diagram
valuable suggestions, e.g.:
Electric circuit diagram
- Did the crane function fail without warning?

- Was the operating speed first reduced, or did Electric circuit diagram
the movement run irregularly?
- What manoeuvre immediately preceded the
failure?
Fig. 3.
1 (2)
SERVICE 6.005.7 E rev.: - 2003-02-12
As a first check always try to operate the crane and Analysis of information collected
at the same time check the status of the trouble- By methodical trouble-shooting, it is often possible
shooting panel in the CT2 cabinet, according to error to find, at an early stage, the defect producing the
list and signal overview list, (see instruction under faulty operation, thereby avoiding unnecessary waste
section 6.3). of time.
Also measure the feed pressure at gauge outlets 1 and

16. Pressure setting levels can be found in the pressure All important pressure adjusting devices are sealed.
setting list on the hydraulic circuit diagram. Breaking a seal voids the guarantee unless done with
the explicit consent of MacGREGOR Cranes.
When consulting MacGREGOR Cranes for service
or advice, always give the following information at
once:
1. Is the fault electrical, electronic, hydraulic, or

mechanical in nature?
2. In which function does the fault appear:
- Hoisting circuit
- Luffing circuit
- Slewing circuit
3. Is the trouble limited to:
- Raising or lowering of the load
- Raising or lowering of the jib
- Slewing right or left
4. Special observations:
- Is the hoisting, luffing, or slewing capacity restricted?
- Do disturbances occur only at certain speeds?
- In the event of abnormal noise:
- To which of the main functions does the noise
pertain?
- Is the frequency of the noise high or low?
- Try to describe the noise (hissing, blowing,
humming, rasping etc.)
5. What is the status of the trouble-shooting panel in
CT2 cabinet?
6. Have pressures been measured?
- Feed circuit pressure
- Control circuit pressure
- Hoisting circuit high pressure
- Luffing circuit high pressure
- Slewing circuit high pressure.
2 (2)
SERVICE 6.100 E rev.: b 1998-10-22
Measures Before Starting, During and After Completed

Service/Maintenance Work
WARNING !
When it is necessary to search for/or correct faults
in the crane's electrical, hydraulic or mechanical
systems with the crane powered up, only author-
ized personnel may carry out such work.
The following measures must be taken before any

service or maintenance work is started.
1. The jib must be secured preferably in the park-

ing support, (see separate instruction).
2. All lifting equipment must be parked/secured.
3. All power supplies to the crane must be cut.
A. Cut the main power supply to the crane and

all separate supplies such as heating, light-
ing etc., with the power switch(es) in the
ships engine room.
B. Warning signs must be hung on the switches

involved.
4. Make sure that the crane is completely without

power. If necessary, lock switches, take out fuses
etc. so nobody by mistake can start the crane.
5. When special work has to be done see separate

instruction or contact our service department.
6. If some special arrangements are done for test-

ing during the service, these arrangements have
to be removed after completed service.
7. Function test safety items i.e. limits, brakes etc.

after completed work.
8. Protections i.e. covers, rails etc. to be reinstalled

after completed work.
1 (2)
SERVICE 6.100 E rev.: b 1998-10-22
2 (2)
SERVICE 6.106.4 E rev.: - 2003-02-03
Trouble-Shooting Chart, Overheating
Fault Probable cause Remedy
A. Overheating in hydraulic sys- Oil cooler fan motor not working. Check connections, contactor,
tem. effect repairs as required.
Oil cooler flanges loaded with dirt. Dismantle and clean cooler.
Pressure control valves incorrect-

Correct settings.
ly set.
Trace leaks and replace defecti-

Internal leakage. ve seals, packings, and other
parts.
B. Overheating caused by pump,

Internal leakage because of wear. Contact MacGREGOR Cranes.
valving, or hydraulic motor.
N.B.
When the hydraulic system is overheated thermostat BT2 (+85oC) opens
and crane stops.
To cool the system press the "Start" button to start main electric motor in
idling while the control system is switched off. The control system will then
start automatically when thermostat BT2 closes.
1 (1)
SERVICE 6.117 E rev.: b 1999-12-21
Trouble Shooting, Pumps
Pumps, general
Fault Probable cause Remedy
A. Pump not supplying any fluid. Servo error. Contact MacGREGOR Cranes
Worn or cracked parts in the Measure leakage, contact

pump. MacGREGOR Cranes
B. Excessive wear of the pump. Hydraulic fluid contains abra- Check filters. Change cartridge,
sive particles. if necessary. Analyze sample
of the fluid.
Check pressure switch 1381 and

Low feed pressure.
2481.
C. Fracture of parts in the pump. Pressure shocks. Check valve functions and valve
settings.
Check pressure switch 1381

Low feed pressure. and 2481.
More detailed information regarding the pumps will be found in the

instruction manual.
1 (2)
SERVICE 6.117 E rev.: b 1999-12-21
2 (2)
SERVICE 6.120.18 E rev.: a 2011-02-16
Slewing Gearset
General
The slewing gearset comprises the following com- The brake housing is mounted on top of the gearcase,
ponents: with long assembly screws through the motor adapter
- Motor housing and both parts of the brake housing.
- Brake
- Gearbox The sleeve disc carrier, with the internal discs, is fixed
on the driven shaft with a shaft key or by splines.
The disc assemblies are pressed together by a set

Motor
of pressure springs and the brake is disengaged by
hydraulic power.
Brake
Maintenance
The brake is self-adjusting.
Trouble-shooting
a. Braking torque insufficient
Test of brake torque may be performed according to

Gearbox following:
- Drive hydraulic motors against closed brakes.
Brakes shall be able to withstand motor torque
without slipping.
Note! Test procedure shall be performed only for a

short period, a few seconds.
Fig. 1. Slewing gearset. - Inspect brake discs and replace if excessively worn.
Motor - If discs are coloured dark yellow to blue, the discs
See separate instruction. have been overheated. Replace discs and springs.
- Inspect sealings for wear. If sealings are defect
Multiple-disc brake replace complete pressure unit.
b. Brake heats
Technical description Check the hydraulic pressure to make sure that it is
The brake comprises the following major components, sufficient in order to disengage the brake completely.
see Fig. 2: See hydraulic drawing, section 9.4, setting for control
- Brake piston pressure gauge outlet 2.
- Pressure unit
- Disc carrier
- Internal discs
- External discs
- Sealings
- Pressure springs
1 (4)
SERVICE 6.120.18 E rev.: a 2011-02-16
Motor side
Pressure springs Brake piston Pressure unit
Pressure oil
connection Sealing
Sealing
Total thick-
ness Leakage oil
of discs
Disc carrier
Internal discs
External discs
Gear side
Fig. 2. Disc brake.
Attention: Please select the required number of pressure springs from parts list "gear".
Gearbox
2
The gearbox is a three planetary stage type.
3
1
Maintenance
4
Lubrication
The slewing gear is splash lubricated. The output shaft 5
roller bearing is for-life lubricated with ball bearing
grease.
Oil level check

Check oil level. If necessary fill up to the middle of
the min/max marking of the oil dipstick. 6
Inspect oil level when the gear is at rest with the brake
engaged.
Caution!
C-00116
As oil expands during operation, this expansion can

falsify the oil level. Examine the oil level only when the
slewing gear is cold!
1. Oil filling plug
2. Ventilation filter
3. Brake connection
4. Position "a"
5. Oil dipstick/Air venti-
lation valve
6. Oil outlet (x4)
Fig. 3. Slewing gearset.
2 (4)
SERVICE 6.120.18 E rev.: a 2011-02-16
Oil changes for slewing gears the actual amount of foreign matter present.
Checking and setting slewing bearing
- For oil change open the oil filling plug. backlash
- Remove the oil dipstick/ air ventilation valve, at
position "a", for better ventilation. See Fig. 3. An oversize backlash between the pinion and the
- Remove the oil drain plug to allow the oil to drain. slewing bearing will cause irregularities in the slewing
- Clean the oil plug thoroughly. If necessary, replace movement of the crane. Read this instruction carefully
the seal ring. prior to checking or resetting!
- Install the oil drain plug.
- Top up with oil up to the middle of the min/max Checking backlash
marking of the oil dipstick. The backlash should be checked by a dial gauge or a
- Install the oil dipstick/ air ventilation valve. feeler. When slewing the crane, the backlash may vary
At low ambient temperatures, flush out the gear case from one position to another due to some slight play
with a quantity of fresh oil to remove abraded matter of the slewing bearing. It is therefore recommended
and contamination particles. to check the backlash at four positions of the slew-
ing bearing.
Proceed as follows:
Oil inspection
- Check the backlash at one spot.
Sampling oil - Put the dial gauge on the tooth of the pinion. By
Withdraw a sample of gearcase oil for inspection from manual turning at the input, the pinion can be
the oil drained off at intervals as described in the moved in both directions up to contact with the
Maintenance Chart. To obtain a representative sample, teeth. Now, the tooth flank clearance can be exactly
drain the gearcase during operation and with the oil measured on the dial gauge.
at operating temperature. - Proceed to check the backlash at four 90-degree
position in the bearing.
- Compare the four backlash values.
Oil discoloration
A darkish or black colour of the used oil suggests that
The backlash shall be set at the position of the slewing
temperatures in excess of 100o C did occur in opera-
bearing with the lowest backlash value.
tion, causing accelerated aging of the oil and impaired
lubricating properties. In this case the oil should be
Contact MacGregor Cranes for advice.
changed at shorter intervals.
Setting backlash
If the oil sample displays a cloudy aspect, it may be The backlash may be set by turning the entire gearset
that water has managed to seep into the oil. The oil one or more screw hole divisions.
must then be changed a t o n c e, and the gearcase
flushed out very thoroughly several times with fresh oil. Proceed as follows:
- Slew the crane into the position with the
lowest backlash value.
Overall assessment
- Remove all screws holding the gearset to crane
The maximum permissible amount of foreign matter
house floor.
carried by the oil is some 0.15 per cent of the total
- Release the disc brake hydraulically by means of
mass of the oil in the gearcase. These impurities must
a manual pump.
be, exclusively, very fine abraded matter (max. 25 ). If
- Turn the entire gearset one or more screw
the contamination keeps within these limits, continued
hole to achieve the desired backlash.
operation of the gearset is permitted after the oil has
To turn the gearset, remove the hydraulic motor
been changed.
and turn the spline sleeve on top of the gear.
If larger particles (above 25 ) or flake off material is
- Install the screws holding the gearset to the crane
found, the gearset must be repaired, irrespective of
house floor.
3 (4)
SERVICE 6.120.18 E rev.: a 2011-02-16
4 (4)
SERVICE 6.120.64 E rev.: o 2011-04-27
Hydraulic Motors
Hoisting, Luffing, and Slewing Circuits
Hydraulic motor 188 1221-801 Oil filling

Drain connection
Before the first operation the hydraulic motor housing

should be pre-filled with hydraulic oil.
Displacement: 106.7 cm3/rev.

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

Drain connection

Displacement Vg: 160-79 cm3/rev.

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

Drain connection


Oil filling
Drain connection
1 (8)
SERVICE 6.120.64 E rev.: o 2011-04-27

Drain connection


Oil filling
Drain connection

Drain connection


Oil filling
Drain connection

Drain connection


Oil filling
Drain connection
2 (8)
SERVICE 6.120.64 E rev.: o 2011-04-27
Hydraulic motor 188 1774-801 Oil filling / Drain

connection
Displacement: 40 cm3/rev.
T1 alternatively T2 can be used as oil filling and drain

connections.
Oil filling / Drain

connection
Hydraulic motor 189 2418-801

Oil filling
Before the first operation the hydraulic motor housing Drain connection

Oil filling
Drain connection
Oil filling
Drain connection

Displacement Vg: 160.4 cm3/rev.

Oil filling
Drain connection
3 (8)
SERVICE 6.120.64 E rev.: o 2011-04-27

Oil filling

Oil filling
Drain connection

Drain connection



Oil filling

Oil filling
Drain connection
4 (8)
SERVICE 6.120.64 E rev.: o 2011-04-27

Drain connection


Oil filling
Drain connection

Drain connection
Displacement Vg: 160-72.5 cm3/rev.

Oil filling
Drain connection

Oil filling
Drain connection
Displacement Vg: 160-72.5 cm3/rev.

Oil filling
Drain connection
5 (8)
SERVICE 6.120.64 E rev.: o 2011-04-27

Drain connection
Displacement: 200 cm3/rev.

Oil filling
Drain connection

Drain connection


Oil filling
Drain connection

Drain connection

Oil filling
Drain connection
6 (8)
SERVICE 6.120.64 E rev.: o 2011-04-27

Drain connection


Oil filling
Drain connection

Drain connection

Displacement: 200-100 cm3/rev.

Oil filling
Drain connection

Drain connection


Oil filling
Drain connection
7 (8)
SERVICE 6.120.64 E rev.: o 2011-04-27

Drain connection


Oil filling
Drain connection
8 (8)
SERVICE 6.120.108 E rev.: b 2009-11-06
Winches, Hoisting/Luffing
Winch and gearbox
4
General 1
The luffing winch (upper) is driven by one high speed
hydraulic motor with fixed displacement, via a
2
planetary gearbox.
The hoisting winch (lower) is driven by one high
speed hydraulic motor with variable displacement,
via a planetary gearbox.
The planetary gearbox has splash lubrication and is
filled with gear oil.
A brake is integrated in each winch gear set. When
the winch is running, the brake is automatically 3
released by hydraulic pressure.
Fig. 1. Luffing winch.
Maintenance 1. Oil filler inlet / Oil dipstick
2. Oil filler inlet for wet running motor shaft (for
- Change gearbox oil. assembly)
- Grease journal bearing. 3. Oil drain
- Check oil level. 4. Journal bearing, grease nippel
Maintenance interval and number of grease nipples:

See "Lubricating Chart", section 5. 1
Type of oil and grease: 8
2
See "Lubricants for Deck Machinery", section 5.
Oil volume: 3
See "Technical data", section 2.
Oil level check, luffing winch (Fig. 1)

- Remove the oil dipstick, item 1.
- Clean the dipstick.
- Put back the dipstick.
- Remove the dipstick. 4
- Note the oil level. 7 5
6
Oil level check, hoisting winch (Fig. 2)

Fig. 2. Hoisting winch.
- Remove the pressure relief valve, item 2.
- Remove the oil dipstick, item 1. 1. Oil filler inlet / Oil dipstick
- Clean the dipstick. 2. Pressure relief valve (Oil filler inlet for wet running
motor shaft, for assembly)
- Put back the dipstick.
3. Connection for oil cooler feeding
- Remove the dipstick. 4. Thermo switch, high temperature
- Note the oil level. 5. Thermo switch, low temperature
6. Oil drain
Note! 7. Connection for oil cooler draining
Oil level can only be inspected with non-running gear. 8. Journal bearing, grease nipple
1 (4)
SERVICE 6.120.108 E rev.: b 2009-11-06
Oil change Foreign solid matter

Whenever practicable, drain oil while still hot.At low As a first simple test, drop some of the used oil onto
ambient temperature, flush out the gear case with a a absorbing paper. Big particles, if present, will then
quantity of fresh pre-heated oil to remove particles show up on inspection, preferably through a
and sediment and continue with items below. magnifying glass.
- Open the pressure relief valve. (Hoisting winch

Overall assessment
only.)
The maximum permissible amount of foreign matter
- Open the oil drain.
carried by the oil is some 0.15 per cent of the total
mass of the oil in the gear case. These impurities
Sampling oil must be, exclusively, very fine abraded matter (max
Withdraw a sample of gearbox oil for inspection at 25 m). If the contamination keeps within these
intervals as described in the "Maintenance Chart". limits, continued operation of the gear set is permitted
after the oil has been changed.
Procedure for oil sampling: If bigger particles (above 25 m) or flake of material
- The oil temperature in the gearbox should be more from the gear teeth is found, the gear set must be
than +40 0C. dismantled for inspection/repair.
- Special oil sampling bottles should be used that
can be obtained from oil companies.
- The oil sample should be taken from the oil drain on
the winch, see Fig. 1 and 2. Hydraulic-Release Multiple-Disc Brake
- Drain 1-2 litres of oil into a bucket. This oil should Technical description
be disposed of.
The brake comprises the following major components.
- Fill the oil sample bottle.
See also Fig. 3.
- Send the oil sample to an oil company for analysis.
The oil company will be able to recommend if the - Brake piston
oil can be further used. - Brake cylinder
Feedback on the oil analysis can also be obtained - Disc carrier
from MacGregor Cranes. - Inner discs
- Outer discs
- Hydraulic part for disc brake
Oil discoloration
- Pressure spring
A darkish or black colour of the used oil suggests
that temperatures in excess of 100 C did occur in The brake housing is mounted on top of the gearbox,
operation, causing accelerated aging of the oil and with long assembly screws through the motor adap-
impaired lubricating properties. In this case the oil ter housing and both parts of the brake housing.
should be changed at shorter intervals. The disc assemblies are pressed together by a set
If the oil sample displays a cloudy aspect, it may be of thrust springs and the brake is disengaged by
that water has managed to seep into the oil. The oil hydraulic power.
must then be changed at once, and the gear case
flushed out very thoroughly several times with fresh Maintenance
oil.The gearbox should preferably be dismantled for
The brake is self-adjusting.
inspection.
2 (4)
SERVICE 6.120.108 E rev.: b 2009-11-06
Trouble-shooting
Braking torque insufficient
Test of brakes may be performed as follows:

- Drive the winch hydraulic motors against closed
brakes. The motors shall not be able to rotate.
Note! Test procedure shall be performed only for a
short period; a few seconds.
- Inspect brake discs and replace if excessively
worn. If brake discs are coloured dark yellow to
blue, the discs have been overheated. Replace
discs and springs.
- Inspect brake for leakage. If leakage appears in
the oil pressure unit, the complete unit must be
replaced.
Brake heats
Check the hydraulic pressure to make sure that it is
sufficient in order to disengage the brake completely.
Hydraulic part Motor side

for disc brake Pressure spring
Connect
pressure oil
Leakage oil
Outer disc Arrangement of Inner discs Disc carrier

the brake discs
Gear side
Fig. 3. Disc brake.
3 (4)
SERVICE 6.120.108 E rev.: b 2009-11-06
Hoisting winch, additional equipment

(optional)
Adjustment of pressure roller

After the replacement of the wire the pressure roller
must be re-adjusted.
- Tighten the adjusting nut (2) carefully until the

pressure roller (1) touches the hoisting wire on the
drum.
- Tighten the adjusting nut (2) 12 turns to get the
correct spring force.
- Secure with the locking nut (3).
Fig. 4. Hoisting winch with pressure roller.
1. Pressure roller
2. Adjusting nut
3. Locking nut
4 (4)
SERVICE 6.121.3 E rev.: a 1999-03-16
Trouble-Shooting Chart, Hydraulic High Speed Motors
Fault Probable cause Action
The motor does not run. Mechanical stop in the drive. Check system pressure. If the pres-
sure has risen to the relief valve set-
ting, remove the load from the drive.
The motor does not deliver enough Investigate the pressure level in the
torque because the pressure differ- system and correct the setting of the
ence across the motor is not great pressure limiting valve if necessary.
enough for the load.
Insufficient or no oil being supplied Check the hydraulic system. Check

to motor. the external leakage of the motor.
(The T connection)
Motor rotates in wrong direction. Oil supply connections to motor in- Connect the oil supply correctly.
correctly connected.
Motor runs jerkily. Pressure or flow fluctuations in the Find the cause in the system or in
hydraulic system. the driven unit.
Noise in the motor. The motor is being operated with the Adjust the charge pressure to the
charge pressure too low. correct level. See Hydraulic Circuit
- gauge connection 1.
Internal faults in the motor.

Investigate the drain oil.
External oil leakage on the motor. The radial lip seal is worn. Replace the radial lip seal.
1 (2)
SERVICE 6.121.3 E rev.: a 1999-03-16
Insufficient braking torque. The brake discs are worn out. Dismantle the brake and replace
the worn discs.
The brake does not open. Insufficient brake opening pres- See Hydraulic Circuit - gauge con-
sure. nection 2.
Seals or piston damage. Replace seals. Replace the piston.

IMPORTANT!
The springs in the brake cylinder
are tensioned.
Variable hydraulic motors
Motor only works at one speed. Pilot pressure low. Suitable pilot pressure. See Hy-
draulic Circuit - gauge connection
2.
The valve 1221 has stuck due to Inspect valve piston and remove
impurities in the oil. impurities.
No electric supply to the valve Check the electric system.

1221.
2 (2)
SERVICE 6.127.50 E rev.: b 2010-10-25
High Pressure Pumps
General
All pumps are of the straight axial piston type with variable A complete hydraulic circuit diagram relating
displacement controlled by a servo valve mounted on the specifically to your crane will be found in the
pump housing. instruction manual, section Spare Parts, Group
9.4.
The pumps have one set screw for the adjustment of
plussing. Plussing of the pumps is done to compensate Minor variations in the hydraulic system may
for internal leakage in pumps and motors to prevent load occur in individual cranes of the same type.
drops. See Fig. 1.
B-0020
Set screw for
adjustment of "plussing"
"Plussing" screw
Connection 3.1 (5.1)
Fig. 1. Hoisting and luffing pump.
1 (8)
SERVICE 6.127.50 E rev.: b 2010-10-25
Adjustment of the hoisting and luffing

pump
Set screw for

adjustment of
plussing
Servo valve
*)
Locking nut
*) Note! The allowed adjustment range of the set screw is

limited according to the measure X, specified in Table 1.
Table 1. An X-measure outside this interval is not allowed. The
difference in X-measure from zero to maximum plussing
X (mm) (0.75 mm) corresponds to one complete turn clockwise of
the set screw.
14.75 Max. dimension (position at zero plussing)
14.0 Min. dimension (position at max. plussing) After adjustment tighten the locking nut with 25 Nm.
Fig. 2. Hoisting and luffing pump.
2 (8)
SERVICE 6.127.50 E rev.: b 2010-10-25
Function checking / Adjusting of

plussing
Hoisting winch
- No load in hook.
- Stop the crane.
- Install a pressure gauge 0-400 bar at connection 3.1
on pump 1111. See Fig. 3.
- Lock the brake in closed position by closing ball
valve 1663.
- Start the crane. The oil temperature should be 40C.
- Operate directional valve 1221 manually with a
small screwdriver or similar during checking and
adjustment, see Fig. 3.
- Measure the plussing pressure on the pressure
Pump 1111
gauge at connection 3.1 refer to the hydraulic circuit
diagram. Connection 3.1
- If the plussing pressure is incorrect refer to the

hydraulic circuit diagram an adjustment must be
made.
- Stop the crane.

- Loosen the locking nut with a hook wrench.
- Start the crane.
- Operate the directional valve 1221 manually with a
adjustment, see Fig. 3.
Directional valve 1221
Operate Ball valve 1663

C-00013
Fig. 3. Valves on hoisting winch.
3 (8)
SERVICE 6.127.50 E rev.: b 2010-10-25
- Adjust the plussing pressure on the hoisting pump by

turning the set screw. Turn the set screw clockwise or
counterclockwise to increase or decrease the plus-
sing pressure. See *) in note (page 2) and in Fig. 2.
Pressure should be set refer to the hydraulic circuit
diagram in section Spare Parts, Group 9.4.
- Control the pressure at connection 3.1.
- After adjustment tighten the locking nut. See *) in
note (page 2) and in Fig. 2. After tightening of the
locking nut, make sure the hydraulic pressure has
not been changed.
- If there is more than one hoisting pump, the upper
pump should be adjusted.
- Stop the crane.
- Open ball valve 1663, see Fig. 3.
4 (8)
SERVICE 6.127.50 E rev.: b 2010-10-25
Luffing winch
- No load in the hook. - Adjust the plussing pressure on the luffing pump by
- Park the crane or move the hook block close to the turning the set screw. Turn the set screw clockwise
jib top. or counter clockwise to increase or decrease the
- Stop the crane. plussing pressure. See *) in note (page 1) and in Fig.
- Install a pressure gauge 0-400 bar at connection 5.1 1. Pressure should be set according to the hydraulic
on pump 2111. circuit diagram in section 9.4.
- Lock the brake in closed position by closing ball - Control the hydraulic pressure at connection 5.1.
valve 2661, see Fig. 4. - After adjustment, tighten the locking nut. See *) in
- Start the crane. The oil temperature should be 40C. note (page 1) and in Fig. 1. After tightening of the
- Operate the directional valve 2221 manually with a locking nut, make sure the hydraulic pressure has
small screwdriver or similar during checking and not been changed.
adjustment. See Fig. 4. - If there is more than one luffing pump, the upper
- Measure the plussing pressure at connection 5.1 pump should be adjusted.
refer to the hydraulic circuit diagram. See Fig. 4. - Stop the crane.
- If the plussing pressure is incorrect refer to the - Open ball valve 2661, see Fig. 4.
hydraulic circuit diagram an adjustment must be
made.
- Stop the crane.

- Loosen the locking nut with a hook wrench.
- Start the crane.
- Operate the directional valve 2221 manually with a
adjustment. See Fig. 4.
"Plussing" screw
Pump 2111 Connection 5.1
Operate
Ball valve 2661

C-00012
Fig. 4. Valves on luffing winch.
5 (8)
SERVICE 6.127.50 E rev.: b 2010-10-25
Slewing machinery
Zero setting of slewing pump Zero setting

- No load in the hook. - If the crane does move, right or left, an adjustment
- Start the crane. The oil temperature should be 40C. must be made using the set screw for zero setting,
- Operate the directional valve 3221 manually with see Fig. 6.
a small screwdriver or similar during checking and - Loosen the locking nut with a hook wrench.
adjustment. See Fig. 7. - Operate the directional valve 3221 manually with a
- Make sure that there is no slewing movement, small screwdriver or similar during checking and
otherwise the zero setting must be adjusted. adjustment. See Fig. 7.
- Adjust the zero setting on the slewing pump by
turning the set screw. Turn the set screw clockwise
or counterclockwise. See *) in note (page 7) and in
Fig. 5.
Note! Do not turn the set screw more than 1/2 turn.
- After adjustment tighten the locking nut. After
tightening of the locking nut make sure that the
zero setting has not been changed.
B-0020
Set screw for

adjustment of zero setting
Fig. 5. Slewing pump.
6 (8)
SERVICE 6.127.50 E rev.: b 2010-10-25
Set screw for

adjustment of
zero setting
Servo valve
XX*)
Locking nut
*) Note! The allowed adjustment range of the set screw

is limited according to the measure XX, specified in
Table 2. An XX-measure outside this interval is not
Table 2. allowed. The difference in XX-measure from min. to max.
dimension (0.70 mm) corresponds to one complete turn
XX (mm)
clockwise of the set screw.
14.4 Min. dimension
15.1 Max. dimension After adjustment tighten the locking nut with 25 Nm.
Fig. 6. Slewing pump.
7 (8)
SERVICE 6.127.50 E rev.: b 2010-10-25
Slewing machinery
Hydraulic oil tank

Ball valve 3661
Operate
Fig. 7. Valves for slewing.
8 (8)
SERVICE 6.132.18 E rev.: a 2010-10-07
Replacement of Vane Pump

Crane Type GLB
Introduction
The vane pump is attached to the pump unit. To Note! Ball valve 4335 must be open before the crane
replace the vane pump follow the sequence below. is started otherwise the vane pump will be damaged.
- Close ball valve 4335. To limit the oil leakage.

- Remove the suction hose.
- Replace the vane pump.
- Open ball valve 4335.
Pump unit
Suction hose
Ball valve 4335
Oil tank
Vane pump 4113
Vane pump 4113
Ball valve 4335
Fig. 1. Pump unit.
1 (2)
SERVICE 6.132.18 E rev.: a 2010-10-07
2 (2)
SERVICE 6.142.5 E rev.: a 2002-01-09
Recommendation for Inspection and

Replacement of Hydraulic Hoses
Hydraulic hoses and couplings assembled

inside crane house
Hydraulic hoses assembled inside crane house If the rubber in the hose is damaged so that the steel
should be inspected for damage every five (5) years, core can be exposed to corrosion the hose should be
see Maintenance Chart in section 5. replaced.
If the rubber in the hose is damaged so that the steel The hose couplings should also be inspected for
core can be exposed to corrosion the hose should leakage and damage of the corrosion protective Den-
be replaced. syl tape. If the corrosion protection is damaged so
The hose couplings should also be inspected for that the coupling can be exposed to corrosion the
damage and leakage. If the coupling is damaged or corrosion protection should be removed and the
severely corroded the hose should be changed. coupling inspected for damage and severe corrosion.
If the coupling is leaking the coupling should be tighte- If the coupling is damaged or severely corroded the
ned at first. If tightening does not help, the hose and hose should be changed.
the mating couplings should be changed, see Fig. 1. If the coupling is leaking the coupling should be tighte-
If the coupling is of flange type the O-ring and screws ned at first. If tightening does not help, the hose and
should be changed, see Fig. 2. the mating couplings should be changed, see Fig. 1.
If the coupling is of flange type the O-ring and screws
Hydraulic hoses and couplings should be changed, see Fig. 2.
assembled on outside of crane house
Replacement of hydraulic hoses
Hydraulic hoses assembled on outside of crane house
should be inspected for damage every two (2) years, All hydraulic hoses assembled inside crane house
see Maintenance Chart in section 5. should be replaced after ten (10) years due to safety
reasons.
All hydraulic hoses assembled on outside of crane
house should be replaced after five (5) years due to
safety reasons.
Hose coupling
Mating coupling O-ring
Screw
Fig. 1. Hose coupling with O-ring. Fig. 2. Flange coupling with O-ring.
1 (2)
SERVICE 6.142.5 E rev.: a 2002-01-09
2 (2)
SERVICE 6.189 E rev.: f 2007-04-11
Hydraulic Piston Accumulators
Function Charging hydraulic accumulators with nitrogen (N2)

A hydraulic accumulator functions as a source of pres- All crane motors must be immobilized.
surized fluid. Conversely, when the pressure falls off,
the accumulator supplies oil to the hydraulic system. 1. Dismount valve guard and unscrew the
protective cap from gas valve.
Note! - Do not bleed hydraulic accumulators! 2. New design, see Fig. 1. Connect the three-way
valve to the gas valve of the accumulator. The
bleed valve should be tightly closed.
Charging equipment
2a. Old design, see Fig. 2. Connect the three-way
To charge hydraulic accumulators, art. nos. see
valve to the gas valve of the accumulator. The
below, MacGREGOR (SWE) AB supply a charging
filling screw of the three-way valve shall be
valve and associated equipment, Fig. 2, comprising:
backed out completely, and the bleed valve
- a three-way valve
tightly closed.
- a 0-25 bar pressure gauge
3. Connect the charging valve, see Fig. 3 to the
- a 0-60 bar pressure gauge
reducing valve at the nitrogen cylinder.
- a 1-metre hose with a W24 connector for nitro-
4. Back out the adjusting screw of the reducing
gen cylinder
valve on the nitrogen cylinder until the valve
- two reduction connectors, W24/32M and W24/14D.
spring is unloaded.
5. Open the nitrogen cylinder valve.
Charging pressure for 388 0362-801: 15 1 bar at 20C.
6. Adjust the reducing valve to the correct charg-
ing pressure.
New design
Valve guard
Protective
Gas valve cap
Protective cap Gas valve Open/close
Valve guard hexagonal nut
Open/close
hexagonal nut
Fig. 1. New design. Piston accumulators.
1 (4)
SERVICE 6.189 E rev.: f 2007-04-11
7. New design, see Fig. 1. Open the hexagonal nut 10. Close the nitrogen cylinder valve.
on the gas valve counter-clockwise to stop, by 11. Open the bleed screw of the three-way valve to
using a 19 mm fork wrench. discharge the pressure in the filling hose.
7a. Old design, see Fig. 2. Screw in the filling screw 12. Adjust the reducing valve to zero.
of the three-way valve but not so tightly that the 13. Unscrew the charging equipment from the nitro-
gas valve of the accumulator is damaged. gen cylinder and from the accumulator.
8. Fill nitrogen. 14. Check tigthness of accumulator gas valve, us-
9. New design, see Fig. 1. Check the nitrogen ing soap water.
pressure when the temperature and the pressure Note! - The protective cap shall be fitted with an
of the gas become stable. When the correct O-ring which must fit correctly into its groove.
charging pressure has been obtained, close the 15. Screw on protective cap of the gas valve.
gas valve by turning the hexagonal nut clockwise 16. After charging the accumulator, fit a lable carry-
by use of the 19 mm fork wrench. ing the charging date and signed by the operator.
9a. Old design, see Fig. 2. Check the nitrogen
pressure when the temperature and the pressure Note! For charging, it is not necessary to install a
of the gas have become stable. When the correct reducing valve on the nitrogen cylinder.
charging pressure has been obtained, again
back out the filling screw of the three-way valve.
Old design
Valve guard Valve guard
Protective cap Gas valve Gas valve Protective

cap
Fig. 2. Old design. Piston accumulators.
2 (4)
SERVICE 6.189 E rev.: f 2007-04-11
Filling screw, to be
used for old design
Pressure gauge
Bleed valve connection
Connector for hose

Connector for accumulator coupling
gas valve
Hose
W24 connector for

nitrogen cylinder
Fig. 3. Charging equipment.
3 (4)
SERVICE 6.189 E rev.: f 2007-04-11
4 (4)
SERVICE 6.209.15 E rev.: - 2004-04-28
Inspection of Climb Protection, Jib and Crane House Top
- Check climb protection for wear and damage.

- Check distance between outer edge of wire she-
ave and climb protection.
Distance between outer edge of wire sheave and
climb protection should not exceed 1/3 of wire rope
diameter, max. 10 mm and 8 mm respectively, see
Fig. 1 and Fig. 2.
Max. 10 mm Max. 8 mm
Fig. 1. Jib top, example. Fig. 2. Crane house top, example.
1 (1)
SERVICE 6.214 E rev.: i 2007-03-02
Tightening Torques
Studs/Screws and Bolts
Introduction
This instruction applies to studs, screws and bolts Note!

generally, if separate recommendations are not gi- Threads that have been rolled after hardening have a
ven. Apply Molykote R 1000 lubrication on the threads lower surface notch indicating that the permitted ten-
and under the bolt head. For stainless elements and sion amplitude at fatigue can be about doubled
hydraulic pipe couplings apply Gleitmo paste. compared to threads that have been rolled before
hardening. If the screw has been loaded beyond the
yield limit, this feature will disappear.
Slewing bearing, studs/screws
See drawings "Slewing bearing mounting" and
"Slewing bearing yard mounting" in Section 9.3.
Phosphatized bolts greased with Molykote R 1000 Untreated bolts greased with Molykote R 1000
(Also valid for bolts greased with Loctite 243 or oil.) (Also valid for bolts greased with Loctite 243 or oil.)
Thread Tightening torque in Nm Thread Tightening torque in Nm

10 Nm 1 kpm 10 Nm 1 kpm
M UNC 8.8 10.9 12.9 M UNC 8.8 10.9 12.9
4 2.5 3.4 4.2 4 2.9 4.0 4.9

5 4.9 7.0 8.3 5 5.7 8.1 9.7
6 8.4 12.0 14.6 6 9.8 14.0 17.0
7 13.8 19.8 23.2 7 16.1 23.0 27.0
8 20.6 28.4 34.4 8 24.0 33.0 40.0
10 40.4 55.9 67.9 10 47.0 65.0 79.0
12 69.7 98 117 12 81.0 114 136
1/2" 80.8 114 136 1/2" 94.0 132 158
14 110 156 187 14 128 181 217
5/8" 159 224 269 5/8" 185 260 312
16 169 238 286 16 197 277 333
3/4" 280 393 471 3/4" 325 457 548
18 237 332 398 18 275 386 463
20 331 465 558 20 385 541 649
22 445 626 752 22 518 728 874
24 572 804 963 24 665 935 1120
1" 670 942 1131 1" 779 1095 1315
27 826 1161 1393 27 961 1350 1620
30 1127 1582 1901 30 1310 1840 2210
1 1/4" 1308 1840 2208 1 1/4" 1521 2140 2567
33 1522 2133 2563 33 1770 2480 2980
36 1961 2761 3311 36 2280 3210 3850
39 2520 3543 4248 39 2930 4120 4940
42 3130 4395 5280 42 3640 5110 6140
1 (4)
SERVICE 6.214 E rev.: i 2007-03-02
As a rule, always change screws with specified tight- Stainless bolts and hydraulic pipe couplings
ening torque on cranes in operation if the joint has to greased with Gleitmo paste
be opened for some reasons.
Thread Tightening torque in Nm
If any joint has been opened apply Intertuf after tight- d 10 Nm 1 kpm
ening the joint to avoid rust damage. Austenite (A)
50 70 80
6 3.3 7 9.3
8 7.8 17 22
SAE flange for high pressure hose couplings
10 15 33 44
Tightening torque in Nm 12 27 57 76
Flange Screw 10 Nm 1 kpm 14 43 91 121
6000 psi Class H 10.9 and 12.9 16 65 140 187
18 91 195 260
3/4" M10 54
20 127 273 364
1" M12 94
22 171 367 490
1 1/4" M14 150
24 220 472 629
1 1/2" M16 230
27 318 682 909
2" UNC 3/4 377
30 434 930 1240
33 585 1250 1670
36 755 1620 2160
39 969 2080 2770
2 (4)
SERVICE 6.214 E rev.: i 2007-03-02
Strength of screws and bolts
Strength class Min. ultimate strength Min. tensile strength Corresponding strength
N/mm2 (kp/mm2) N/mm2 (kp/mm2) class of nuts
4.6 400 (40) 240 (24) 4

5.8 500 (50) 400 (40) 5
6.6 600 (60) 360 (36) 6
8.8 800 (80) 640 (64) 8
10.9 1000 (100) 900 (90) 10
12.9 1200 (120) 1080 (108) 12
Examples of markings:
Hexagonal screw Allen screw
Strength class 4.6: Strength class 12.9:
BH 12 9 M
Strength class 8.8:
Hexagonal nut
Strength class 8:
Strength class 10.9:
M-thread UNC- and UNC- and

UNF-thread UNF-thread
Cold forged Forged
Strength class 10:
M-thread UNC- and UNF-thread

Forged
3 (4)
SERVICE 6.214 E rev.: i 2007-03-02
Tightening Torques
Hydraulic Couplings
The values below presume greasing of threads when

assembling.
Type of Thread Tightening Type of Thread Tiightening

coupling M and R torque in Nm coupling M and R torque in Nm
GE 10-LM M 14x1,5 ca 39 GE 10-SM M 16x1,5 ca 59

GE 10-LR R 1/4 ca 39 GE 10-SR R 3/8 ca 69
GE 12-LR R 3/8 ca 59 GE 12-SR R 3/8 ca 69
GE 15-LR R 1/2 ca 108 GE 14-SR R 1/2 ca 128
GE 18-LR R 1/2 ca 108 GE 16-SR R 1/2 ca 128
GE 22-LM M 26x1,5 ca 128 GE 20-SM M 27x2 ca 196
GE 22-LR R 3/4 ca 157 GE 20-SR R 3/4 ca 206
GE 28-LM M 33x2 ca 216 GE 25-SM M 33x2 ca 294
GE 28-LR R1 ca 265 GE 25-SR R1 ca 314
GE 35-LM R 42x2 ca 353 GE 30-SM M 42x2 ca 491
GE 35-LR R 1 1/4 ca 392 GE 30-SR R 1 1/4 ca 491
GE 42-LM M 48x2 ca 491
GE 42-LR R 1 1/2 ca 491 Table 2.
Example: GE 10 - LM
Table 1. Sealing
d = 10
Fitting
Sealing cone
Insert the sealing cone into the 24-degree coupling
fitting, firmly tighten the coupling by hand. Using a
wrench, tighten the coupling nut another 1/4 to 1/2
turn. The O-ring should preferably be oiled.
Hose Coupling Tables 1 and 2

Grease
O-ring sealed Sealing
4 (4)
SERVICE 6.215.21 E rev.: b 2007-06-08
Service Door (Opening and Closing)

Service and Lubrication of Door Hinges
Warning!
There is a risk of falling down when opening or
closing the service door. Always use a safety belt!
Note! Before opening the service door you should A. Procedure for opening
always check the condition of the door hinges. Also
make sure that the doors are secured before opening, 1. Put on safety belt.
see Fig. 1. 2. Loosen the two nuts (1) and the washer (2), see
Fig. 2.
3. Unhook the eye bolt (3).
4. Swing service door outward.
Note! Do not forget to secure yourself using safety
belt.
5. Release the locking rod (5) from its parking posi-
tion by loosening the chapel strop (6), see Fig. 3.
6. Remove the screw (7) from its bracket.
7. Swing the locking rod (5) and secure it by use of
the screw (7).
1
2
3
4
Fig. 1. Securing service door to top of crane. Fig. 2. Opening service door.
1 (2)
SERVICE 6.215.21 E rev.: b 2007-06-08
B. Procedure for closing
1. Put on safety belt.

2. Remove the screw (7), see Fig. 3.
3. Swing the locking rod (5) back to its parking position.
4. Secure the locking rod (5) by use of the chapel strop
(6).
5. Reinstall the screw (7).
6. Swing the door inward, see Fig. 3.
7. Hook on the eye bolt (3) on the bracket (4), see Fig.
2.
8. Retighten the two nuts (1) and the washer (2).
C. Procedure for lubrication of service

door hinges
5 7
The service door hinges should be lubricated every 5
6
six months. See also "Lubricating Chart" in section 5
of your Instruction Manual.
Note! To be able to properly lubricate the hinges the

service door must be open.
D. Inspection of door hinges Fig. 3. Locking rod.
At the same time as the service door is opened for

lubrication of the hinges, inspection of the hinges and
the surrounding areas should be done. If the findings
show that any areas are rusty or are otherwise in bad
condition a proper repair must be done.
Please contact MacGREGOR if you have any

questions.
2 (2)
SERVICE 6.216.83 E rev.: a 2003-03-11
Rope Reeving Diagram for Cranes Type GLB-2
Important! Important!
It is of utmost importance to grease the wire thimble The wire rope thimble must be safely secured by
according to instructions "Lubricating Chart" and bending the lock washers, see Fig. 2 on page 2.
"Lubricants for Deck Machinery".
Number of reeving parts: Note! Before rigging slacken the pressure roller on
Luffing: 6 parts the hoisting winch. See Fig. 4.
Hoisting: 6 parts
Fig. 1. Rope reeving and securing wire rope thimbles.
1 (3)
SERVICE 6.216.83 E rev.: a 2003-03-11
Luffing wire rope
Hoisting wire rope
Fig. 2. How to secure the lock washer for the wire Fig. 3. Rope reeving for Slack wire safety switch,
rope thimble. hoisting and luffing. Slack wire condition.
2 (3)
SERVICE 6.216.83 E rev.: a 2003-03-11
Adjustment of pressure roller on the

hoisting winch
After replacement of wire the pressure roller on the - Tighten adjusting nut 12 turns to get correct spring
hoisting winch must be re-adjusted. force. Adjustment shall be done at full drum
condition.
- Tighten adjusting nut carefully until the pressure - Secure with the locking nut.
roller touches the hoisting wire on the drum.
- Check that the play (approx. 2 mm) between wire
and pressure roller corresponds to Fig. 4. Adjust if
necessary by changing location (rotation) of frame
bearings, see Fig. 4.
Empty drum Full drum

Approx. 2 mm
Approx. 2 mm
Full drum
Empty drum
Pressure roller
Frame bearing Adjusting nut
Frame
Adjust play by rotating Frame bearing

the washer/bearing.
Locking nut
Fig. 4. Hoisting winch with pressure roller.
3 (3)
6.216.101 E rev.: - 2009-03-05
Parking and Rigging

of Cable Winch Cable and Stabilizing Winch Wire
Sea stowing parking arrangement
1 2 3 4
Fig. 1. Parking position of power cable and stabilizing wire.

1. Cable winch.
2. Stabilizing winch.
4. Power cable from cable winch.
1 2
Fig. 2. Parking position of power cable and stabilizing wire during sea voyage.
1 (2)
6.216.101 E rev.: - 2009-03-05
Rigging preparations and temporarily

parking arrangement
CAUTION! Note!
This parking arrangement is not receommended for sea In this position the hatch cover cannot be opened.
stowing.
Power cable and stabilizing wire will wear out quickly
if parked according to Fig. 3 during sea voyage.
1
2
Fig. 3. Prepared for rigging of grab, and temporarily parking position of power cable and stabilizing wire.
Fig. 4. Temporarily parking position of power cable.
2 (2)
SERVICE 6.222.1 E rev.: a 1998-04-17
Handling, Installation and Maintenance

of Steel Wire Ropes
1 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
Unloading steel wire ropes It is advisable to lift a reel by means of a shaft which
is put through its axis bore.
When handling a steel wire rope, the first trouble
often occurs immediately upon receiving it: the fork
of the fork lift truck is either placed under the reel
or inside the coil.
If the fork of the fork lift truck is longer than the

width of the reel, the reel can also be lifted at the
flanges.
In both cases it might damage the surface of the

rope. The damage may not be discovered until much
later and it could happen that the manufacturer of
the wire rope is held responsible.
If possible, the rope, when recieved on cils or reels,

should not have any contact with a metal hook or
the fork of a fork lift truck.
Instead, it should be lifted by means of a wide tex-

Storing steel wire ropes
tile webbing sling.
Steel wire ropes should be stored in a clean, cool,

dry place indoors. The ropes must not be allowed
to rest on the floor. They can be placed on pallets.
2 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
If outdoor storage cannot be avoided the ropes must Unwinding steel wire ropes from the reel
be covered in a way that moisture cannot create
corrosion problems. Although plastic foil protects An unreeling stand (turnable) should be used to
the ropes from rain, condensation from beneath unwind a wire rope from its reel.
might not be able to escape and could damage the
ropes permanently. To avoid condensation prob- Another accepted unreeling method is to mount the
lems, it is advisable to use breathable water-proof reel on a shaft supported by two jacks or a stand.
fabric covers readily available from tarpaulin manu-
factures.
When storing a number of spare ropes, the follow-

ing rule should be applied: first in - first out. This
means, the ropes should be used in the order of
delivery. In this way it can be avoided that certain
ropes are only put in service after being stored for
many years.
It is self-evident that the different ropes in stock must

be clearly marked to avoid the possibility of
confusion (e.g. if similar ropes of diffferent tensile
strength are stored).
In addition proper records have to be kept which

make it possible to trace the "history" of any rope
back to the manufacturer on the basis of storing
number, specification, date of order and date of
delivery.
Installing steel wire ropes
When installing steel wire ropes, extra care must

be taken that the ropes are unwound from the ring Rolling the wire rope along the floor, as is some-
or reel without torsions and without any outer dam- times recommended in the relevant literature, does
age. The same applies to reeving the ropes into not work very well in practice because the reel al-
the system. ways unwinds less wire than the distance the reel
travels, so that with this method the rope has to be
dragged along the worker.
Unwinding steel wire ropes from the coil
If a rope is delivered on a coil, it is either unwound

on a turntable or the coil is rolled along the ground
like a hoop. In the latter case ensure that the sur-
face is clean; sand or grit that sticks to the lubricant
might damage the wires when the rope travels or
sheaves.
3 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
Under no circumstances must the rope be pulled If one end of the ropes has a fitting attached, as it
off a coil while it is lying on the ground or looped is mostly the case with deck cranes, there is no
over the head of the reel, because this will inevita- other possibility than pulling the loose rope end
bly induce one torsion per wrap into the rope. through the whole reeving system.
The most common rope fittings for deck cranes are

shown below.
The aluminum ferrule with mechanical splice.

Every torsion will change the lay lengths of the
stands and of the wire rope; at the same time the
proportions of lengths of the rope elements and fi-
nally the distribution of load within the rope are
changed. A rope that is unwound at the sides of a
coil or reel will try to resist the enforced torsions The cast steel ferrule with mechanical splice.
and form loops. When pulled taut these loops will
result in irreparable kinks.
Steel wire ropes with kinks are not safe to operate

and must be discarded.
The spelter socket.
The installation procedure Typical deck crane example
The most advantageous way of installing a steel Below is shown an example of a typical deck crane,
wire rope varies from crane to crane. In any case a where the rope must be spooled from the reel via
procedure should be chosen that (under justifiable sheaves S1 through S9 onto the drum.
expenditure) guarentees the least risk of torsions
and avoids damage to the rope by contact with parts
of the construction.
With some cranes it may be advisable to discard

the old rope first and to install the new one after-
wards. With other cranes, particularly with bigger
ones, it might be better to pull in the new rope at-
tached to the old one. Another possibility is to use
a thinner rope by which the wire rope proper is pulled
into the system. This method is often used with new
equipment.
In every single case careful consideration is ne-

cessary as to whether the wire rope should be pulled
through the whole reeving system or whether it
should first be wound from the coil or reel onto the
drum and afterwards be reeved into the system.
4 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
Here, special attention must be paid to the hook tional wire ropes one must at least make sure that
block. It must be secured in an upright position so they have the same direction of lay as rope to be
that the rope can be spooled without any fleet an- installed.
gles occuring between the rope and the blocks
sheaves. If the new rope is pulled in with help of the used
one, the two rope ends are often buttwelded to-
gether. A connection of that kind can transfer the
Winding the steel wire rope from the reel twist of the old rope, built up in the reeving system,
onto the drum into the new rope. By that method of installation the
new rope may be extremely damaged.
During the manufacturing process every steel wire
rope receives its preferred bending direction when There are even more reasons why that procedure
being drawn from the wire rope closer by means of is highly problematic: It is true, that when using spe-
a capstan. When delivered to the customer the rope cial electrodes the welded connection presents
is bent in that direction. Make certain that it bends acceptable results in a pull test with a straight rope;
in the same direction when it is wound from the reel but because of the great length of rigid connection
onto the drum. zone the very same connection could break due to
the enormous bending stresses when running over
sheaves.
If that connection is applied, its safety should be

increased by using a Chinese finger. Fewer prob-
If the rope is wound at the bottom of the drum, it lems are caused by con-
should leave the reel at the buttom and vice versa: necting wire ropes with
i.e., always reel from top to top or from bottom to welded-on pad eyes or
bottom. chain links, which are
joined by either strands or
If this procedure is not strictly followed, the rope thin wire ropes.
will either try to twist between reel and drum or it
will later try to regain its preferred position when in
practical service. In both cases structural changes
of the rope may occur. This connection provides satisfactory
load capacity, it is flexible and pre-
vents the transfer of twist from the old
rope into the new one. When using
two strands to pull the rope into place,
these will indicate the intensity of twist
in the old rope on the basis of the
number of turns they have made dur-
Installing the rope with the help of the old ing the installation procedure.
one or by a thinner rope
Another possibility is connecting the
If the new rope is pulled in by the old one or by a rope ends with Chinese fingers. These
thinner rope one must make sure that the connec- are tubes made out of braided
tion between these ropes is absolutely safe. In ad- strands, which are pulled over the
dition it must be ensured that the thinner rope can- rope ends and then secured at their
not rotate. Rotation-resistant steel wire ropes or ends with tape or seizing wire. Under
three-strand ibre ropes for instance, can be re- load the Chinese fingers will contract
commended for this purpose. When using conven- and hold the rope ends by friction.
5 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
When installing a lang lay rope one must take care Under no circumstances should one attempt to gen-
that the Chinese finger cannot unwind from the rope erate the tensioning load by jamming the rope, for
like the nut from a screw. It is recommended to wrap instance between two boards. Structural changes
a tape around the whole rope length to be held by would deform the rope beyond repair.
the Chinese finger to increase the friction.
Installing under load
To achieve perfect spooling of the rope on the drum

it is very important to apply a tensioning load to the
wire ropes during the installation.
This is particularly important with drums spooling

in two or more layers, which, however, is not very
common with deck cranes. If the first layer(s) are
not under tension, they might be too loose, so that
the top layers might be wedged into the bottom lay-
ers under load. This could seriously damage the
rope. The unwinding rope might even be clamped, Attaching the rope termination to the fix
so that the direction of spooling could suddenly be point
reversed during the course of unwinding. The re-
sult could be the abrupt lifting of the load that was After the rope has been pulled through the reeving
actually travelling downwards. system, the rope termination (e.g. the mechanical
splice with the aluminum ferrule) must be brought
The tensioning load should range from 1% to 2% of up to the fix point. A pulling jack can be used to pull
the minimum breaking load of the wire ropes. In the rope termination to the fix point, where it must
many cases it might suffice to wind the rope quite secured with a bolt.
normally in order to unwind it and then rewind it
with the help of an outer load. Prior to fixing, if necessary, the rope termination
may be aligned with the fix point by using a steel
In other cases, however, the procedure mentioned bar. The bar should be attached to the rope by
above is not possible. In these cases the tensioning means of a short length of chain. Under no circum-
load must already be applied when installing the stances should the rope be gripped with a wrench,
rope. as this will damage the outer wires.
Ample rope tension can be provided by a simple

plank bearing against the reel flanges or by a brak-
ing disk attached to the reel.
6 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
"Breaking-in" the steel wire rope The rope and this wire end are now wrapped mov-
ing away from the location of the intended cut.
After the rope has been installed and before it is
going to do its proper job, several run-throughs of
the normal operational circle should be carried out
under light load. The new rope
should be "broken-in", so that the
component parts can settle and
adjust themselves to the actual The rope is tightly wrapped for a distance of approx.
operating conditions. It is most un- three rope diameters.
fortunate that in practice only too
often the exact opposite of this
recommendation is performed:
quite frequently after installing the
rope overload tests are carried out
with loads beyond the safe work-
ing load of the system. Both ends of the seizing wire are then pulled tight
and twisted together for a length of one rope diam-
eter.
Cutting steel wire ropes
In some cases the user must cut steel wire ropes.

Hand cutters are sufficient for rope diameters up to
8 mm. Mechanical or hydaulic cutters will be re-
quired for larger sizes. The twisted connection is then hammered into a
gusset between the strands. After preparing the
The best method is to use a high speed disk cutter. other side of the intended cut accordingly the rope
Unless the rope is being scrapped the use of flame can now be cut.
cutting equipment is not recommended.
Careless cutting can result in the balance of ten-

sion in the rope being destroyed. This is particu-
larly important when cutting rotation resistant ropes
where the strands may have been deliberately non-
preformed as part of the manufacturing specifica- Instead of using one long seizing it is also possible
tion. to apply at least three seizing the size of one rope
diameter each on both sides of the intended cut.
In every case, each side of the cut must be prop-
erly seized to prevent strand disturbance. Insulat-
ing tape cannot prevent strand movement, so an- The maintenance of steel wire ropes
nealed (iron) wire should always be used.
Steel wire ropes must be serviced regularly, the kind
After marking the position of the cut the end of the of maintenance depending on the lifting device, its
seizing wire is laid along the rope axis leaving suf- use and the selected rope. Regular maintenance
ficient length to secure both ends by twisting when may considerably increase the service life of a steel
the seizing complete. wire rope.
7 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
Relubricating steel wire ropes It is important with all different methods of

relubrication of steel wire ropes that they are car-
During production the rope receives intensive lu- ried out regularly right from the beginning of the
brication. This in-process treatment will provide the service life of the rope and not only after the first
rope with ample protection against corrosion and is damage has been ascertained.
meant to reduce the friction between the elements
which make up the rope as well as the friction be-
tween rope and sheaves or drums. This lubrication, Cleaning steel wire ropes
however, only lasts for a limited time and should be
re-applied periodically. DIN 15 020 recommends: "From time to time very
dirty steel wire ropes should be cleaned externally".
German Standard DIN 15 020, e. g. specifies: "Steel
wire ropes must be relubricated at regular intervals, This applies particularly to ropes operating in ex-
depending on their use, particularly along the zones tremely abrasive conditions and to those that take
subjected to bending. If for operational reasons up chemicals.
relubrication cannot be carried out, shorter service
life of the rope is to be expected and the inspection Effective cleaning without proper tools is quite a
intervals have to be arranged accordingly." laborious job. For cleaning steel wire ropes the Ca-
nadian Rigging Manual recommends an appliance
When choosing the relubricant, it must be ensured with three rotating wire brushes and an air blast
that it is in accordance with the recommendations drying system to follow. An American manufacturer
of the rope manufacturer. offers a "rope porcupine", a sleeve equipped with
brushes, which is drawn along the steel wire rope.
There are several techniques of lubricant applica-
tion: The most common ones at present are paint-
ing or swabbing. Removing broken wires
Quite often the lubricant is applied at a sheave, If during an inspection ends of broken wires are
sometimes a continuous drip method is used. If only detected which might cross adjacent wires and
a little lubricant is required, pressure spray nozzles destroy them when running over sheaves, these
can be applied. broken wire ends must be removed.
Maximum penetration of the lubricant into the gaps Under no circumstances should the broken wire
of the rope, can only be quaranteed if high pres- ends be pinched off with a pair of nippers. The best
sure lubrication is applied with the help of a pres- method is to move the wire ends backwards and
sure lubricator. forwards until they break deep in the valley between
two outer strands. With thicker wires a tool should
With this method the two halfs of a sleeve, which is be moved backwards and forwards on the surface
equipped with rubber sealings, are clamped round of the rope, thus bending the wires until they break.
the rope and screwed together. While the rope runs
through the lubricator the lubricant is pressed into
the sleeve at a pressure upto about 30 bars.
8 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
Cutting or shifting steel wire ropes
Very often wire ropes must be discarded although

only short rope sections, e. g. the one that climbs
to the second layer on the drum, are seriously dam-
aged, while the rest of the rope is still in perfect
condition.
In cases such as this the service life of wire ropes

can be enormously increased by shortening, shift-
ing them at the fixing point by a span that removes
the section of the rope which has had most abuse
out of the critical zone.
After this procedure an adjacent section will be sub-

jected to the abuse.
Another typical local damage occurs on the drum

at those sections where the rope rubs against the
adjacent winding (crossover point) and must be
deflected to the side. If the damage caused in these
sections is the main reason for discarding the rope,
several cuttings or shiftings will move the stresses
to different rope zones and possibly multiply the
service life of the rope.
9 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
Examples of damage to steel wire ropes
The following pages illustrate some typical exam-

ples of damage to steel wire ropes which should
always decree immediate rejection of the rope.
Surfacelayer wires frayed by abrasion; wire ropes

has been running over sharp edges under load.
Localized wear caused by chafing against adjacent

steel structures possibly because of vibrations of
the length of wire rope laying between drum and
sheave.
Heavy wear caused by high contact pressure in

sheave groove.
Severe corrosion.
Typical wire rupture caused by bending fatigue.
Typical example of localized wear and indentation

caused by a kink in the rope.
Nonrotating multi-strand wire rope with outer strand

partially disengaged because of nonuniform tor-
sional stress.
High shock loads have caused outer layer to split

open exposing steel wire rope core between strands
that have come apart.
10 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
Some examples of wire rupture
Contraction rupture caused by excessive stress, Wear and identations of surface wires also promote
(e.g., if a slack line suddenly snaps taut under full fatigue and lead to premature wire rupture.
load).
Crown wires of outer strands may wear so thin that Corrosion may cause wire ropes to break. As a
the residual cross sectional area of steel in the rope safety measure, inspect ropes regularly and care-
will not support the normal design load and con- fully to prevent catastrophes; observe manufactur-
traction rupture may ensue. er's instructions
Rupture from fatigue will often occur when under-

size sheaves are used. Vibrations and torsional
stress loads in the rope accelerate fatigue rupture.
11 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
12 (12)
SERVICE 6.223.20 E rev.: c 2011-02-07
Replacement of Wires, One or Two Fall Rigging

General
The procedure is general and should be seen as a - Stop the crane. Use pushbutton S13 Start/Stop on
guidance only. the control panel in cabin.
- Mark the position of the wire drum in relation to the
See instruction "Handling, Installation and Maintenance bracket, this to avoid setting of all hoisting limits
of Steel Wire Ropes" in section 6.2. again after installing the new hoisting wire.
- Remove the cover from the limit switch box.
Hoisting winch / wire - Mark the position of the shaft in relation to the box.
See Fig. 5.
For cranes with one or two fall rigging proceed as
- Remove the limit switch box.
follows:
- Measure the AL measure, see Fig. 3.
- Place the jib in the jib rest.
- Secure the wire, so the wire clamps that hold the
If applicable, park the crane, slewing position locked
end of the wire can be removed safely.
with parking cylinders, and the jib at maximum
- Attach a long rope (longer than the wire rope) to
outreach.
the wire end and place it 4 to 5 turns around the
If applicable see also special instruction "Parking
wire drum.
of Crane in Wires" in section 4.
- Park the lifting block on deck and support it so that
WARNING!
the wire can easily be spooled through the lifting
When the crane is operated in Rig mode the crane
block, see Fig. 1.
has no software limits.
- Disengage the slack wire switch by blocking the
It is not permitted to have any load in the hook.
spring tensioned roller, which can be done with a
Inappropriate use may cause severe damage to the
piece of wood, see Fig. 2.
crane and bodily injury.
- Loosen the wire rope socket/thimble attached to
the crane house top, see Fig. 9 or 11.
See instruction "Preparation for Rig Mode", section
- Run the winch by paying out the hoisting wire, and
6.3.
at the same time pull on the loose wire end.
- Stop the winch just before it enters into the empty
- Activate Rig mode.
drum limit.
- Run the winch to pay out the old wire until it is on
the deck.
- Attach the new hoisting wire to the same rope by
using tool 662 0754-000, see Fig. 8.
- Attach the wire rope end to the wire drum with the
wire rope clamps and tighten the bolts. For tightening
torques, see instruction "Tightening Torques..." in
section 6.2.
- Run the winch by pulling in the new hoisting wire,
so that the AL measure is the same as noted earlier
and that the winch corresponds to the position
marked earlier.
- Stop the crane. Use pushbutton S13 Start/Stop on
the control panel in cabin.
- Exit Rig mode. Set key switch in position Normal.
- Assemble the limit switch box in its proper place,
Fig. 1. Lifting block parked in support. the marking on the shaft/box must correspond.
1 (6)
SERVICE 6.223.20 E rev.: c 2011-02-07
- Start the crane again. Piece of wood

- Run in the rest of the wire. Leave enough slack to 100 x 200
secure the wire rope socket.
- Secure the hoisting wire rope socket/thimble on
jib top and the luffing wire thimble on crane house
top. See Fig. 9 or 11. Piece of wood
- Remove the wooden piece holding the slack wire 100 x 200
roller.
- Test the winch and check all limits, which should
now function correctly, if the new wire is the same
length as the old one. If necessary, adjust the limits
according to instruction "Limit Switches in..." in
section 6.3, instruction "Technical Data" in section
2, and calibrate the encoder according to instruction
"Absolute Encoder Calibration" in section 6.3.
Luffing winch / wire

- Place the jib in the jib rest or move the lifting block
up against the jib top.
- Disengage the slack wire switch by blocking the Fig. 2. Disengage of slack wire safety switch.
spring tensioned roller, which can be done with a
piece of wood, see Fig. 2. AL
- Run winch and stop just before it enters into empty
drum limit.
- Stop the crane. Use pushbutton S13 Start/Stop on
- Note how many revolutions of the wire there are
left on the drum at this position. Make a mark on
the drum. Measure the AT measure, see Fig. 4.
- Mark the position of the wire drum in relation to the AL = Empty drum flange
bracket. side/ At least three locking
turns/Tank top
- Remove cover from the limit switch box.
Mark the position of the shaft in relation to the box.
Fig. 3. Hoisting winch.
See Fig. 5.
- Remove the limit switch box.
AT
- Loosen the wire rope socket/thimble attached to
the crane house top / jib, and lower it to deck by Wire lock
side
means of a rope, see Fig. 9 , 10 or 11.
- Secure the wire, so the wire clamps that hold the
end of the wire can be removed safely.
- Attach a long rope to the wire end (longer than the
wire rope) and place it 4 to 5 turns around the wire
drum.
- Start the crane again. AT = Empty drum flange
side/ Stop lowest position/
At least three locking turns
Fig. 4. Luffing winch.
2 (6)
SERVICE 6.223.20 E rev.: c 2011-02-07

- Run the winch to pay out the old luffing wire, and at
the same time pull on the loose wire end until it is
on the deck.
- Attach the new luffing wire to the rope, by using
tool 662 0754-000, see Fig. 8.
- Run the winch by pulling in the wire so that the wire
rope end just enters into the crane house.
- Attach the wire rope socket/thimble to the crane
house top or jib, see Fig. 9, 10 or 11.
- Secure the hoisting wire rope socket on jib top and
the luffing wire thimble on crane house top. See
Fig. 5. Marking inside limit switch box.
Fig. 9 or 11.
- Run the winch by pulling in the wire, so that the AT
measure is the same as noted earlier and that the
winch corresponds to the position marked when the
limit switch box was disconnected.
Limit box
Check that the AT measure is the same as before
removing the wire.
- Attach the wire rope end to the wire drum by the
wire rope clamps and tighten the bolts. For tightening
torques see instruction "Tightening Torques..." in
section 6.2.
- Stop the crane. Use pushbutton S13 Start/Stop on Winch drum
- Exit Rig mode. Set key switch in position Normal.
Fig. 6. Limit switch box, hoisting winch.
- Assemble the limit switch box in its proper place.
- Start the crane again.
- Run in the rest of the wire.
- Remove the wooden piece holding the slack wire Winch drum
roller.
Limit box
- Test the winch and check all limits, which should
now function correctly, if the new wire is the same
length as the old one. If necessary, adjust the limits
according to instruction in section 6.3 and calibrate
the encoder according to instruction "Absolute
Encoder Calibration" in section 6.3.
Tightening torque: In the first place look for tightening

torque on the winch spare part picture, in the second Fig. 7. Limit switch box, luffing winch.
place see instruction 6.214 E.
Note!
To adjust the pressure roller on winch see instruction
"Rope Reeving Diagram ..." in section 6.2 in the
instruction and spare parts manual.
Fig. 8. Tool, wire rigging sock, 662 0754-000.
3 (6)
SERVICE 6.223.20 E rev.: c 2011-02-07
Securing of wire rope socket applicable

to crane type GL
See the "Rope Reeving Diagram" (6.216.xx E) that

applies to your crane.
Example Install a new split pin

when replacing wire
Securing the luffing wire socket to crane house top
Securing the hoisting wire socket to crane house top

Applicable to cranes with loadcell
New pin attached to wire socket.
New pin
Fig. 9. Securing wire sockets to crane house top.
New pin
Fig. 10. Securing the wire socket to the crane jib.
4 (6)
SERVICE 6.223.20 E rev.: c 2011-02-07
Securing of wire rope thimble applicable

to crane type GLB
See instruction "Rope Reeving Diagram..." in section

6.2.
Important!
Important! It is of utmost importance to grease the wire thimble
The wire rope thimble must be safely secured by refer to instructions "Lubricating Chart" and "Lubricants
bending the lock washers, see Fig. 12. for Deck Machinery" in section 5.
Fig. 11. Securing of the wire thimbles to the crane house top.
Fig. 12. How to secure the lock washer for the wire rope thimble.
5 (6)
SERVICE 6.223.20 E rev.: c 2011-02-07
Securing of wire, applicable to cranes

with attached load cell
Load cell
Wire rope socket
Install a new split pin

when replacing wire
Fig.13.Securing of the wire socket to the loadcell on jib top.
6 (6)
S E RV I C E I N F O R M AT I O N
625/1473 E rev.: c 2010-06-23
Indentation and Wear on Wire Sheaves
General
To ensure safe working conditions and long lifetime The wear, see Table 1, can certainly occur on every
of the wire rope it is important to inspect the condition spot where the wire rope is in contact with the wire
of the wire sheaves. sheave, not only on places shown in Fig. 1.
Wear criterias Indentation

When the wear on the wire sheave exceeds 3mm, it A new wire rope and wire sheave are in contact on
will according to our experience decrease the lifetime certain spots, see Fig. 2. After some time the
of the wire rope. The wear of the wire sheave will also indentation will have the shape shown in Fig. 3. This
reduce the load capacity. Maximum wear is therefore is considered as normal wear.
25% of the wire sheave thickness (t) with a limit to
maximum 3mm, see Fig. 1.
Fig. 1. Wear on wire sheave. Fig. 2. Contact spots.
t a
max
16 3
12 3
10 2.5
8 2
6 1.5
Fig. 3. Good contact between an old wire rope and

Table 1. the wire sheave.
1 (2)
625/1473 E rev.: c 2010-06-23
An old wire rope and a worn wire sheave might have

good contact condition, see Fig. 3, but when a new
wire rope is installed the contact condition might be
very bad, see Fig. 4. This will decrease the lifetime of
the wire rope and wire sheave.
It is therefore important to inspect the wire ropes

according to paragraph "Wear criterias".
Fig. 4. Bad contact between a new wire rope and the

wire sheave.
2 (2)
625/1560 E rev.: f 2010-01-14
Lifting Block/Beam
Warning!
Where equipment has swivelling and moving parts
there are potential safety hazards. Care should be
taken when working with or repairing equipment. If
used incorrectly, breakage could occur injury or
death.
General safety Eyes for stabilizing

wires (extra equipment)
When equipment is in use, do not put hands:
1. Between sheaves, sideplates, and guards.
2. In area of hook, hook nut, and swivel.
Fig. 1. Lifting block for crane with two sheaves.
Take great care to avoid clothing becoming trapped.
Repair and reeving should be carried out by trained

personnel only. Power should be switched off be-
fore operations are carried out. Work should only
take place when equipment is supported on a firm
surface.
Maintenance and service
Inspection should be carried out on every possible

occasion before taking into operation. Fig. 2. Lifting block for crane with one sheave.
Particular attention should be paid to the items

below:
1. Wear in hook, centre pin, steel structure, and
threads.
2. Play in sheave bushes or bearings.
3. Spacer bolts and nuts.
4. Examine for cracks in welds in steel structure.
5. Condition of safety latch and grease nipples.
6. Wear in holes in sideplates and links.
If cracks or heavy gouges appear, the equipment

should not be used until a qualified person examines
the equipment. Contact MacGREGOR Cranes,
Service Division.
NO welding should be carried out unless prior

authority is obtained. Fig. 3. Lifting beam for 4-rope crane.
1 (2)
625/1560 E rev.: f 2010-01-14
If the holes in the sideplates, eyes, and swivels are Important!

enlarged by more than 5%, the part should be When replacing genuine parts an overload test of
replaced or maybe repaired, see Fig. 4. Contact the complete unit must be performed and new cer-
MacGREGOR Cranes, Service Division, for tificate must be issued. See Table 1.
instructions.
Lubrication
As a general rule sheaves, shafts, and swivels

should be greased through nipples every 100
working hours, see also separate lubrication chart.
Pins without nipples should be removed and
lubricated with a brush.
Limitation of use
1. Safe working load should never be exceeded, see

Table 1.
2. Crane blocks should be used in vertical lift only.
3. Shock or side loading should not be applied, un-
Fig. 4. Lifting eye.
less equipment is desigend for that purpose.
4. Load should always be in seat of hook or eye.
All repairs should be carried out by responsible

personnel, and great care should be taken in the
reassembly of the equipment and retaining parts,
i. e., grub screws, pins, etc. Make sure they have
the correct sizes and threads and refit them.
Table 1.
Proof load for lifting blocks with 2-part rigging

Class Working load limit Proof load
ABS PL = 2 x WLL
BV WLL < 25 T PL = 2 x WLL
25 T < WLL < 160 T PL = (0.933 x WLL) + 27
WLL > 160 T PL = 1.1 x WLL
DNV PL = 2 x WLL
GL WLL < 25 T PL = 2 x WLL
WLL > 25 T PL = (1.22 x WLL) + 20
LRS WLL < 25 T PL = 2 x WLL
WLL > 25 T PL = (1.22 x WLL) + 20
WLL = Working Load Limit (SWL)
T = 1 metric ton = 1000 kg
PL = Proof Load
2 (2)
625/1579 E rev.: i 2010-08-25
Measuring Procedure for Wear in Slewing Bearings
General
Below measuring procedure is valid for the crane Measurements shall be taken at four positions of the
types G, TG, GL, TGL, GLB, H, TH, L, and TL. slewing bearing, if possible. With the jib pointing:
Note! The procedure is not valid for measuring the - Forward to the ship
slewing bearing under the twin platform. - Starboard
- Aft
The slewing bearing is an essential part of the crane - Port side
and must be well maintained. Over the years the It is important to use about the same position for all
slewing bearing will have some wear, and to be able further measurements to be able to compare the
to know if there is a need for changing the slewing measurements.
bearing it is needed to keep a record of the wear.
With the jib at maximum outreach two measurements
The initial measurements should be taken when are to be taken, see Fig. 1.
the crane is installed at yard or within 2 months
from crane installation. With the jib at minimum position one measurement is
to be taken, see Fig. 2.
If the wear measurement shows wear, grease
samples can be taken for analysis. Enclosed table can be used to record the
measurements.
Slewing bearing grease sampling
procedure Note!
Measurements should be recorded with an accuracy
See Inspection Instruction 625/1651 E. of 0.1 mm.
If B - C = 0, or negative, the measurement is wrong.

Measuring If B - A is greater than 7 mm the crane must not be
used.
The measurements should be taken regularly, every
6 months. Measurements can be sent to MacGregor Maximum allowed play is:
Cranes, rnskldsvik, Sweden for evaluation. for roller bearings 1.5 mm
for ball bearings 3.0 mm.
Note!
When measurements are to be taken the ship shall
have as little list/trim as possible.
Neither a load nor a cargo handling equipment should

be attached to the hook.
Procedure
First time a measurement is to be taken two reference
points on the crane's bottom plate must be marked.
These reference points shall then always be used at
any future measuring, see Fig. 4.
1 (4)
625/1579 E rev.: i 2010-08-25
Jib at maximum outreach
Measurement B
(back of crane) Empty hook
Jib direction Jib direction
Measurement A
(front of crane)
Fig. 1. Jib in outer position.
Measurement C
(back of crane)
Jib direction
Min. outreach,
empty hook
Fig. 2. Jib at minimum outreach.
2 (4)
625/1579 E rev.: i 2010-08-25
Note! If there is a machined surface this shall be used

as reference point. In other cases a reference point
must be marked.
Machined surface/ Machined surface/

reference point reference point
Jib
Fig. 3. Machined surface on crane bottom plate.
Reference point
Reference point
Fig. 4. Reference points.
3 (4)
625/1579 E rev.: i 2010-08-25
Vessel name: ...........................................................

Fore Note!
- If B - C = 0 or negative the
IMO No.: ...................................................................
Ps Stb measurement is wrong.
- If B - A is greater than 7 mm
Date: .........................................................................
the crane must not be used.
Crane No.: 1 Aft
Measurement (accuracy 0.1 mm) Play Difference Jib direction

Jib at max. outreach Jib at min. outreach in level
A (front of crane) B (back of crane) C (back of crane) B-C B-A
Fore
Stb
Aft
Ps
Crane No.: 2
Fore
Stb
Aft
Ps
Crane No.: 3
Fore
Stb
Aft
Ps
Crane No.: 4
Fore
Stb
Aft
Ps
4 (4)
INSPECTION INSTRUCTION
625/1651 E rev.: - 2010-04-12
Slewing Bearing Grease Sampling Procedure
General
One of the criteria's to evaluate a slewing bearing's - Clean up the seal and the surrounding areas
condition is to analyse the grease samples. The where the sample will be taken. When cleaning
other is to make play measurements. The grease the area of the seal, prevent the cleaner from
analysis can be done in two steps, simplified or in a contacting the seals or from entering the
laboratory. What method to be used must be raceway's system.
decided after the play measurement is taken. It must - Push new grease into the grease nipples / bearing
be noted that a single laboratory test of a grease without rotation and collect the first used grease
sample gives very little information. Laboratory tests which will come out at the seal.
must be done on regular basis to see trends.
Attention: Do not take fresh grease for analysing!
The play measuring normally tells more about the The required quantity of grease for analysing is
bearing condition than a grease sample. Both approximately 3 cm 3.
methods provide together the best basis for
evaluation of the bearing condition. The normal interval for grease sampling is 6 months.
If steel particles are seen when the simplified grease

Procedure of grease sampling analysis is done or if the laboratory grease analysis
shows a too high value the grease sampling period
Following information is necessary in order to give should be increased to each 50 crane operating
a correct statement and allow further advice: hours or every two months.
1. Type of grease used at lubrication (manufacturer

and type)
2. Lubrication intervals (crane running hours or
months)
3. Crane running hours
4. Information where the samples are taken
5. Has the slewing bearing been replaced? If so,
when was this done. Also state bearing article
no.
As a correct procedure of grease sampling is very

important, below procedure should be done.
Procedure
- Slew the crane until the jib is in the main working
area.
- The grease sample should be taken at the inner
or outer seal of the bearing, see Fig. 1 and 2.
- One sample should be taken from the front part
of the crane and one sample from the back part
of the crane.
1 (6)
625/1651 E rev.: - 2010-04-12
Grease sampling area Grease sampling area

(see below figures) (see below figures)
Grease sampling
area (inner seal) Grease sampling
area (inner seal)
Outer seal
Slewing bearing with rollers.
Outer seal
Slewing bearing with balls.
Fig. 1. Grease sampling areas.
2 (6)
625/1651 E rev.: - 2010-04-12
Grease sampling area Grease sampling area

(see below figure) (see below figure)
Inner seal
Grease sampling
Slewing bearing with balls. area (outer seal)
Fig. 2. Grease sampling area.
3 (6)
625/1651 E rev.: - 2010-04-12
Simplified grease analysis
1. Take a grease sample.
2. Spread the grease on a white paper.
3. Spread it out in a very thin layer.
4. Place the sample under a lamp and look for steel

particles.
4 (6)
625/1651 E rev.: - 2010-04-12
Laboratory grease analysis
Normally a grease laboratory analysis should give

results showing Fe, PQ, Si, Na, and water.
To best interpret the grease analysis a

corresponding analysis of fresh grease should be
available to recognize the deviations of the used
grease.
If any of the following limitations are exceeded

please contact MacGregor Cranes for further
recommendations.
Fe: 10.000 ppm

PQ: 2000
Si: 300 ppm
Na: 250 ppm
Water: 2000 ppm
5 (6)
625/1651 E rev.: - 2010-04-12
6 (6)
SERVICE 6.303.49 E rev.: e 2010-05-31
Troubleshooting
GLB-Crane
CT2
Contents
1. Description of input and output signals ............................................................................................. 2
2. Control system input and output signal levels................................................................................... 6
3. Troubleshooting for the control system............................................................................................ 9
4. Spare parts ....................................................................................................................................... 11
1 (12)
SERVICE 6.303.49 E rev.: e 2010-05-31
Error MP SP
Display
Select/Info button
Up
Down/Exit
1 Description of input and output signals
1.1 General
The following description refers to the
microcomputer based crane control system
CC3000 for MacGREGOR hydraulic deck cranes.
Minor variations in the use of control system input

and output signals due to differences in hydraulic
and electric system may occur, the objective of this
description is only to provide a general orientation
concerning the principles of control system
interface signals and of troubleshooting.
For a general description of the principles of the

Crane Control system CC3000 see "Function",
section 3. For detailed information about the control
system a complete electric circuit diagram, relating
specifically to your crane, will be found in the
instruction manual, section "Spare Parts", Group
9.5. Also for detailed information about the
hydraulic system a complete hydraulic circuit
diagram will be found in section "Spare Parts",
Group 9.4.
2 (12)
SERVICE 6.303.49 E rev.: e 2010-05-31
1.3 Power supply, Control system anti-

1.2 Power supply, Control system condensation heating
operation The anti-condensation heating in CT2 cabinet is
powered with 24V DC when the control system is
The power supply transforms the input
switched off and the crane is not in operation. A
380/400/440V AC to 24V DC. See Fig. 1.
separate power supply is used for all anti-
condensation heating in the crane. A separate
It consists of a three-phase power supply. The
power line feeds the power supply.
output 24V DC is divided into two supplies, one for
the control system and its output signals (terminal
48) and one for the limit switches, pressure 1.4 Control levers - potentiometers,
switches (terminal 42). There are fuses on each outputs to and inputs from
supply in the CT1 cabinet.
The control levers linear potentiometers are fed
with 0V, +6V and +12V from their appropriate MC
The 0V level for 24V DC is grounded in power
and CC card. The potentiometer output is approx.
supply unit.
+6V with the lever in neutral. The output signal is
controlled by the lever and is depending on the
direction of lever movement. The output signal is
increased to approx. +10.5V for maximum speed
hoisting, luffing in, and slewing left respectively. The
output signal is decreased to approx. +1.5V for
maximum speed lowering, luffing out, and slewing
right respectively.
Fig. 1. CC3000 Power supply principle.
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SERVICE 6.303.49 E rev.: e 2010-05-31
1.6 Pressure/force sensor input

1.5 Control levers - direction signal If fitted a pressure sensor giving 4-20 mA is used to
inputs measure the hydraulic oil pressure for hoisting
winch in use, to be used for calculation of the hook
The control lever for hoisting selects two out of four
load. The signal is connected to the control system
24V direction signals, for selection of low speed/
via the backplane card.
high speed and hoisting/lowering. See Fig. 2. The
control lever for luffing/slewing gives two out of four
24V direction signals for selecting luffing in/luffing
out and slewing left/slewing right.
Fig. 2. Control lever signals, hoisting movement.
4 (12)
SERVICE 6.303.49 E rev.: e 2010-05-31
1.7 Overload pressure switch input 1.10 Displacement/unloading outputs

Each MC card has two separate outputs. They are
The overload pressure switch makes the MC card
used for selecting low speed or high speed for the
control program to switch over from high speed to
hoisting movement and for the unloading function
low speed operation or, if already in low speed,
for the luffing movement. Each output giving a fixed
stopping the hoisting and luffing crane movement.
24V output with a maximum current of 2A. The
The input signal from the overload pressure switch
system is capable of detecting short-circuited
is often only seen as a short pulse.
output and then giving an error-message, see sign
ERROR MESSAGES.
1.8 Pump solenoid outputs
Each hydraulic pump has two solenoid valves, one 1.11 Low feed pressure input
for each direction of the oil-flow. The solenoids are
The low feed pressure switch indicates that the
controlled with a 24V PWM (Pulse Width
pump feed pressure is too low for safe operation.
Modulated) signal with current feedback control. If
Output signals to pumps, displacement/unloading
wanted output current is not reached (due to short-
valves and brake relief valves are immediately
circuit, open-circuit or MC card failure) the system
switched off. If the low-pressure signal comes back
then gives an error message, see sign ERROR
within approx 0.3 s the crane operation continues
MESSAGES. Each MC card is capable of
with the same output signal levels as before the
controlling a maximum of four pumps with a total of
pressure drop. However, if short pressure drops are
eight output drivers, one for each solenoid valve.
repeated 4-5 times within a short period of time the
Each driver is capable of outputting a maximum
crane operation is stopped and starts 4-5 seconds
current of 1A. To obtain the value of the current it is
after the feed pressure has a stable high level
possible to get it on the display on the cards in CT2
again.
cabinet.
1.9 Brake release/direction valve 1.12 Lamp output "Control System Error
outputs in CT2"
The LED no 28 on the CC Card are wired to a lamp
Each MC card has an output driver for the brake
in crane operator's cabin. The first time an error
release signal (or direction valve for cranes
occurs, the lamp flashes. When the error is
equipped with cylinder luffing). The system is
acknowledged by pushing the Select/Info push-
capable of detecting short-circuited output and then
button on the appropriate MC or CC card the lamp
giving an error-message, see sign ERROR
is on if the error remains or out if the error is not
MESSAGES.
present for the moment. See chapter 3.5 for
detailed information about error messages.
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SERVICE 6.303.49 E rev.: e 2010-05-31
2 Control system input and output signal levels
Power for control system input and output CT2-X10:48

+24V. 0V, connected to ground.
signals CT2-X10:50
CT2-X10:42
Power for limit switches, pump servos, etc +24V. 0V, connected to ground.
CT2-X10:50
CT2-X10:44 24V AC, powered when crane
Anti-condensation heating -
CT2-X10:46 stopped.
Parking of jib CT2-X10:109
CT2-X10:201
12V from MC "Ho". 6V from MC
Outputs to control lever potentiometer hoisting CT2-X10:202 Ho
"Ho". 0V from MC "Ho".
CT2-X10:203
Analogue input signal 1.5 to
Control lever potentiometer input hoisting CT2-X10:204 Ho
10.5V with 6V in neutral position
Control lever direction inputs hoisting
Hoisting CT2-X10:207 Ho 24V when control lever actuated
Lowering CT2-X10:208 Ho hoisting lowering low speed high
Low Speed CT2-X10:209 Ho speed
High speed CT2-X10:210 Ho
Outputs to control lever potentiometer CT2-X10:301 12V from MC "Lu". 6V from MC

Lu
Luffing CT2-X10:302 "Lu". 0V from MC "Lu".
CT2-X10:303
Control lever potentiometer input signal luffing CT2-X10:304 Lu
10.5V with 6V in neutral position.
Control lever direction inputs slewing
24V when control lever actuated
Luffing In CT2-X10:307 Lu
luffing in luffing out
Luffing Out CT2-X10:308 Lu
CT2-X10:401
12V from MC "SL". 6V from MC
Outputs to control lever potentiometer slewing CT2-X10:402 SL
"SL". 0V from MC "SL".
CT2-X10:403
Control lever potentiometer input signal slewing CT2-X10:404 SL
10.5V with 6V in neutral position.
Control lever direction inputs slewing
CT2-X10:407 24V when control lever actuated
Slewing Left SL
CT2-X10:408 slewing left slewing right
Slewing Right SL
Brake relief valve - outputs
Ho
Hoisting CT2-X10:230 24V, max. 2A, open circuit gives
Lu
Luffing - (direction valve if cylinder luffing) CT2-X10:330 error message.
SL
Slewing CT2-X10:430
24V, max. 2A, open and short
Hoisting displacement low speed output CT2-X10:231 Ho
circuit gives error message.
Hoisting displacement output high speed CT2-X10:232 24V, max. 2A, open and short
Ho
Current return CT2-X10:248 circuit gives error message.
Luffing unloading output CT2-X10:331 Lu 24V, max. 2A, open and short
circuit gives error message.
Pump PWM signals for Hoisting Pump1 CT2-X10:233 Ho 24V, 0 to approx. 600 mA, error
6 (12)
SERVICE 6.303.49 E rev.: e 2010-05-31
Hoisting output CT2-X10:234 message if wanted current not

Lowering output CT2-X10:235 achieved. 1mA gives approx.
Current return and current measure input 1mV.
Pump PWM signals for hoisting pump2 (if fitted) 24V, 0 to approx. 600 mA, error
CT2-X10:236 Ho
Hoisting output message if wanted current not
CT2-X10:237 Ho
Lowering output achieved. 1mA gives approx.
CT2-X10:238 Ho
Current return and current measure input 1mV.
Pump PWM signals for luffing pump1 24V, 0 to approx. 600 mA, error
Luffing In output CT2-X10:333 Lu message if wanted current not
Luffing Out output CT2-X10:334 Lu achieved. 1mA gives approx.
Current return and current measure input CT2-X10:335 Lu 1mV.
Pump PWM signals for luffing pump2 (if fitted) 24V, 0 to approx. 600 mA, error
Luffing In output CT2-X10:336 Lu message if wanted current not
Luffing Out output CT2-X10:337 Lu achieved. 1mA gives approx.
Current return and current measure input CT2-X10:338 Lu 1mV.
Pump PWM signals for slewing pump1 24V, 0 to approx. 600 mA, error
Slewing Left output CT2-X10:433 SL message if wanted current not
Slewing Right output CT2-X10:434 SL achieved. 1mA gives approx.
Current return and current measure input CT2-X10:435 SL 1mV.
24V, 0 to approx. 600 mA, error
Pump PWM signals for slewing pump2 (if fitted)
CT2-X10:436 SL message if wanted current not
Slewing Left output Slewing Right output
CT2-X10:437 SL achieved. 1mA gives approx.
Current return and current measure input
CT2-X10:438 SL 1mV.
Limit switch inputs hoisting 24V at normal operation, 0V at
CT2-X10:214
Hoisting Ho limit. At limit movement is
CT2-X10:215
Lowering, slack wire stopped and brake closed.
Speed-reduce limit inputs hoisting
CT2-X10:211 Ho 24V at normal operation, 0V at
Hoisting
CT2-X10:212 limit.
Lowering
Limit switch inputs luffing 24V at normal operation, 0V at
CT2-X10:314 Lu
Luffing In limit. At limit movement is
CT2-X10:315
Luffing Out, slack wire stopped and brake closed.
Speed-reduce limit inputs luffing
CT2-X10:311 Lu 24V at normal operation, 0V at
Luffing In
CT2-X10:312 limit.
Luffing Out
Limit switch inputs slewing 24V at normal operation, 0V at
CT2-X10:414 SL
Slewing left limit. At limit movement is
CT2-X10:415
Slewing right stopped and brake closed.
Speed-reduce limit inputs slewing
CT2-X10:411 24V at normal operation, 0V at
Slewing left SL
CT2-X10:412 limit.
Slewing right
CT2-X10:256
Slack wire
CT2-X10:356
CT2-X10:219 Ho
24V at normal operation, 0V at
Pressure switch input for low feed pressure CT2-X10:319 Lu
low feed pressure.
CT2-X10:419 SL
Pressure switches for overload CT2-X10:220 Ho 24V at normal operation, 0V at
CT2-X10:320 Lu overload.
Output "Error in control system CT2" CT2-X10:128 Sc 24V outputs wired together to
error lamp in drivers cabin.
7 (12)
SERVICE 6.303.49 E rev.: e 2010-05-31
Output for "Speed dependent" overload function 24V when the hoisting speed is
CT2-X10:229 Ho
(if fitted). less than approx. 3 rpm.
Ho 24V when the hoisting pressure
Output for "Hoisting Overload" indication lamp CT2-X10:255
Lu exceeds adjusted value.
24V input from cabin switch,
CT2-X10:217 Ho
Speed reduction, input signal ext. 1 (bit 0) to such as Grab operation, Parking
CT2-X10:317 Lu
reduce normal operation speed (utilization). Lock Slewing, Power Limiter,
CT2-X10:417 SL
Twin operation, etc.
Speed reduction, input signal ext. 2 (bit 1) to
CT2-X10:218 Ho
reduce normal operation speed (utilization). 24V input from cabin switch,
CT2-X10:318 Lu
Same as above, but could be used with different same as above.
CT2-X10:418 SL
utilization.
Prevent high speed function. CT2-X10:210 Ho 24V (Optional)
input from switch in cabinet CT2.
Two-position switch
Normal/Low speed
Jack-knife CT2-X10:358 Lu 24V (Optional)
High hook CT2-X10:359 Lu 24V (Optional)
8 (12)
SERVICE 6.303.49 E rev.: e 2010-05-31
3 Troubleshooting the Crane Control system
3.1 General
This section provides information for identifying and When troubleshooting a malfunction: Locate the
correcting malfunctions, which may develop while symptom or symptoms that best describes the
operating the cargo crane. Before performing malfunction. If the appropriate symptom is not
troubleshooting, read and follow all safety listed, notify your supervisor.
instructions found in section "General", section 1, of
this manual. This chapter cannot list all Read this section in conjunction with the electrical
malfunctions that may occur, nor all inspections and and hydraulic diagrams provided in Group 9.5 and
corrective actions. If a malfunction is not listed, or is 9.4.
not corrected by the listed corrective actions, notify
your supervisor.
3.2 Troubleshooting Chart

Troubleshooting the
Crane Control System
CC3000.
Crane movement Crane movements function but the lamp

malfunction. "Control System Error" in driver's cabin
is flashing or on.
Check the lamps "Control

System Error CT2" in
driver's cabin.
Both lamps One or both lamps are Check the error code in
are off. flashing or on. Control System cabinet
CT2.
Check 24V power Check limit switches,

supply, see chapter joysticks and electro-
4.3. hydraulic interfaces,
see chapter 4.4.
9 (12)
SERVICE 6.303.49 E rev.: e 2010-05-31
Check for missing Green input signal LEDs

3.3 Checking Power supply 24V DC in - from joystick.
CT2 cabinet
Check electric cable connections to control
See chapter 1.2. for explanation of the power lever.
supply function. Check analogue input signal from joystick
Check over-current relay F3 in cabinet potentiometer.
CT1. Check for missing Green output signal
Check fuse F16 in CT1 for 24V in terminal LEDs: Exchange the MC card with other
48 in CT2 cabinet. movement MC card. Replace broken MC
Check fuse F17 in CT1 for 24V in terminal card with a new one.
42 in CT2 cabinet.
Check relay K34 in cabinet CT1, see Check direction and brake valves
electric circuit diagram.
No LED and display readout on MC card See hydraulic circuit diagram in Spare Parts
indicates missing 24V in terminal 48. Manual, group 9.4.
Check electric cable connections.
Replace electric coil.
3.4 Checking Limit switches, Joysticks
Replace valve.
and Electro-Hydraulic Interfaces
Check Limit Switches, see Control system CT2 Check pump servo valves on each high
cabinet pressure pump
See chapter 3 for explanation of signal indication See instruction High Pressure Pump in section 6.1
and hydraulic circuit diagram in Spare Parts
LEDs.
Manual, group 9.4.
No LEDs on and no display readout -
indicates missing 24V in terminal 48. Check electric cable connections.
Check for Red LEDs - indicating stop limits. How to obtain error codes from the CC3000
Check for Yellow LEDs - indicating speed system.
reduces.
Check electric cable connections for limit 3.5 Error message codes from CC3000
switches.
For checking and adjustment of limit If the error from the CC3000 has no influence on
switches see instruction for Limit Switches the performance of the crane the control system
in Hoisting in "Service", section 6.3. error lamp in the drivers cabin will not flash.
Check control lever (joystick) With the crane still running, the following steps are
necessary to obtain the error code(s).
See chapter 1.4 for explanation of the control lever
functions.
10 (12)
SERVICE 6.303.49 E rev.: e 2010-05-31
4 Spare parts
4.1 MC card and CC card

When ordering a MC or CC card do one of the
following:
Look for:
- The software version and the hardware specified
on both handles on the replaced card.
or
- refer to the crane's mfg. no., which can be found
on the sign in crane operator's cabin.
or
- Refer to section 9.5 in the instruction manual.
Customers that purchase a replacement card will

receive a credit note of 15% of the sales price when
the damaged card has been returned to Cargotec
Sweden AB, MacGREGOR Cranes in rnskldsvik.
4.2 Parameter Memory Card

The parameter Memory Card is individually for each
crane. Each parameter Memory Card needs to be
programmed with the crane's unique parameter
values. When ordering a parameter Memory Card
always specify the manufacturing number (Mfg. no.)
of the crane, which can be found on the sign in the
crane operator's cabin.
The programmed Memory Card delivered by us, will

be labelled with the crane mfg. no.
4.3 Return report

It is essential that the service department gets
information about when and why the card is
removed from the crane system. Fill out the Return
Form, see section 6.0, and send it back with the
exchanged card.
4.4 Conductive transit boxes

To protect all types of electronic cards from
damages from ESD (Electro Static Discharge) it is
important to use pink anti-static plastic bags and
conductive transit boxes of the same type as used
for delivered original spare parts.
11 (12)
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12 (12)
SERVICE 6.303.61 E rev.: c 2011-07-14
Card front menus CT2, CC3000
General Depending of crane type there can be

This instruction describes how to use the additional cards. On the front of each card
display and buttons on the Micro Processor there is a display and three buttons: Select/
Cards (MC- and CC) placed inside the CT2- Info, Up and Down/Exit.
cabinet.
Each crane with CC3000 is equipped with at
least one CC-card and three MC-cards. Note! Depending on equipment or software
versions the number of alternatives may vary.
1. Error MP (Main Processor) and SP

4. Select/Info
(Safety Processor)
Push the button = Select.
Flashing diode = there are active
Push and hold the button = Information
errors that have not been
will scroll by on the display.
acknowledged.
The diode is on (fixed) = there are 5. Up button
active errors but they have been Browse upwards
acknowledged.
The diode is off = there are no 6. Down/Exit
active errors. Push the button - Browse downwards.
2. Encoder Calibration button Push and hold the button - Exit, back to
top menu.
Used for calibrating encoders
3. Display
See below
1 (4)
SERVICE 6.303.61 E rev.: c 2011-07-14
Display
At power on the software version will appear. For more information about errors refer to
To view that in a later stage, see below Troubleshooting CC3000 in section 6.3 in
paragraph 6 VER. the Instruction Manual.
For each card there will be two letters
representing the card. When holding the Select
button the complete name will appear. 2. CAL - CALIBRATION MODE (LOGIN
REQUIRED)
Standard Complete Calibration mode makes it possible to
view name
calibrate one or several encoders and
Sc Supervisor other equipment depending of crane type.
Ho Hoisting Calibration can only be done if Rig-mode
Lu Luffing is on. For more information see Absolute
Sl Slewing Encoder Calibration in section 6.3 in the
Au Auxiliary Instruction Manual.
Cl Closing Each card will be calibrated at a time.
Ec Eccenter For twin cranes, when in twin mode and
Ll Lift Line from the master crane and from card Sc:
Tl Tag Line Left Ho Ll Tl Tr but not Lu will be calibrated.
Tr Tag Line Right
Io Input/Output 3. LU Plussing Adjustment
Only on Sc card
Menu tree
Only to be used during commissioning of
All errors must be acknowledged before you
can move on to other modes. (Diode must not the crane.
be flashing). There are seven main modes.
Push Select/Info to enter menu tree. 4. CUT Cut off valve Adjustment
Only on Sc card
1 ERR Error Mode
Only to be used during commissioning of
Calibration Mode (Login
2 CAL required) the crane.
3 PLU Plussing Adjustment
4 CUT Cut off valve Adjustment 5. VAL - VALUE MODE
5 VAL Value Mode
Value Mode makes it possible to monitor
6 VER Software Version different values. How many values that
Manufacturing number appear is dependent on equipment and
7 MFG (from version H04.00) parameter settings.
Push Select/Info to enter menu tree.
1. ERR - ERROR MODE Push Down/Exit until the display shows
VAL
Error mode shows all active errors in the Push Select/Info to select Value Mode
respective control card. Push Down/Exit until the value is on
Push Select/Info to enter menu tree. display.
Push Select/Info to select Error Mode. Push select to see the value.
Push Down/Exit or Up to browse
between errors.
2 (4)
SERVICE 6.303.61 E rev.: c 2011-07-14
Values
Sc Ho Lu Sl Au Cl Ec LL TL TR IO
JOY Joystick %
AN1 Jib angle degrees (360)
AN2 Winch angle degrees (360)
SP1 Speed rpm rpm
SP2 Speed mpm mpm
PRE Pushure bar
WE1 Weight Dynamic ton
WE2 Weight max ton
LIF Lift height m
OUT Outreach m m
FOR Hook to hook FOR m m
AFT Hook to hook AFT m m
AL1 ALM line voltage V
AL2 ALM line current A
AL3 ALM power kW
AL4 ALM DC voltage V
PW0 PWM0 mA
PW1 PWM1 mA
PW2 PWM2 mA
PW3 PWM3 mA
PW4 PWM4 mA
AI1 "Parameter" Parameter value
CAR Card Temperature Degrees
MFG.
6. VER - SOFTWARE VERSION
Push Select/Info to see the MFG-
Software Version makes it possible to number
read the version of the software. This will
also appear at power on.
Push Down/Exit until the display shows
VER.
Push Select/Info to select Version
Mode
7. MFG MANUFACTURING NUMBER
From software version CC3K H04.00 it is

possible to see the manufacturing number
of the crane.
Push Down/Exit until the display shows
3 (4)
SERVICE 6.303.61 E rev.: c 2011-07-14
4 (4)
SERVICE 6.303.68 E rev.: - 2011-01-18
Absolute Encoder Calibration, CC3000
General Preparation of minimum outreach luffing
Absolute encoders are used for position control WARNING! Always use safety belt when measuring
purposes. Each encoder gives an accurate position the MV distance.
feedback to the control system.
To operate the crane in Rig mode see instruction
The encoder calibration has to be done when the wire "Preparation for Rig Mode" in section 6.3.
or the absolute encoder has been replaced.
WARNING!
Absolute encoders for hoisting and luffing winches When the crane is operated in Rig mode the crane has
are installed in the limit switch box or on jib bearing. no software limits.
It is not permitted to have any load in the hook.
For slewing motion the absolute encoder is mounted Inappropriate use may cause severe damage to the
under the crane towards the slewing bearing. crane and bodily injury.
Center line of crane house
MV
(m
m)
MV distance
First jib stay
Center line of jib profile

(calibration point)
There must be a distance

between the front of the
crane house and the first jib stay.
Fig. 1. Crane house top.
1 (4)
SERVICE 6.303.68 E rev.: - 2011-01-18

- Carefully position the minimum outreach until the
MV distance is achieved.
Caution! Do a visual inspection of the distance
between the front of the crane house and the first
jib stay on jib. AL
- Measure the MV distance on top of the crane
house, see Fig. 1, refer to table in Technical Data,
section 2.
- Calibration of the encoder in cabinet CT2, see
Table 1, page 4.
- Adjust the limit switch for "Min Outreach", see
instruction "Limit Switches and Software Limits
..." in section 6.3 and table "Limit switches -
luffing winch" in Technical Data, section 2. Fig. 2. Definition of "AL" hoisting winch.
- Luff out a few meters and stop.
- Exit Rig mode by stopping the crane and switch
the key switch to Normal.
- Luff in until the jib stops at "Min Outreach".
- Recheck the MV distance.
Preparation of hoisting

- Start to operate the crane to definition "AL"
(hoisting winch), see Fig. 2, refer to table "Limit
switches - hoisting winch" in Technical Data,
section 2.
- Measurement to be done in front of the hoisting
winch, from the empty drum flange to the side of
the wire.
- Adjust the limit switch for empty drum. Hoist the
hoisting wire a few meters and stop. Lower the
wire until it stops at position empty drum, i.e. at
least three locking turns or tank top.
Table 1, page 4.
- Exit Rig mode by stopping the crane and set the
key switch to Normal.
2 (4)
SERVICE 6.303.68 E rev.: - 2011-01-18
Preparation of slewing
- To calibrate the absolute encoder for slewing aim

the crane jib straight ahead, i.e. 0, see Fig. 3.
Table 1, page 4.
Fig. 3. Reference points.
3 (4)
SERVICE 6.303.68 E rev.: - 2011-01-18
Calibration of encoders in cabinet CT2
Hoisting Luffing/slewing
Operation of rig mode see instruction "Preparation for To calibrate the encoder on the other cards proceed in
Rig Mode" in section 6.3. the same way as in items 1, 2, 3, and 4 in above
paragraph except for choosing the corresponding card.
1. Push the "Select/Info" button on the front of the
MC-card which you want to calibrate, for example
Ho-card. The display on the Ho-card shows
"ERROR".
2. Push the "Down/Exit" button on the Ho-card
front. The display on the Ho-card shows "CAL".
3. Push the "ENCODER CALIBRATION" button in
cabinet CT2. The display in the Ho-card then
flashes and shows "ANG".
4. Push the "Select/Info" button on the Ho-card.
Angle encoder is calibrated in this position.
Table 1. Encoder calibration modes
Function/ Purpose Calibration position

Mode
Ho Zero position of hoisting winch Empty drum, at least three locking turns (AL).
Lu Zero position of luffing winch Full drum, min. outreach, MV distance.
SL Zero position of slewing Aim crane jib straight ahead for 0.
Display
ENCODER
CALIBRATION
button
Select/Info
button
Up button
Down/Exit
button
Fig. 4. Cabinet CT2, CC3000.
4 (4)
Page Date
SIGNAL OVERVIEW 1 (2) 2010-08-25
No Revision
Crane Control System CC3000 C
424 0738
LEDs - 24V Input/Output signals are indicated with coloured LEDs
.Colour Indicating LEDs on External communication
when LEDs within the COM box are external communication and
communication with Main Processor (MP).
Green Normal inputs and outputs +24V
The external communication LEDs are blinking when
Yellow 11,12 Speed reduce limits 0V transmitting data in one direction and is lit when data is
transmitted both ways. The MP LED must always be lit.
Yellow 17,18 Speed reduction switches +24V
Software
Red Limit switches, low pressure, 0V Sw before LED No means the software (orange means
slack wire and overload that the motion is blocked).
SC Supervisory Ho Hoisting
CC Card MC Card
LED Plinth LED Plinth
Signal Description Signal Description
No No No No
07 Overload test 107 07 Hoisting, input 207
08 Rigging mode 108 08 Lowering, input 208
Hardware 09 Parking of jib 109
Hardware
09 Low speed, input 209
324 1670-901
10 110 324 1665-901 10 High speed, input 210
11 Mode A (Container) 111 11 Speed reduce hoisting 211
12 Mode B (Grab) 112 12 Speed reduce lowering 212
13 Mode C (Hatch C.) 113 14 Limit switch hoisting 214
16 116 Sw14/15 Speed reduce, stop, block
17 Pump Unit 1/ RBTS 117 15 Limit switch lowering 215
18 Pump Unit 2 118 17 Speed reduction, ext1 217
19 119 18 Speed reduction, ext2 218
20 120 19 Low pressure switch 219
26 Run enable in 126 20 Overload switch input 220
27 Run enable out 127 Sw20 Overload load cell/pressure
28 Alarm (error in CT2) 128 26 Run enable in 226
29 Ready to run 129 27 Run enable out 227
Indication Speed
30 Twin not synch. 130 29 229
reduce/stop
31 131 30 Hoisting brake, output 230
32 132 31 Low speed, output 231
33 133 32 High speed, output 232
34 134 33 Pump1 hoisting, output 233
35 135 34 Pump1 lowering, output 234
36 136 36 Pump2 hoisting, output 236
37 137 37 Pump2 lowering, output 237
38 Brake Failure lamp 138 39 239
39 139
40 140 40 240
49 149 43 243
51 151 45 245
53 153 49 Angle Check Cam 249
56 Twin on 156 51 251
57 Calibration 157 52 252
58 Twin reset 158 53 VFD Run enable out 253
59 159 54 254
60 Em. op. request 160 55 Indication Overload 255
61 Em. op. activated 161 56 Slack wire 256
24 V Power supply +24V Sw56 Slack wire from LU
Software
C1 CAN1 (ALM) Sc_C1 Software
CC3K H01_00
57 Brake Open Indication 257
CC3K H01_00
Rev B
C2 CAN2 (Cabin display) Sc_C2 Rev B 58 Ext stop 1 258
C3 CAN3 Sc_C3 59 Ext stop 2 259
C4 CAN4 Sc_C4 C1 CAN1 (VFD) Ho_C1
R1 RS485_1 (Remote) Sc_R1 C2 CAN2 Ho_C2
R2 RS485_2 (Twin) Sc_R2 R1 RS485_1 Ho_R1
R3 RS485_3 Sc_r3 MP Internal communication
MP Internal communication
Page Date
SIGNAL OVERVIEW 2 (2) 2010-08-25
No Revision
Crane Control System CC3000 C
424 0738
LEDs - 24V Input/Output signals are indicated with coloured LEDs

.Colour Indicating LEDs on External communication
when LEDs within the COM box are external communication and
communication with Main Processor (MP).
Green normal inputs and outputs +24V
The external communication LEDs are blinking when
Yellow 11,12 speed reduce limits 0V transmitting data in one direction and is lit when data is
transmitted both ways. The MP LED must always be lit.
Yellow 17,18 Speed reduction switches +24V
Software
Red limit switches, low pressure, 0V Sw before LED No means the software (orange means
slack wire and overload that the motion is blocked).
Lu - Luffing Sl - Slewing
MC Card MC Card
LED Plinth LED Plinth
Hardware Signal Description Signal Description
324 1665-901
No No Hardware
No No
07 Luffing in, input 307 324 1665-901 07 Left, input 407
08 Luffing out, input 308 08 Right, input 408
11 Speed reduce luffing in 311 11 Speed reduce left 411
12 Speed reduce luffing out 312 12 Speed reduce right 412
14 Limit switch luffing in 314 14 Limit switch left 414
Sw14/15 Speed reduce, stop, block Sw14/15 Speed reduce, stop, block
15 Limit switch luffing out 315 15 Limit switch right 415
17 Speed reduction, ext1 317 17 Speed reduction, ext1 417
18 Speed reduction, ext2 318 18 Speed reduction, ext2 418
19 Low pressure switch 319 19 Low pressure switch 419
20 Overload switch input 320 20 320
26 Run enable in 326 26 Run enable in 326
27 Run enable out 327 27 Run enable out 327
29 Indication Speed 29
329 329
reduce/stop
30 Luffing brake, output 330 30 Slewing brake, output 430
31 Unloading, output 331 31 431
32 32 432
33 Pump1 luff in, output 333 33 Pump1 left, output 433
34 Pump1 luff out, output 334 34 Pump1 right, output 434
36 Pump2 luff in, output 336 36 Pump2 left, output 436
37 Pump2 luff out, output 337 37 Pump2 right, output 437
39 339 39 439
40 340 40 440
43 343 43 443
45 345 45 445
49 Angle Check Cam 349 49 Angle Check Cam 449
51 351 51 Remote on 451
52 352 52 452
53 VFD Run enable out 353 53 VFD Run enable out 453
54 354 54 454
55 Indication Overload 355 55 455
56 Slack wire 356 56 456
57 Brake Open Indication 357 57 Brake Open Indication 457
Software 58 Ext stop 1 (Jack knife) 358 Software 58 Ext stop 1 458
CC3K H01_00
CC3K H01_00 59 Ext stop 2 (High hook) 359 Rev B 59 Anti-collision off (stat) 459
Rev B
C1 CAN1 (VFD) Lu_C1
C2 CAN2 Lu_C2 C1 CAN1 (VFD) Sl_C1
R1 RS485_1 Lu_R1 C2 CAN2 Sl_C2
MP Internal communication R1 RS485_1 Sl_R1
MP Internal communication
Page Date
ERROR MESSAGES 1(2) 2010-08-25
No Revision
424 0739 D
Error message codes from CC3000 LED flashing New error, not acknowledged
If the error from the CC3000 has no influence on the
performance of the crane the control system error lamp LED on Error remains, now acknowledged
in the drivers cabin will not flash. LED off No error present at the moment
With the crane still running, the following steps are
necessary to obtain the error code(s). The display returns to normal mode (Sc, Ho, Lu, Sl, Cl, Au,
Open the control system cabinet and look for the Sc-card Ec, Tl, Tr, Li, Io) fifteen seconds after one of the three
(the lestmost card in the rack). LED 28 is now flashing. Then buttons was last pressed, or holding on pressing
look for the card with the flashing LED error MP or error Down/Exit button longer than one second.
SP on top of the cards.
If the system is restarted (i. e. 24V power supply is switched
Green LED 28 on the Indicate error status in the off for a short time) all alarms disappear and only reappear
Sc-card whole system (All cards) when the error recurs.
Red LED Error MP Indicate error status from MP How to see the remaining errors after acknowledging (i.e.
in the local card error LED is always on)?
Errors can show again from normal mode when pressing
Red LED Error SP Indicate error status from SP
Select/Info twice.
in the local card
Pressing Up or Down/Exit button to see the previous
Push the Select/Info button once on the card with error respective next error, following the same instruction above.
LED flashing. An error code (e.g. E51_11) is shown on the
display on the card.
Hold on pressing Select/Info button, the description of Hardware
324 1670-901
Hardware
324 1665-901
Hardware
324 1665-901
Hardware
324 1665-901
this error will be rolling on the display. Release the button,

the description disappears and the error code is shown. Encoder
Calibration
Continue to press Select/Info or Down/Exit button once Error MP SP
to see the next error and so on.
Pressing Up button once to show the previous error and
so on.
When there are no more error messages, the display shows
three hyphens ---. When all errors have been shown on
the display, the error LED is either on or off.
Display
All errors can be shown round and round if you continue
pressing Select/Info or Down/Exit button or Up
button. Select/Info
button
Up
Software
CC3K H01_00
Rev B
Software
CC3K H01_00
Rev B
Software
CC3K H01_00
Rev B
Software
CC3K H01_00
Rev B
Down/Exit
Note!
Before reporting to MacGREGOR (SWE) AB in rnskldsvik, please look for the error code in the display of the MPC-
card and use the select/info button to view all error codes. It is essential that all faults to be corrected to allow the
crane to function correctly.
Error Error Description 24 01-04 24 supply voltage error
code sub-
Check 24V supply
code
30 01 Joystick level, which should normally be 1.25 to 11.75 V.
01 01-11 System errors Check connection to joystick
Contact MacGREGOR(SWE) AB rnskldsvik Check switches/cam in joystick
12 System Software version missmatch Measure potentiometers in joystick
Check the software version in the cards
02 Joystick logic error for Lowering, Luffing Out or
02 01-61 MC or CC card errors Slewing Right movement. Check according to 30_01.
Restart system or replace the card
03 Joystick logic error for Hoisting, Luffing In or
Contact MacGREGOR(SWE) AB rnskldsvik
Slewing Left movement. Check according to 30_01.
03 01-91 Safety processor errors
04 Joystick is not in zero position when system starts.
Check according to 30_01.
10 10 MEM card errors
31 01 Angle encoder communication error
Replace the MEM card
Check angle encode connection
Replace the angle encoder
11 01-30 Parameter errors
Page Date
ERROR MESSAGES 2(2) 2010-08-25
No Revision
Crane Control System CC3000 D
424 0739
02 Angle shaft coupling 41 Weght: Loadsystem change to main

Check angle encoder connection 42 Weght: Loadsystem change to whip
Replace the angle encoder
35 01-02 MC card temperature is too high
03 Angle encoder or speed encoder error Power off system
Replace the angle encoder or speed encoder Contact MacGREGOR(SWE) AB rnskldsvik
03-05 Temperatur Low limit, High1 limit, high2 limit
04 Angles at CAM control place mismatch.
Check angle encoder cable and connection 37 01-06 Limit error at stop cam (hoist stop cam, lower stop cam,
Replace a new angle encoder in stop cam, out stop cam, left stop cam, right stop
Calibrate encoder again. cam)
Contact MacGREGOR Cranes in rnskldsvik Check stop cam connection or switch
05 Shaft not connected 10 Limit: Software limits
Angle encoder on Lu has different angle with other 21 Limit: Anticollision static
11
angle encoders (depend on parameter) (Only on Sc- 22 Limit: Anticollision dynamic
card). 38 01 Run enable: No input on X26
See above. 02 Run enable: X26 is always set
12 Angle encoder on Sc has different angle with other 39 01-02 Low feed pressure
angle encoders (depend on parameter) (Only on Sc-
card). 49 01-05 External analog in(AI1, AI2, AI3, AI4, AI5) errors
See above. Check cable, connection
13 Speed encoder on Sc has different angle with other Check encoder
angle encoders (depend on parameter) (Only on Sc- Replace the MC or CC card
card). 50 11,21, Displacement open circuit (Low speed, high speed,
See above. 31,41 unloading)
32 01 No data from speed encoder Check cable and connection
Check speed encoder cable and connection
12,22, Displacement short circuit (Low speed, high speed,
Replace a new speed encoder
Exchange card place. 51 32,42 unloading)
Check output cable is not connected to 0V(ground)
Check the brake opens when it shall open.
Replace the MC or CC card
03 Wrong speed direction
13,23, Displacement transistor (Low speed, high speed,
Change speed encoder direction or shift cable
33,43 unloading)
connection (switch A and B)
Check cable and connection
Replace a new speed encoder
Replace the MC or CC card
Exchange card place.
Contact MacGREGOR Cranes in rnskldsvik 24 Displacement: High speed valve
05 Following error from 32_01 or 32_03 depends on 34 Displacement: No plussing pressure

parameters
11 Brake open circuit
See E32_01 or E32_03
Check according to code 50_11
33 01 Weight: loadcell
12 Brake short circuit
Check loadcell cable and connection
52 Check according to code 50_12
Replace the loadcell
Contact MacGREGOR(SWE) AB rnskldsvik 13 Brake transistor
02 Weight: pressure Check according to code 50_13
01-04, PWM current
03 Weight: Loadcell Check
05, (Pwm1 LOR, Pwm2 LOR, Pwm3 LOR, Pwm4 LOR, Pwm0
04 Weight: Torque 11-14 LOR, Pwm1 HIL, Pwm2 HIL, Pwm3 HIL, Pwm4 HIL)
07 Weight: Load system, in EO Check that PWM output is not connected to
0V(ground)
11 Weight Difference Loadcell
Check that cable is not broken
12 Weight Difference Pressure Replace the MC or CC card
13 Weight Difference Loadcell check 55 04 Stab winch: Broken wire
14 Weight: Diffeerence Torque
62 01-02 Twin: No data or error in Slave Crane
31 Weight: Outreach, angle Lu
10-24 Twin: Angle errors
32 Weight: Outreach, angle Sc
33 Weight: Outreach, angle Sc speed 99 01 Test: Larm
37 Weight: Outreach, in EO
SERVICE 6.305.16 E rev.: - 2008-10-30
Electrical Equipment, General Maintenance
Introduction
General maintenance of the electric equipment of the
crane is important in order to prevent unexpected
breakdowns. The following general advice may be
useful. Relevant block diagrams and detailed circuit
diagrams can be found in section 9, SPARE PARTS.
Start the crane and try out all combinations of

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

components. Any defective component must be repai-
red or replaced without delay. A detailed inspection
and overhaul at two-year intervals is recommended.
Check that all screws and nuts are securely tighte-
ned in the contactor cabinets, that all switches and
pushbuttons operate correctly, and that cable
connections are perfectly tight and all insulating parts
intact. Make sure that inspection door gaskets seal
perfectly.
Fig. 1. Electrical equipment cabinet.
Danger!
Electrical equipment can be alive unless the main
switch and the separate supply is disconnected.
- Clean contacts, insulating parts, cams, contact
Earth connection, hull rolls, and rotary potentiometers.
- Make sure that all cable connnections are clean
Verify that the protective earth connection of the crane
and securely tightened.
is made to the ships hull.
- Clean the control levers, and grease their sliding
Clean contact surfaces, when required.
surfaces.
- Check on the return springs and grease lightly so
Earth connection, crane that no grease transfers to the contacts.
Check crane system earth connections, and clean
contact surfaces as required.
Jib light
Make sure that connections in the junction box are
Portable control boxes (Optional) clean and well tightened.
Control panels and remote control boxes may be
subjected to abuse an abnormal wear, and should be - Remove moisture and dirt.
inspected after every use. The control boxes must - When necessary, clean contact surfaces of termi-
be stored in a compartment that is well protected nal strips and of lamp holder.
against moisture. Remove moisture that may have - Make sure that lamp holder gasket seals correctly.
collected in the boxes, and find out how it entered. - Make sure that the work light can be rotated.
1 (2)
SERVICE 6.305.16 E rev.: - 2008-10-30
Slip-ring unit
Danger!
Before opening the slip-ring unit, make sure that
power supplied by separate transformers is switched
off in the ship's engine room. Also check by means of
a voltmeter that the slip-ring unit is not alive.
- Verify that slip ring contact surfaces are smooth

and even, clean as required.
- Check contact pressure of brushes.
- Replace carbon brushes or entire slip ring
assemblies as required.
- Make sure that cable connections are securely
tightened.
- Make sure that rocker arm mounting screws are
securely tightened.
The removal and installation of the slip-ring unit is the

subject of a separate description.
Oil thermostats
BT 2
The task of the oil thermostat is to protect the crane
against overheating.
Verify that the thermostat is set to +85oC, and that it

functions correctly. The thermostat is placed on the
oil filter outlet line.
BT 3 (Optional)
The task of the thermostat is to start the oil cooler
when the oil reaches +45oC when crane is set to winter
position.
Verify that the thermostat is set to +45oC, and that it

functions correctly. The thermostat is placed on the
oil filter outlet line.
2 (2)
SERVICE 6.307.14 E rev.: - 2003-02-19
Slip-Ring Unit
The function of the slip-ring assembly may not be

Danger! changed in any way. Especially safety devices must
Before opening the slip-ring unit, make sure that not be made ineffective. Other than during mainte-
power supplied by separate transformers is nance and inspection work the housing must always
switched off in the ship's engine room. Also check remain closed.
by means of a voltmeter that the slip-ring unit is not
alive. Make sure that the current can not be Use only insulated tools and original spare parts.
switched on again during the maintenance
operation. No responsibility will be assumed for damage to
property or injury to persons caused by improper
General use of the slip-ring assembly.
The slip-ring unit is mounted inside the crane house

under the platform.
Work on a slip-ring assembly may only be carried

out by a qualified electrician or by persons under
the supervision of a qualified electrician and only
according to accepted electrical safety procedures.
Connection crane
Slip-ring unit
Mounting screws
Connection box
Connection ship
power Guide pins
Driver
Rubber protection
Note! Must be
tightened.
Fig. 1. Slip-ring unit.
1 (2)
SERVICE 6.307.14 E rev.: - 2003-02-19
Removal Maintenance
1. Park the jib in a suitable manner. Always cut current before accessing the collector
2. Disconnect the ship's power supply at all points for inspection or maintenance. Make sure that the
of feed. current can not be switched on again during the
3. Disconnect all the cables connection from crane- maintenance operation.
and ship supply.
4. Remove the driver. Note the cables' mounting At regular intervals
sequence.
- Check collector for damaged parts
5. Remove mounting screws holding the slip-ring unit
- Check contact pressure of brushes
to the platform. See Fig. 1.
- Check brush holders
6. Remove the slip-ring unit.
Any extra equipment such as extra limit switches Carbon brushes

fitted on top of the slip-ring unit are removed prior to - The carbon brushes must never wear down so
removal of the entire slip-ring unit. far that metal parts of the brush holder come into
contact with the slip-ring.
The carbon dust is to be removed with dry, oil
Installation free, compressed air or with a vacuum cleaner.
No substance containing oil or grease may come
Clean all contact surfaces between slip-ring unit and into contact with the brushes or the slip-rings.
platform. Tighten all screws properly. See instruc-
tion "Tightening torque". Wire brushes
- Check wire brushes.
- Assemble the slip-ring unit under the platform.
Debris caused by wear is to be removed with dry,
- Assemble the driver to the bottom of the
oil free, compressed air or with a vacuum cleaner.
foundation.
Afterwards the slip-ring ways and wire brushes
- Remove the cover around the slip-ring unit.
should be lightly sprayed with "Cramolin B" or
- Fit the slip-ring unit guide pins to the driver's slot- equivalent contact spray.
ted holes by pulling apart the driver and lock it
with help of the through bolt.
- Install the cables against the driving bar. Others
- Connect the crane cables from the crane in cor- - Check tightness of electric and mechanical
rect mounting sequence. fasteners.
- Remove the connection box plates. - Check gaskets and cable glands for tightness.
- Connect the cables to the plinths.
Keep grease and oil products away from the plastic
After installation insulating parts in the collector.
- Check tightness of all electric and mechanical

fasteners regularly for the first working period.
- Check alignment. The slip-ring unit must not be
allowed to slope in relation to the driver.
- Rotate the crane to ensure that no mechanical
side forces are transferred to the unit.
- Tighten the rubber protection , see Fig. 1.
2 (2)
SERVICE 6.311.12 E rev.: - 2008-09-03
Oil Level Float Switch and Overheating Protector
Introduction
To prevent operation of the crane with too little oil in
the hydraulic oil tank, an oil level guard is installed in
the oil tank, see Fig. 1. The level float switch controls
an alarm lamp on the control panel and a siren. A
FLOAT SWITCH key switch is placed on the control
panel to select different modes depending on oil level
in hydraulic oil tank. See Fig. 2.
LOW OIL LEVEL lamp
FLOAT SWITCH key switch
Fig. 1. Oil level float switch. Fig. 2. Control panel in cab.
1 (4)
SERVICE 6.311.12 E rev.: - 2008-09-03
Normal oil level

Normal oil level is between marks MIN and MAX and MAX
LOW OIL LEVEL warning lamp is off. Key switch
FLOAT SWITCH must be in position "0". See Fig. 3.
MIN
Low oil level

A low oil level should be attended to as soon as
possible. Certain emergency measures may be under-
taken as described below. Fig. 3. Normal oil level.
MAX
Oil level MIN
If the oil level drops to MIN, the float activates the
upper switch and lamp LOW OIL LEVEL goes on. At MIN
the same time, the siren sounds. See Fig. 4.
Oil level MIN, continued operation

In an emergency, the operation of the crane may be Fig. 4. Oil level MIN.
continued for a short time if there is no important leakage
of oil. In this case, turn key switch FLOAT SWITCH to
MAX
position "1"; the siren will then be silent and lamp LOW
OIL LEVEL goes out. See Fig. 5.
MIN
Note!
Operating crane when oil level is below MIN can cause
damage to crane equipment.
Fig. 5. Oil level MIN, continued operation.
Oil level below MIN

MAX
When the oil level has dropped a certain distance below
MIN level, the float activates the lower switch and stops
the crane. LOW OIL LEVEL lamp goes on. See Fig. 6.
MIN
Oil level below MIN, emergency operation

In an extreme emergency (e.g. if the crane has stopped
with a load suspended on the hook) the crane can be
Fig. 6. Oil level below MIN.
started again and operated if key switch FLOAT
SWITCH is turned to position "2". The lamp LOW OIL
MAX
LEVEL goes on and the alarm siren sounds. This is
permitted if no important leakage is present, but is entirely
at the risk and responsibility of the crane operator
MIN
or the officer who gives the order. See Fig. 7.
Fig. 7. Oil level below MIN, emergency operation.
2 (4)
SERVICE 6.311.12 E rev.: - 2008-09-03
Testing oil level float switch

The float of the level float switch is fitted with a built-
in magnet which makes a control circuit when the oil
level drops below certain levels. The function of the
float is preferably tested when performing oil changes
or tank cleaning. For the purpose of this test, the main HIGH OIL TEMP lamp
switch will have to be temporarily switched on.
Overheating protector
The crane stops automatically when the oil tempera-
ture exceeds 85C. The overheating protector is fitted
on the inlet line of the oil cooler. An alarm lamp HIGH
OIL TEMP on the control panel lights when oil tempera-
ture is more than 85C, see Fig. 8.
Fig. 8. Right-hand control panel.
3 (4)
SERVICE 6.311.12 E rev.: - 2008-09-03
4 (4)
SERVICE 6.320.367 E rev.: b 2011-05-12
Limit Switches in Hoisting and Luffing Winch Systems

CC3000
General High hook (optional)
The movements and outreaches of the crane jib and This function prevents the jib from mechanical
hoisting block are controlled by limit switches in the touching of the hook block when luffing out, see
limit switch boxes. At large outreaches there is a risk page 6. If the crane is equipped with high hook,
that hook block and jib top will meet and that is taken values for outreaches for both luffing and hoisting
care of by crane's safety system, see page 7 and 8. winches can be found in tables in instruction
Some cranes are equipped with extra limit switches "Tecnical Data", section 2.
to prevent this, see paragraph "High Hook (optional)".
Limit switches
The limit switches of the hoisting and luffing winches

are contained in limit switch boxes in the cranehouse,
one box for each winch system. Every switch function
is set separately by means of a rotating cam which
controls a microswitch. The cams are driven by the
winches through gearboxes.
The limit switch system performs the following func-

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

at chosen safety limits.
2. Speed reduction - the speed of a hook or jib move-
ment is reduced to 25-30% at a predetermined
point before the stop position is reached.
3. Position control function - the jib working radius
and the level of the crane hook are controlled in
relation to each other.
The limit switch boxes of the hoisting and luffing Limit switch box,
luffing winch
winches are similar except for the demultiplication
ratios of their driving gearboxes. Limit switch box,
hoisting winch
The cams in the luffing winch limit box are marked
BL1, BL2, BL3 etc.; those of the hoisting winch box,
BH1, BH2, BH3 etc.
Fig. 1. Limit switch boxes in crane house.
1 (10)
SERVICE 6.320.367 E rev.: b 2011-05-12
Setting limit switches
Back off the lockscrews of the switch cams in the li-

mit switch boxes, using a 10 mm articulated wrench;
the cams are then easily rotated to their proper
settings.
H
- Use the cam end as measure line when setting the H

K
cam(s), see Fig. 2 and 3. The measure between
each hole is 5.
Jib radius
- Set the cam(s) according to the table in instruction
"Tehnical Data", section 2.
K
Measure line Jib radius
5
Adjustment screw
Fig. 4. Jib radius lifting height.
30 55 Measure references
The following measures are stated in the document

"Technial Data" in section 2, Technical Description.
Lock screw
Jib radius, Max. (m)
Jib radius, Min. (m)
Jib radius, High hook (m)
Fig. 2. Cam. Force limitation for parking position (m)
Lifting height, H (m)

Lifting height, K (m)
Lifting height, High hook (m)
Center line
Note that the jib radius measures refer to the crane

5
house slewing centre (Not to the jib bearing centre!).
Measure line Measure line
The measures H and K refer to the jib bearing centre.
Adjustment Adjustment
screws screws
100 245 Setting outreaches and hook position by

measuring on winches
- AT and BT - luffing winch

- AL and BL - hoisting winch
Lock screw AT, BT, AL, and BL measurements should be taken

on the front side of the winch.
Fig. 3. Cam.
2 (10)
SERVICE 6.320.367 E rev.: b 2011-05-12
AT and AL measures (wire lock side), - from the Limit switches - Luffing winch
side of the empty drum flange side to the side of the
wire, see Fig. 5 and 6. The included limit switches are shown in the below
figs. Note that switches BL2 and BL4 actuate speed
BT and BL measures - second layer, from the side reduction of the crane jib.
of the full drum flange side to the wire, see Fig. 5
and 6. Note! When adjusting the luffing limits it is important
to start with BL1 and to continue according to Fig. 8.
Values of AT, BT (luffing) and AL, BL (hoisting) can For measurement values see table "Basic limit
be found in instruction "Technical Data", section 2, switches" in Technical Data.
see tables for hosting and luffing winches.
When changing wires it is important that the proce-
dure in instruction "Replacement of Wires" in section
6.2 is followed, thus to avoid readjustments of limits.
AT - Empty drum flange side/

Stop lowest position/
At least three locking turns
BL1
Wire lock side BT - Full drum flange
side/second layer BL2
BT BL3
AT
BL4
BL5
BL6
BL7
~
~ ~
Fig. 5. Luffing winch outreaches.
BL13 ~
BL14
BL15
AL - Empty drum flange side/
At least three locking turns/Tank top BL16
BL - Full drum flange

side/second layer Wire lock side
Fig. 7. Limit switch box on the luffing winch.
BL
AL
Fig. 6. Hoisting winch, hook position.
3 (10)
SERVICE 6.320.367 E rev.: b 2011-05-12
Basic limit switches - luffing winch

For setting values see "Technical Data", section 2.
After the cam settings are done, retighten the lock

screws and operate the luffing movements to check
all cam settings on the luffing winch. Begin at mini-
mum jib outreach and luff out to maximum jib outreach.
Measure of the "Distance MV", see Fig. 9.
Min. jib outreach BL5 Measure of the "Distance MV".
BL4 Speed reduce, luffing in
BL2 Speed reduce, luffing out
BL3 Max. jib outreach
BL6 Force limitation for

parking position
BL1
C (m) A - Jib parking position

(Stop lowest position -
C spr (m) B spr (m)
at least three locking
turns.)
B (m)
D (m)
Fig. 8. Luffing winch limit switches.
= Max. jib outreach. To by-pass this position,

correct operation mode has to be selected by
= Force limitation for parking position. help of the key switch "Parking of jib" in cabin.
= Speed reduce. = Stop position.
4 (10)
SERVICE 6.320.367 E rev.: b 2011-05-12
Measurement of the minimum jib outreach,

CC3000
See also instruction 6.303.48 E.
Center line of crane house
MV
(m
m) First jib stay
Measure of
the distance MV
Center line of jib profile

(calibration point)
There must be a distance

between the front of the
crane house and the first jib stay.
Fig. 9. Crane house top.
5 (10)
SERVICE 6.320.367 E rev.: b 2011-05-12
Limit switches - hoisting winch

BH1
For setting values see "Technical Data", section 2. BH2
Raise the jib into the MIN Jib radius position, which is BH3
the correct jib position for setting the limit switches BH4
according to the below figures. Note that the switches
BH5
BH2 and BH3 actuate speed reduction of the crane
hook. BH6
After cam settings are done, retighten the lock screws

and operate the hoisting movements. Lower the lifting
block until empty drum limit is reached and then hoist
the lifting block until full drum limit is reached and Fig. 10. Limit switch box on the hoisting winch.
check the cam settings.
BH 4 Full drum limit, stop position.
BH3
BH 3
Speed reduce,
full drum H spr (m)
H (m)
Speed reduce,
empty drum K spr (m)
K (m)
BH 2
Empty drum limit, stop position.

BH1 At least three locking turns or tank top.
Speed reduce
= Stop position.
Fig. 11. Hoisting winch limit switches.
6 (10)
SERVICE 6.320.367 E rev.: b 2011-05-12
Limit switches, high hook (optional) *)

Speed reduce, luffing out BL(X)
Max. jib,
For setting values see "Technical Data", section 2. stop limit
BL(X) *)
Note! Not all cranes are equipped with the function
high hook. If the crane is equipped with high hook,
values for outreaches for both luffing and hoisting
winches can be found in tables in instruction "Tecnical
Data", section 2.
E spr (m)
This function prevents the jib from mechanical
E (m)
touching of the hook block when luffing out.
*) If high hook is applicable then BL7 and BL8 are used.
Limit switch BH5 (speed reduce switch, hoisting) takes NA = High hook is not applicable.
care of the area . See Technical Data, section 2.
Speed reduce.
Limit switch BH6 (detector switch) takes care of the
area and gives signal to BL8 (stop cam, luffing) Stop. To by-pass those positions correct operation
mode has to be selected by help of the key switch
if the hook block is in the wrong area. in cabin.
There is no stop function on the hoisting winch. Fig. 12. Extra luffing limit switches, high hook.
Detector switch BH6 prevents the jib from mechanical
touching of the lifting block.
Full drum 500 mm
BH4
F ds - Detector switch
ib E (m) BH(X)*)
c/c j Note! To be set
Stop limit at maximum
F spr (m)
outreach (BL3),
BH(X) *) luffing winch.
Speed reduce switch
towards jib top
*) If high hook is applicable

then BH5
and BH6 are used.
Max. R NA = High hook is not applicable.
See Technical Data, section 2.
Fig. 13. Extra hoisting winch limit switches, high hook.
7 (10)
SERVICE 6.320.367 E rev.: b 2011-05-12
Jib top and hook block functions at large

outreaches
Note! If the crane is equipped with a high hook The cranes are designed, calculated and manufac-
function, this is not applicable. tured in accordance with and approved by classifica-
tion societies.
In a certain area there is a possibility that hook block
and jib top will meet. See Figs. 14 and 15. This will A slacking luffing or hoisting wire rope should stop
not cause any problem as the cranes safety system the luffing out and hoisting movements by use of the
takes care of it. slack wire switch BWL1.
It is only possible for the hook block to reach jib top at Hook block hoisting the jib:
large outreaches. - This actuates the slack wire switch BWL1 and the
hoisting movement stops.
The hook block and the crane jib is designed and
calculated to take care of the forces which occur when Jib landed on the hook block:
the hook block is hoisting the jib top or the jib top - Luffing wire slackens and the slack wire switch
lands on the hook block. BWL1 actuates. The luffing out movement stops.
At small outreaches the full drum limit, BH4, on the

drum will be in operation.
Area for large outreaches where hook block

and jib top will possibly meet.
Fig. 14. Large outreaches.
8 (10)
SERVICE 6.320.367 E rev.: b 2011-05-12
Hook way (full drum) limit BH4
Lifting height
H (m)
Block touches
jib top
jib
c/c
Jib bearing
centre Outreach (m)
Min. jib Max. jib

outreach outreach
Fig. 15. Hook way.
Hook stop
Hook stop
Fig. 16. Jib top.
9 (10)
SERVICE 6.320.367 E rev.: b 2011-05-12
10 (10)
SERVICE 6.321.13 E rev.: a 1999-11-23
Slack Wire Safety Switch Hoisting and Luffing Winches
Function Functional test, luffing

A slacking luffing or hoisting wire rope shall stop the Run the hoisting wire block/swivel slowly against the
respective winch movement before the spooling of jib top and lift the jib, to cause the luffing wire to
the rope on the drum has been damaged. The slacken. The hoisting winch shall then stop. Some
adjoining figs. show the arrangement of the wire sen- cranes are equipped with safety switches to prevent
sing device with built-in switch. When the wire slack- the block from touching the jib. This safety switch must
ens, the spring-loaded pressure roll forces the wire be made inoperative. Lower the hoisting wire block/
towards the wire drum, at the same time swinging swivel so that the luffing wire rope is taut. Check that
the arm to actuate the built-in switch. The pump the switch returns properly.
returns to zero and the winch stops.
The slack wire function is approved as long as the Note! The slackwire device is not designed to detect
wire is spooling properly on the drum. slack in the rope at the position of the lifting block. It
will only detect slack at winch.
Functional test, hoisting The lifting block may lay flat on the ground/deck and
the slack wire device may still not be activated.
Lower the hook block on to the deck to slacken the
hoisting wire rope. Hoist the hook in order to check
This is most evident at minimum outreach. In these
that the switch returns properly.
cases there will probably never be a slack at the winch
and therefore never an automatic stop of the lowering
motion.
Wire rope slack

Wire rope
Switch
Arm
Slack wire safety switch. Normal condition. Slack wire safety switch. Slack wire condition.
1 (2)
SERVICE 6.321.13 E rev.: a 1999-11-23
2 (2)
SERVICE 6.324.1 E rev.: b 2010-11-02
Preparation for Overload (OL) Test Mode
WARNING!
Overload test is only permitted when requested by
the classification society. A classification surveyor
must be present during the overload test. Key switch
Note! The surveyor has to fill in and undersign the
form on page 2.
WARNING! Error
Input
07 18
08 19
09 20
10 26
11 49
12 51
13 56
14 57
15 58
16 59
MP SP
Output
27
28
29
30
31
32
33
34
35
36
Error
07
08
09
10
19
20
11
Input
31
32
Sw19
MP
33
39
34
40
30
Sw20 55
14 Sw14
56 Sw56
SP
Output
36
43
37
45
Error MP
07
08
09
10
19
20
11
Input
31
32
Sw19
33
39
34
40
30
Sw20 55
14 Sw14
56 Sw56
SP
Output
36
43
37
45
Error
07
08
09
10
19
20
11
Input
31
32
Sw19
MP
33
39
34
40
30
Sw20 55
14 Sw14
56 Sw56
SP
Output
36
43
37
45
Error
07
08
09
10
19
20
11
Input
31
32
Sw19
MP
33
39
34
40
30
Sw20 55
14 Sw14
56 Sw56
SP
Output
36
43
37
45
17 60 37 12 15 Sw15 12 15 Sw15 12 15 Sw15 12 15 Sw15

24V 38 26 27 26 27 26 27 26 27
Com 39 58 59 58 59 58 59 58 59
During the overload test the load limits increase and

40 49 17 29 49 17 29 49 17 29 49 17 29
53 51 18 53 51 18 53 51 18 53 51 18 53
61 52 54 52 54 52 54 52 54
57 57 57 57
Com Com Com Com
the crane can lift a specified per cent more than the SC
C3
IO
C3
SC Supervisory
A1 C1
HOHoisting
A1 C1
LU Luffing
A1 C1
SL Slewing
A1 C1
AU Auxiliary
A1 C1
IO
A1
Input/Output
C1
HO_C1
SC_C3
SC_C1
AU_C1
LU_C1
SL_C1
IO_C3
IO_C1
HO_A1
SC_A1
AU_A1
LU_A1
SL_A1
IO_A1
safe working load. Inappropriate use may cause severe C4 C4 A2 C2 A2 C2 A2 C2 A2 C2 A2 C2 A2 C2
HO_C2
SC_C2
AU_C2
LU_C2
SL_C2
IO_C2
HO_A2
SC_C4
SC_A2
AU_A2
LU_A2
SL_A2
IO_C4
IO_A2
485.2 485.2 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1
HO_485.1
SC_485.1
AU_485.1
LU_485.1
SL_485.1
IO_485.1
SC_485.2
IO_485.2
HO_A3
SC_A3
AU_A3
LU_A3
SL_A3
IO_A3
485.3 485.3 Sp SSI Sp SSI Sp SSI Sp SSI Sp SSI Sp SSI
SC_485.3
IO_485.3
HO_SSI
SC_SSI
AU_SSI
LU_SSI
SL_SSI
IO_SSI
HO_Sp
SC_Sp
AU_Sp
LU_Sp
SL_Sp
IO_Sp
damage to the crane and bodily injury.
- Start the crane with pushbutton S13, START/STOP.

Fig. 1. Key switch in cabinet CT2.
- Wait until pilot light H1, "DO NOT OPERATE", goes
off.
- Wait until the display comes on.
- Set the key switch in position OL test. See Fig. 1.
NOTE! The key switch has to be set within 4 minutes
after the pilot light H1 goes off.
- A login window shows on the display. See Fig. 2.
- Write the password to accept overload test mode.
Use the software keyboard on the display.
NOTE! The password is the last four digits of the
manufacturing No., which can be found in the
instruction manual or at the sign in the cabin. The
password must be written within 5 minutes after
the key switch has been turned.
- The display should now show "OVERLOAD TEST" Fig. 2. Login window overload test.
and the diagram for load/outreach should have an
additional red area on top of the normal green area.
See Fig. 3.
- Overload test can now be done refer to MacGregor
Cranes' procedure. Contact MacGregor Cranes for
further information.
NOTE! Motions are speed reduced in overload test

mode. When the test is finished, the crane has to
be stopped to exit the overload test mode.
Fig. 3. Example of display in overload test mode.
1 (2)
SERVICE 6.324.1 E rev.: b 2010-11-02
Overload test report
Cause Date Classification Signatur Clarification of signature
2 (2)
SERVICE 6.324.2 E rev.: - 2010-11-10
Preparation for Rig Mode
WARNING! NOTE! The password is the last four digits of the

When the crane is operated in Rig mode the crane crane's manufacturing No., which can be found in
has no software limits. the instruction manual or on the sign in the cabin.
It is not permitted to have any load in the hook. The password must be written within 5 minutes after
Inappropriate use may cause severe damage to the the key switch has been turned.
crane and bodily injury.
- The display should now show "RIGGING" and the
WARNING! diagram shows only a red line. See Fig. 3.
Operation in Rig mode is only permitted together with NOTE! Motions are speed reduced in Rig mode. To
below intructions: exit Rig mode the crane has to be stopped and the
- Absolute Encoder Calibration, CC3000 key switch must be set to position "Normal".
- Rope Reeving Diagram
- Limit Switches and Software Limits
- Replacement of Wires
Procedure
- Set key switch in position Rig. See Fig. 1.

- A login window shows on the display. See Fig. 2.
- Write the password to accept Rig mode. Use the
software keyboard on the display.
Fig. 2. Login window.

Key switch
Fig. 1. Key switch in cabinet CT2. Fig. 3. Example of display in Rig mode.
1 (2)
SERVICE 6.324.2 E rev.: - 2010-11-10
2 (2)
SERVICE 6.324.3 E rev.: - 2010-10-28
Prevent Operation in High Speed
General Function
In normal operation the hoisting/lowering movement The switch has two positions:
operates in high or low speed. This crane has a - Normal
function that prevent hoisting/lowering in high speed. - Low Spd
A switch is installed inside cabinet CT2 to control this
function. In position "Normal" the crane operator can choose
between high and low speed with the control lever.
Note!
The cabinet CT2 is locked. In position "Low Spd" you can only hoist and lower in
low speed.
Normal
Hardware Hardware Hardware Hardware
314 3603-902 314 3603-902 314 3603-902 314 3603-902
replaces -901 replaces -901 replaces -901 replaces -901
Low
Spd
STEP STEP STEP STEP
07 33 07 33 07 33 07 33
Encoder 36 36 36 36
Calibration 39 39 39 39
08 34 08 34 08 34 08 34
37 37 37 37
40 40 40 40
09 31 09 31 09 31 09 31
30 30 30 30
Normal 10 32 10 32 10 32 10 32
11 14 11 14 11 14 11 14
12 15 12 15 12 15 12 15
13 16 13 16 13 16 13 16
Low
Spd 17
18
19
20
17
18
19
20
17
18
19
20
17
18
19
20
TX 28 TX 28 TX 28 TX 28
42 42 42 42
PROG SET PROG SET PROG SET PROG SET
PROG ON PROG ON PROG ON PROG ON
PC COM PC COM PC COM PC COM
MPC MPC MPC MPC

Software Software Software Software
MGX0401 MGX0401 MGX0401 MGX0401
Rev F Rev F Rev F Rev F
Fig. 1. Switch to prevent operation in high speed, installed in cabinet CT2.
1 (2)
SERVICE 6.324.3 E rev.: - 2010-10-28
2 (2)
SERVICE 6.990.56 E rev.: - 2008-10-16
Emergency Lowering in Case of Complete Power Failure

Operation of Crane Using a Hand Pump (Optional)
Introduction Twin operation

When the cranes are to be used in twin operation the
In the case of a power failure the hoisting, luffing and brakes must be released by using two hand pumps,
slewing circuits of a deck crane may still be operated one for each crane. The necessary crew for this
to a limited extent by releasing their respective brakes operation is two "brake releasers" and one crane
with the utmost care. operator.
The release of the brakes of the hoisting, luffing, and Contact between the two "brake releasers" and the
slewing functions is facilitated by employing a hand crane operator is absolutely essential, e.g. by use of
pump designed for this purpose. Quick couplings and head-sets.
shut-off valves are also installed in the hydraulic
system of the crane for this purpose. All necessary material comprising this emergency
equipment including the hydraulic pressure source are
included in the supply. See Fig. 1.
Connection to quick coupling on

hoisting (1664), luffing (2664) and slewing (3664)
Plug *), to be
used when
emergency
slewing
Gauge 1D
T-coupling to Mp on pump,
hoisting or luffing
Port 3A-B Port 3A-F
Valve 3B Valve 3A
Connection to tank By-pass line Bushing Screw
Fig. 1. Hand pump 1A (optional).
1 (12)
SERVICE 6.990.56 E rev.: - 2008-10-16
Hoisting circuit, see Fig. 4 and 5

Ms (gauge Hoisting pump 1111
connection 3.1)
Mp (gauge
connection 3.2)
CAUTION!
Hose must be connected to Mp-port (gauge connection
3.2) on hoisting pump to avoid uncontrolled lowering.
CAUTION!
Pilot hose - This work has to be done with great care by skilled
(disconnected) personnel.
- Only one function to be activated at the time.
- Verify that nobody is within the working area of the
crane.
3B
- Valves 1663, 2661 and 3661 must not be actu-
By-pass line, included
3A
ated except in emergency brake release operation.
in emergency equipment
Pilot hose
(disconnected) Flush-unloading unit 1128
Ball valve 1663

Pilot hose,
Directional valve 1221 disconnect and plug **)
Connection P
Oil tank
Hand pump 1A
Quick
coupling
4333
Quick
coupling1664
Directional
valve1226
Pilot hose, Wedge valve 4332
disconnect and plug **)
**) Plug to pilot hose and included in pump set.
Fig. 2. Connection of hand pump 1A, hoisting winch.
2 (12)
SERVICE 6.990.56 E rev.: - 2008-10-16
Function
The emergency lowering system works in such a way - Remove check-restriction valve 1241-1 from flush-
that the motor hydraulically controls the load. If the unloading unit 1128, see Fig. 3.
motor tends to overspeed, by the force from the load, - Attach the bushing and screw into coupling in
the brake will close. connection P, flush-unloading unit1128-1. Screw
in the threaded bushing up to the neck, screw to
Hand pump 1A builds up pressue on the low pressure actuate the piston to blocked position. See Fig. 3.
side of the motor and on the brake. The pressure can - Close ball valve 1663 and open wedge valve 4332.
be read on pressure gauge 1D. The brake opens at See Fig. 2 and 4.
approx. 1.2 MPa. Oil from the high pressure side (pump
Ms-port) goes through the needle valve 3B and flow Operation
control valve 3A to the low pressure side (pump Mp-
Release the brake by pumping oil from the hand pump.
port). Valve 3A is fixed and load independent. With a
The load must be lowered slowly and carefully
load in the cargo hook, valve 3B can be completely or
controlled. Speed can be reduced by closing valve 3B,
partially closed in order to reduce the speed.
partially or completely.
Connection, see Fig. 2 and 4 The load must be lowered slowly by pumping in a slow
- Install the hand pump to the base plate using the and even pace.
provided screws.
- Disconnect pilot hoses at Mp- and Ms-port on the Twin operation
pump.
The twin beam must be as horizontal as possible during
- Connect the by-pass line. See Fig. 2 and 4.
emergency lowering.
Caution!
It is of most importance that the hoses to Mp and
Ms are not switched, because the load could be After operation
dropped. After the lowering operation is completed, reset the
- Connect the hoses from the hand pump as shown in crane to "NOT EMERGENCY COUPLED", wedge valve
Fig. 2 and in the hydraulic diagram Fig. 4. 4332 must be closed and ball valve 1663 must be open.
- Disconnect the pilot hose from connection P, flush- See Fig. 2 and 5.
unloading unit 1128. Plug the disconnected hose.
See Fig. 2, 3, and 4.
Check-restriction Connection P
Coupling
valve 1241-1
Pilot hose
Bushing
Screw
Piston
Fig. 3. Flush-unloading unit 1128.
3 (12)
SERVICE 6.990.56 E rev.: - 2008-10-16
Note! Flush-unloading unit 1128

- connection P mec. affected.
3B
3A
Fig. 4. Hydraulic circuit, hoisting. Emergency coupled.
4 (12)
SERVICE 6.990.56 E rev.: - 2008-10-16
Fig. 5. Hydraulic circuit, hoisting. Not emergency coupled.
5 (12)
SERVICE 6.990.56 E rev.: - 2008-10-16
Luffing circuit, see Fig. 8 and 9
Mp (gauge
connection 5.2)
Luffing pump 2111
Gauge
connection
removed
CAUTION!
Hose must be connected to Mp-port (gauge connection
5.2) on luffing pump to avoid uncontrolled lowering.
Ms (gauge
connection 5.1)
Gauge T-connection
connection
removed
3B
3A
Included in Unloading unit 2127
emergency
equipment Connection P
By-pass line
Disconnect and plug
Pilot hose,
disconnect and plug **)
Oil tank
Wedge valve 4332 Quick

coupling
4333
Ball valve 2661 Quick coupling 2664 Hand pump1A
**) Plug to pilot hose and included in pump set.
Fig. 6. Connection of hand pump 1A, luffing winch.
6 (12)
SERVICE 6.990.56 E rev.: - 2008-10-16
Function
The emergency lowering system works in such a way - Remove check-restriction valve 2241-1 from
that the motor hydraulically controls the load. If the unloading unit 2127, see Fig. 7.
motor tends to overspeed, by the force from the load, - Attach bushing and screw into coupling in connec-
the brake will close. tion P, unloading unit 2127. Screw in the threaded
bushing up to the neck, screw to actuate the piston
Hand pump 1A builds up pressue on the low pressure to blocked position. See Fig. 7.
side of the motor and on the brake. The pressure can - Close ball valve 2661 and open wedge valve 4332.
be read on pressure gauge 1D. The brake opens at See Fig. 6 and 8.
approx. 1.2 MPa. Oil from the high pressure side (pump
Ms-port) goes through the needle valve 3B and flow Operation
control valve 3A to the low pressure side (pump Mp-
Release the brake by pumping oil from the hand
port). Valve 3A is fixed and load independent. Valve
pump.The jib must be lowered slowly and carefully
3B can be completely or partially closed in order to
controlled. Speed can be reduced by closing valve
reduce the speed.
3B, partially or completely.
Connection, see Fig. 6 and 8 The load must be lowered slowly by pumping in a slow
- Install the hand pump on the base plate with screws and even pace.
provided.
- Before connecting the by-pass line, remove the Twin operation
gauge connections from Mp- and Ms-port.
The jibs must be as parallel as possible to each
other during the lowering.
Caution!
It is of the utmost importance that the hoses to Mp-
If only the luffing circuit is out of operation, try to lower
and Ms-port are not switched, because the load
the load onto deck or quay with the hoisting winch.
could be dropped.
Remove the twin beam and lower the jib one by one.
- Connect the by-pass line. See Fig. 6 and 8.

- Connect hoses from the hand pump as shown in After operation
Fig. 6 and hydraulic diagram Fig. 8. After the lowering operation has been completed, re-
- Disconnect the pilot hose from connection P, set the crane to "NOT EMERGENCY COUPLED",
unloading unit 2127. Plug the disconnected hose. wedge valve 4332 must be closed and ball valve 2661
See Fig. 6, 7, and 8. must be open. See Fig. 6 and 9.
Check-restriction valve 2241-1 Coupling Connection P
Pilot hose
Screw Bushing Piston
Fig. 7. Unloading unit 2127.
7 (12)
SERVICE 6.990.56 E rev.: - 2008-10-16
Note! Unloading unit 2127

- connection P mec. affected.
3B
3A
Fig. 8. Hydraulic circuit, luffing. Emergency coupled.
8 (12)
SERVICE 6.990.56 E rev.: - 2008-10-16
Fig. 9. Hydraulic circuit, luffing. Not emergency coupled.
9 (12)
SERVICE 6.990.56 E rev.: - 2008-10-16
Slewing circuit, see Fig. 11 and 12
Connection Note!
- Install the hand pump 1A onto the base plate with The brake opens at approximately 1.2 MPa.
the screws provided. See Fig. 10.
- Connect the hoses from the hand pump as shown Warning!
in Fig. 10 and hydraulic diagram Fig. 11.
If the crane is tilted, the brake must be released with
- Close ball valve 3661 and open wedge valve 4332.
great caution. If the speed increases too much, the
See Fig. 10.
brake can be activated by ceasing to pump or opening
ball valve 3661.
Operation
- Release the brake by pumping oil from the hand After operation
pump.
After the slewing operation has been completed, reset
- The crane may now be slewed to a set position
the crane to NOT EMERGENCY COUPLED. Wedge
with the help of another crane. Use caution.
valve 4332 must be closed and ball valve 3661 must
be opened. See Fig. 10 and 12.
Quick-coupling 3664
Ball valve 3661
Wedge valve 4332
Quick coupling 4333
Plug*)
Hand pump 1A
To be plugged at
emergency operation
T-coupling
*) Plug included in pump set.
Fig. 10. Hand pump 1A connected to slewing machinery.
10 (12)
SERVICE 6.990.56 E rev.: - 2008-10-16
Fig. 11. Hydraulic circuit, slewing. Emergency coupled.
11 (12)
SERVICE 6.990.56 E rev.: - 2008-10-16
Fig. 12. Hydraulic circuit, slewing. Not emergency coupled.
12 (12)
CARGOHANDLING EQUIPMENT 7.003.2 E rev.: c 1996-05-22
Cable Winch, Type KFM
a. Function 4. Hydraulic Turbo Coupling

1. General The hydraulic turbo coupling is capable of absorbing
The cable winch is provided for the supply of current up to 100% slip.
to cargo handling equipment. The electric drive motor and the input shaft of the turbo
The cable winch consists of an electric motor, brake, coupling run continuously at the rated speed of the
hydraulic turbo coupling, spur gear, slipring unit and electric motor. When winding up the cable, the output
cable drum (see Fig. 1). Electric cables are connected shaft of the coupling rotates in the same direction as
to the cable drum motor and the slipring unit. The cable the electric motor and input shafts. With the cable drum
drum is driven by the electric motor through the turbo stationary, the turbo coupling output shaft is at rest;
coupling and spur gear. The cable accommondated when the cable is paid out from the cable drum, the
on the drum is connected to the cargo handling turbo coupling output shaft will run in reverse, causing
equipment when in use. The winder maintains cons- the turbo coupling to operate as a pump, braking the
tant tension on the cable throughout cargo operations electric motor.
and prevents unintentional off-reeling if power should This type of operation permits the use of conventional
fail. squirrel-cage induction motor.
The hose pipe pull can be increased by refilling of oil,
and reduced by removing oil.
2. Operation Principle The alteration of the oil quantity is only permitted within
The electric drive motor, which is designed for the limits between the maximum and the minimum
continuous operation, runs constantly at its rated shaft filling.
speed, the slip caused by the cable winch being ta-
ken up by the turbo coupling. The input shaft of the
turbo coupling is driven by the electric motor through Cable drum
a 1:1 V-belt transmission and, consequently, runs at
Gearbox
the speed of the motor. The output shaft of the turbo
coupling delivers motive power through a spur gear Slipring unit
set to the cable drum, which rotates in the same
direction as the electric motor when winding up the
cable. When the cable is paid out, the turbo coupling
output shaft will run in the opposite direction.
Safety plug
3. Brakes
The purpose of the spring actuated disk brake is to
prevent the cable from unwinding when the electric
motor is off. The brake operates in time with the mo- Turbo
tor; i.e. starting the electric motor causes the brake to coupling
be released by the solenoid magnet lifting the spring-
loaded disk off the friction disk. Opening the electric V-belt
transmission
motor circuit will de-energize the solenoid, engaging
the brake. Electric motor Brake
Fig. 1. Cable Winch.
1 (3)
Rather small differences in the oil filling outside the 3. Winch Cable
indicated scope causes great variations of the pulling Remove the drum openside cover, make sure that
force. The turbo couplings are already adjusted in the cable has no twist, introduce it into the drum
the works. through the lead-in, and secure with clamp. Connect
To develop the prescribed output torque, the oil of the phase and earth conductors to slip rings, or to a
the coupling must attain a certain operating tempera- terminal strip. Tighten the lead-in securely and apply
ture, which necessitates continuous operation of the a seawater-resistant sealing compound as required.
drive electric motor. Reassemble side cover.
5. Safety Plug Remove cover and release the brake by pulling the
The operating temperature of the turbo coupling relevant lever; rotate the drum by hand or start the
should not exceed some 85-90 C. A safety plug winch to close, wind the cable on to the drum, adding
affords protection against overheating of the oil and two extra turns for safety.
guards against excessive internal pressure that might
damage the Perbunan seals and cause premature
aging of the oil. The metal filling of the safety plug will N.B.
melt at approx. 140 C, permitting the oil to excape Do not attempt to take up the cable with the brake
from the turbo coupling. engaged.
b. Installation c. Maintenance
1. Cable Winch 1. Brushholders
Before assembling, make sure that the supporting The brushholders are subject to normal wear. They
bedframe is perfectly horizontal and that the shaft of must be replaced when necessary. Always make
the winch drum is at right angles to the direction of certain that the sliprings are clean at all times and
the cable. that there is not a deposit of carbon dust on them
(flashing might occur). The electrical connection to
The power supply, slip rings, and electric motor shall the motor, brake relief and brake must be performed
be connected up by a qualified electrician in by experienced and qualified electricians only.
accordance with the relevant installation regulations.
2. V-Belt, Narrow
The narrow V-belt may be readjusted, if necessary.
2. Power Supply Cable The correct tension is checked by pressing a finger
Introduce the power cable into the slip-ring housing on the belt. If well adjusted, the V-belt should bend 1
through the lead-in bushing, and connect it to the to 2 cm.
brushes. Screw tight and pack the lead-in with a
seawater-resistant sealing compound, if judged 3. Brake
necessary. The brake should be checked for proper function at
regular intervals. When the brake lining is changed
At the end of the running-in period of the brushes, make certain that it is absolutely free from grease
remove all deposits of carbon dust from the inside of and oil. There should be no groves in the brake area.
the slipring housing.
2 (3)
1
4. Electric Motor
2
After about 2000 working hours, the motor bearings
should be refilled with high temperature grease (see
Lubricating Chart).
3
c. Oil Change 3
1. Turbo-Coupling
1. Remove four screws (1), washers (2), and nuts (3)
from protective cover (4) (see Fig. 2). Remove
cover.
2. Remove safety fuse plug (5) and oil filling plug (6) 1
and drain oil into a suitable container (see Fig. 3 2
4
and 4).
3. Install safety fuse plug (5) and oil filling plug (6)
and operate cable winch for a short moment.
Fig. 2. Removing Protective Cover.
4. Remove safety fuse plug (5) and oil filling plug (6)
and drain remaining oil into the container.
Spur Gear.
5. Install safety fuse plug (5) and position oil filling
plug hole in accordance with Fig. 3.
6. Fill oil (see Lubricating chart). The oil level should
just reach up to the filling hole.
7. Install oil filling plug (6).
8. Install protective cover (4) with four screws (1),
washers (2,) and nuts (3) (see Fig. 2).
Note! The pull transmitted by the turbo-coupling can

be increased or decreased, as required, by
increasing or decreasing the amount of oil. Too
much oil will result in unfavorable temperature rise,
the metal in the safety fuse plug will melt, and the
oil will be drained. Too little oil may result in foaming. Turbo-Coupling.
2. Spur Gear Fig. 3. Oil Filling, Turbo-Coupling and Spur Gear.
Note! It is recommended to drain the oil immediately

after stopping the cable winch.
1. Unscrew the oil drain plug (7) and the ventilation

screw (8) (see Fig. 3).
2. Drain the oil.
3. Install drain plug (7).
4. Fill oil (see Lubricating Chart).
5. Install ventilation screw (8).
Fig. 4. Oil Filling, Turbo-Coupling.
3 (3)
EXTRA EQUIPMENT 7.026.6 E rev.: - 2009-01-26
Electric Stabilizing Winch

Function and Rigging of Winch Wire
General Rigging the wire

The purpose of the stabilizing winch is to stabilize the Two persons are required, one in the cabin and one on
load and keep it from rotating. the jib.
- Start the crane.
Function - Pay out the wire from the winch drum with "STAB
WINCH PAY OUT" key switch (Fig. 2) on the control
The tension of the stabilizing wire is constant when the
panel.
crane is running.
- Rigg the wire over the wire sheave on the jib.
- Stop the crane.
- Release "STAB WINCH PAY OUT" key switch.
- Secure the wire on to the hook block or to the power
swivel/grab.
- Start the crane and run the hoisting winch to check
the function.
Stabilizing winch
Power swivel
Fig. 1. Crane with stabilizing winch.
Fig. 2. Key switch in cabin "STAB WINCH PAY OUT".
1 (2)
EXTRA EQUIPMENT 7.026.6 E rev.: - 2009-01-26
2 (2)
7.075.11 E rev.: - 2010-11-10
MacHeavyvisor Release 3.3
General
The MacHeavyvisor software is a part of the

logging and information system delivered by
MacGregor Cranes. The application is installed on
a dedicated display inside the crane cabin.
MacHeavyvisor communicates with the crane
control system (CC3000) via a data communication
cable. The display is automatically started and
stopped when the electric power of the crane
system is switched on/off.
MacHeavyvisor has two main purposes:
- Displays real-time information about current

properties of the crane such as jib outreach,
load in the hook and hoisting speed. Three examples of different cranes and
equipments.
- Log information about crane operations,
allowing future analysis.
Load diagram
The centre part of the screen shows a diagram,
which visualize the current load in the hook and jib
outreach in addition to the text values displayed in
the blue boxes. The current values are indicated
by a white ball with a black circumference. The
areas displayed in the diagram are defined by
CC3000.
A horizontal black line indicates the area with low

speed only.
Note! This view changes depending on the crane's

different load areas and on the extra equipment
delivered with the crane.
1 (6)
7.075.11 E rev.: - 2010-11-10
Icons If an arrow goes yellow the motion is speed

reduced by CC3000.
Standard crane The small white ball on the hoisting joystick

indicates the speed of the hoisting winch. During
GLH crane operating Main operation, the ball will move along the hoisting
Hoist circle, to indicate the direction and movement when
hoisting or lowering. Hoisting is indicated by a
GLH crane operating Whip clockwise rotation and lowering by a
Hoist
counterclockwise rotation.
Crane with ELCCL
Different modes depend on type of crane and

equipment. If there is a mode it shows centered on Ton in hook
top level of the screen.
The current load in the hook. If the value exceeds

The current date and time is displayed in UTC the overload limit the box background will flash in
time. red and an audio warning is also given. The
overload information is indicated by CC3000.
Optional
The MacGREGOR logo is displayed. When Visual warning with or without alarm sound can be
touching the logo, version information will be configured by CC3000 parameter. This warning
displayed. can be set to be triggered between 1-99% of
maximum load (at current outreach). The box will
flash in yellow colour when this warning is on.
If there is no communication with the CC3000

system, the message Disconnected! on the
screen. The current jib outreach
Joystick, hoisting with high and low

speed When reached the limit the box will flash in yellow.
The current
Joystick, hoisting hoisting/lowering speed
The current lifting height

Joystick, luffing/slewing
Above circles represent the joysticks used when

operating the crane. When an operation is not The current
hoisting/lowering speed
permitted by CC3000 a white cross will over cross
together with current
the corresponding arrow. lifting height
2 (6)
7.075.11 E rev.: - 2010-11-10
List When tapping the System Error box below

error log shows.
The list of the ship in degrees. When this value

exceeds an adjustable warning level, the
background in the box starts to flash yellow.
Exceeding the alarm level the background starts to
flash red and an audio warning sounds.
Trim
The trim of the ship in degrees. When this value

exceeds an adjustable warning level, the
background in the box starts to flash yellow.
Exceeding the alarm level the background starts to
flash red, and an audio warning sounds.
ELCCL mode
Jack-knife
When jack-knife limit is reached this icon shows on

the screen.
Standard mode
Buttons to switch different modes.

Anti-collision (optional)
If the crane has anti-collision system an indication

shows the status of the system
Twin platform (optional)
If the crane is a twin crane with anti-collision an

indicator helps the crew to position the twin
platform into single position and operate the anti-
collision system in single mode.
3 (6)
7.075.11 E rev.: - 2010-11-10
1. Admin (top left corner)

This manual does not cover this menu alternative,
which is protected by an administrator password.
The functions are intended for MacGregor Cranes
personnel.
To get access to the Admin dialog box tap the top

left corner of the screen. A password dialog box
shows. Enter admin password and push OK.
If correct password is entered then the Admin

dialog box shows.
Rig mode.
First button:
Overload test.
Dialog alternatives
The program is controlled through a dialog box
system and you get access to it by touching the
background of the display. If the user stays idle
(does not push the screen) for a while (1-2
minutes) any entry will be ignored and the dialog
box closes. There are three areas to get access to
the functions and settings:
Software keyboard
Date, time and the copy logs. This is the same
When a dialog box needs input, a keyboard shows diaolog box that shows for users.
on the screen.
Second button
4 (6)
7.075.11 E rev.: - 2010-11-10
Eighth button
2. User (bottom left corner)

Tap the bottom left corner and a password dialog
box shows. Enter the user password (set to 1111)
Third button and push OK. Input of an incorrect password is
notified by a warning message, push OK to close.
Fourth button:
Fifth button:
Sixth button:
Seventh button
5 (6)
7.075.11 E rev.: - 2010-11-10
3. Offset (weight box)
To change the weight offset tap the box which

displays the weight in the top centre of the screen.
The weight offset dialog box shows on the screen.
The Use Current button will set the offset to the

current weight. To enter an own value just type it in
the box in the Manual Offset and push Use
Manual button. To discard any changes or just
quit the dialog box push Cancel (No Change).
6 (6)
7.076.2 E rev.: c 2009-06-29
USER MANUAL
DISPLAY
CC Pilot XS
1 COMPATIBILITY .............................................................................................................................................. 2
2 THE INSTALLATION AND SERVICE .............................................................................................................. 2
3 THE CONNECTION OF PERIPHERAL DEVICES........................................................................................... 2
4 CODE DATA ..................................................................................................................................................... 2
5 THE SERVICE AND PROTECTION INSTRUCTIONS..................................................................................... 2
6 DISPLAY UNIT ................................................................................................................................................. 3

6.1 BUTTONS:.................................................................................................................................................... 3
6.2 LEDS: .......................................................................................................................................................... 3
6.3 CONNECTORS: ............................................................................................................................................. 3
7 STARTUP ......................................................................................................................................................... 3
8 PROBLEM SOLVING ....................................................................................................................................... 4

8.1 THE DISPLAY IS DARK OR DIM ........................................................................................................................ 4
8.2 SERIAL PORT FAULTS ................................................................................................................................... 4
8.3 LED IS BLINKING RED BUT PROGRAM DOESNT START .................................................................................... 4
9 TECHNICAL DATA .......................................................................................................................................... 4
1 (4)
7.076.2 E rev.: c 2009-06-29
1 Compatibility
The display is compatible with Windows CE and Linux.
2 The installation and service

Only authorized service personnel from MacGREGOR service department is allowed to install, repair or open the
device. Faulty installation, repair or device opening can be dangerous and cancel the product warranty.
3 The connection of peripheral devices

The compatibility of peripheral devices of the display shall be ensured from MacGREGOR Service department to
exclude connection of incompatible products with each other.
4 Code data
Device's code data is placed at the back of the unit.
Code data are important from the service point of view, and so beware from disposing those.
5 The service and protection instructions

Your display is of a high quality product, and it should be used carefully. Following instructions help you to keep
product in good condition for a long time.
The display shall be cleaned regularly. Wipe out the screen of the device by the soft moist fabric. Do not
use alkaline or alcohol including cleaning agents.
Do not scratch, damage or press the surface of the display.
If the display would not work correct, please contact MacGREGOR, Service Department, rnskldsvik,
Sweden.
2 (4)
7.076.2 E rev.: c 2009-06-29
6 Display unit
X1
1 X2
2 X8
3
4 X5
5
X9
X6
The display screen has 10.4 LCD TFT display with a touch screen.
6.1 Buttons:
1. Power button can be used to turn on/off the unit. If pressed for a long time, there will be a
forced power off.
2. Increase brightness.
3. Decrease brightness.
6.2 LEDs:
4. Red LED that blinks at start up.
5. Light detector of automatic brightness adjustment.
6.3 Connectors:
X1 Power
X2 Ethernet1
X5 Misc (Used as Serial communication port)
X6 CAN1
X8 USB1
X9 USB2
7 Start up
The display starts up at the same time as the crane. First it loads the operating system and after that
the display starts the program. When starting, screen is black and the red LED is blinking.
3 (4)
7.076.2 E rev.: c 2009-06-29
8 Problem solving
If there are some problem with the display check the following first, then call MacGREGOR Service Department.
8.1 The display is dark or dim when crane is working
Check the brightness adjustment of the screen.
Check cables and connectors to the display unit.
Push the power on button on the display unit.
8.2 Communication faults
Check that the cables are properly connected.
8.3 LED is blinking red but program does not start
Try to switch off the unit and start again with the power button.
9 Technical Data
This display is especially developed for use of heavy machinery, which guarantees system durability and flexible
expandability to the different applications.
Kernel Power
Processor Intel XScale, 533 MHz Voltage 10 - 36 VDC
Compact Flash 32 MB -> commercially available Current < 500 mA at 24 VDC (6.5)
Kernel Flash 32/ 64 MB Environment
RAM -> 256 MB SDRAM IP-class IP65
Graphic controller Silicon motion, 8 MB RAM Temperature range -40 C - +65 C (operating)
Interfaces -40 C - +70 C (storage)
2 x CAN 2.0B, ISO 11898 24V,1 Mbit EMC conformity In accordance with 89/336/EEC:
2 x Ethernet 10/100 Base-T EN 50081-2: 1993
2 x USB 2.0 Software
RS232 OPTION. 115000 baud, replaces Operating system: Windows CE 5.0
Keyboard & Mouse Via USB Internal control
Display Status LED In front panel
10.4 SVGA 800x600 TFT Photo diode Automatic backlight control
Backlight CCFL ~400 nit Internal temperature protection against overheating
Touch screen Resistive in abnormal ambient conditions.
Mechanical
Enclosure Aluminum Dimensions
Mounting Stand Screen size: 10.4
Connectors DIN M12 Depth: 40 mm
Height: 217 mm
Width: 285 mm
4 (4)
9.0 How to order
spare parts
Cargotec Sweden AB
MacGregor Cranes
Sjgatan 4G
Telephone: 46 - 660 - 29 40 00
Telefax: 46 - 660 - 139 77
9.1 Machinery
www.cargotec.com
Spare Parts Manual 9.2 Pump unit

Oil cooler
9.3 Mechanical
equipment
9.4 Hydraulic
components
9.5 Electric
components
9.6
9.7 Extra equipment

SERVICE 6.000 E rev.: e 2010-09-08
How to Order Spare Parts
Important details when enquiring or ordering spare parts
Please send your inquiry or order to closest MacGregor global service station, see instruction "MacGregor Global
Services", 6.004.1 E.
To speed up the process we request you to provide us with below information:
State name of company as well as your name
Vessel's name and IMO number (and/or Lloyd's number)
Crane type (see manual or name plate in operator's cabin)
Crane place on the vessel. No. 1 counted from the fore
Crane serial number (see manual or name plate in operator's cabin)
Spare part figure or drawing number. To be found in section 9 in the manual
Part description
Item number from spare part figure or drawing respectively
Part number, if available, from spare part figure or drawing respectively
Quantity required
When you order a wire rope or lifting block, please specify which certificate is needed.
Deadline - when or where in the world do you need the parts?
Delivery details such as: consignee as well as phone and fax numbers
Terms of delivery: by DHL, air freight direct or consignment, by truck or shipping freight
The more you can provide us with above details the faster and more reliable replies and deliveries will be made.
Address:
Cargotec Sweden AB
MacGregor Cranes
Phone: 46 - 660 - 29 40 00
Telefax: 46 - 660 - 139 77
1 (2)
6.000 E rev.: e 2010-09-08 page 2 (2)
Tel: 46 - 660 - 29 40 00
Direct: Fax: 46 - 660 - 139 77
Date: ................................................
Spare parts/Service specification

Please use this form whenever assistance is needed. Service request
Confirmation of
phone call/conv.
From: .. ............................................................. E-mail address: ................................................
.............................................................. Phone no.: ......................................................
.............................................................. Telefax no.: ......................................................
Re: M/V ........................................................ IMO /Lloyd's no.: ..............................................
Crane type: ............................................. Serial no: .........................................................
Crane place: ........................................... Our ref.: ..........................................................
For following spares we would like to: have your quotation
place order, deadline for arrival :................................
Part no. Qty Description Fig./Drwg. Item
1. .......................................... ..... ............................................ .............................. ..............
2. ........................................... ..... ............................................ .............................. ..............
3. ........................................... ..... ............................................ .............................. ..............
4. ........................................... ..... ............................................ .............................. ..............
5. ........................................... ..... ............................................ .............................. ..............
6. See enclosure
Delivery/Agent's address: ............................................................................................................
............................................................................................................
............................................................................................................
...................................................................................................................
Name/ Title/
PARTS MANUAL Date Group Fig. Page
2011-04-04 9.1 625-1440.147A 1 (2)
HOISTING WINCH COMPLETE
330 Nm
16
20
189 6696-801
625-1440.147
2011-04-04 9.1 625-1440.147A 2 (2)
HOISTING WINCH COMPLETE

Item Qty Article no Description Supplementary data
000 1 189 6696-801 HOISTING WINCH COMPLETE
001 1 189 6675-801 . HOISTING WINCH SEE FIG. 625-1450.147
003 1 289 2557-801 . VALVE UNIT SEE FIG. 625-7207.007
004 1 388 3580-801 . FLUSH AND UNLOADING UNIT SEE FIG. 625-7449
005 1 391 0458-801 . HYDRAULIC MOTOR SEE FIG. 625-2205.037
016 4 2121 2032-676 . SCREW M6S 20 x 60 -8.8 FZB; DIN 933
020 4 2151 2022-192 . WASHER BRB 21 x 36 FZB; DIN 125A

2011-04-27 9.1 625-1450.147A 1 (4)
HOISTING WINCH
Pressure roller
24 1 arrangement:
36
385 Nm
447 448
385 Nm
660 Nm
223 205
220
660 Nm
534 536
221
533 535
404 405 531 532
930 Nm
1000000084999
622 506
503
621
46 Nm
60 519
517
505
502
189 6675-801 625
625-1450.147 /A 626 627 411 412
Weight 2.400 kg
2011-04-27 9.1 625-1450.147A 2 (4)
HOISTING WINCH
000 1 189 6675-801 HOISTING WINCH
001 1 875 13019-122 . GEAR, COMPLETE SEE FIG. 625-1451.155
024 1 875 13004-133 . DRIVE IN, COMPLETE SEE FIG. 625-1451.156
036 1 875 13030-006 . PRESSURE ROLLER, COMPLETE SEE FIG. 625-1451.010
060 1 875 13009-071 . OIL PIPE, COMPLETE SEE FIG. 625-1451.072
205 1 875 13017-014 . CABLE FIXING
220 24 2121 2032-719 . SCREW M6S 24 x 55 -8.8 FZB; DIN 933
221 24 2121 2032-719 . SCREW M6S 24 x 55 -8.8 FZB; DIN 933
223 4 875 13018-007 . SCREW M 20 x 60
404 22 2121 2030-721 . SCREW M6S 24 x 65 -10.9; DIN 933
405 22 875 13014-002 . WASHER M 24
411 2 875 13016-001 . SPACER
412 4 2121 2532-380 . SCREW MC6S 6 x 50 -8.8 FZB; DIN 912
447 8 2121 2032-676 . SCREW M6S 20 x 60 -8.8 FZB; DIN 933
448 8 875 13014-023 . WASHER M20
502 1 875 13026-013 . FLANGE PLATE
503 1 875 13014-011 . WASHER
505 x 875 13020-004 . SEALING BAND L = 400 mm
506 1 875 13011-009 . BEARING
517 1 875 13023-003 . COVER
531 1 875 13010-002 . COUPLING
532 1 875 13009-062 . PIPE
533 1 875 13016-002 . CLAMP

2011-04-27 9.1 625-1450.147A 3 (4)
HOISTING WINCH
Pressure roller
24 1 arrangement:
36
385 Nm
447 448
385 Nm
660 Nm
223 205
220
660 Nm
534 536
221
533 535
404 405 531 532
930 Nm
1000000084999
622 506
503
621
46 Nm
60 519
517
505
502
189 6675-801 625
625-1450.147 /A 626 627 411 412
Weight 2.400 kg
2011-04-27 9.1 625-1450.147A 4 (4)
HOISTING WINCH
534 1 875 13010-003 . COUPLING
536 1 2545 2011-025 . GREASE NIPPLE A-M10 x 1 FZB; DIN 71412
621 1 875 13031-005 . THERMO SWITCH 100 - 95 C (NC) (Right pos.)
622 1 875 13031-006 . THERMO SWITCH 55 - 50 C (NO) (Left pos.)
625 1 875 13034-001 . COUPLING BOX
626 2 2121 2034-368 . SCREW M6S 6 x 16 -A2-70; DIN 933
627 2 875 13014-041 . WASHER

2008-05-12 9.1 625-1451.155 1 (2)
GEAR, COMPLETE
41 42 43
520 521
462
463
454 491
192003009
875 13019-122
625-1451.155
Weight 491 kg
2008-05-12 9.1 625-1451.155 2 (2)
GEAR, COMPLETE
000 1 875 13019-122 GEAR, COMPLETE
041 x 875 13020-001 . SEALING BAND L = 1.6 m
042 x 875 13020-002 . LOCKING BAND L = 1.7 m
043 1 875 13020-003 . SOCKET
454 1 875 13007-014 . SHAFT SEALING
462 4 875 13006-017 . PLUG M 30
463 4 875 13007-037 . SEALING
491 1 875 13014-010 . WASHER
520 2 875 13038-001 . PLUG WITH OIL VALVE
521 2 875 13007-008 . SEALING

2009-11-25 9.1 625-1451.156A 1 (2)
DRIVE IN, COMPLETE
80 Nm
75 97
60 61 22 76 98
58
59
55
40
30
53
41
4 50
70
43
192001818
23
80 Nm
Disc arrangement, 8 7 95 96 69 20
item 97 + 98
195 Nm
Outer discs
Motor side
Gear side
Inner discs
Center line
875 13004-133
625-1451.156 /A
Weight 60 kg
2009-11-25 9.1 625-1451.156A 2 (2)
DRIVE IN, COMPLETE

000 1 875 13004-133 DRIVE IN, COMPLETE
004 1 875 13013-017 . DRIVING SLEEVE
007 1 875 13027-008 . MOTOR FLANGE
008 1 875 13027-007 . MOTOR FLANGE
022 12 2121 2532-556 . SCREW MC6S 12x120 -8.8 FZB; DIN 912
030 1 875 13011-010 . BEARING
040 1 875 13012-014 . CIRCLIP
041 1 875 13012-013 . CIRCLIP
043 1 875 13012-012 . CIRCLIP
050 1 875 13007-015 . SHAFT SEALING
053 1 875 13007-006 . SHAFT SEALING
055 1 875 13015-028 . O-RING 174 x 4
058 1 875 13015-006 . O-RING 285 x 3
059 1 875 13015-005 . O-RING 200 x 3
060 4 875 13006-003 . PLUG M10
061 4 875 13007-007 . SEALING
069 1 875 13008-011 . VENTILATION FILTER M10
070 2 875 13014-012 . SHIM
075 18 875 13002-003 . SPRING Change all springs at the same time.
076 18 875 13002-004 . SPRING Change all springs at the same time.
095 1 875 13003-008 . PRESSURE UNIT
096 1 875 13028-001 . DISC CARRIER
097 8 875 13001-003 . MULTIPLE DISC, OUTER Change all discs at the same time.
098 7 875 13001-004 . MULTIPLE DISC, INNER Change all discs at the same time.
2003-11-07 9.1 625-1451.010 1 (2)
PRESSURE ROLLER, COMPLETE
9 10 13 14 12 11 8
195 Nm
4 7
875 13030-006
625-1451.010
Weight 40 kg
5 6 4 3
195 Nm
2003-11-07 9.1 625-1451.010 2 (2)
PRESSURE ROLLER, COMPLETE

000 1 875 13030-006 PRESSURE ROLLER, COMPLETE
001 2 2126 2032-124 . NUT M6M 16 -8 FZB
002 4 875 13039-001 . SPRING
003 1 875 13025-004 . PIN 8 x 50
005 1 875 13040-001 . KEY
006 1 875 13037-002 . BUSHING
007 1 875 13037-003 . BUSHING
008 2 875 13033-009 . COVER
009 2 875 13033-008 . ROLLER
010 1 875 13033-007 . ROLLER
011 2 875 13012-034 . CIRCLIP
012 2 875 13014-043 . WASHER M 24
013 6 875 13012-020 . CIRCLIP
014 6 875 13011-029 . BEARING

2009-09-15 9.1 625-1451.072A 1 (2)
OIL PIPE, COMPLETE
ALT 1 ALT 2
HOLDING/CLOSING HOISTING WINCH
HOISTING WINCH
2009-09-15 9.1 625-1451.072A 2 (2)
OIL PIPE, COMPLETE

000 1 875 13009-071 OIL PIPE, COMPLETE
005 1 875 13007-001 . SEALING
108 1 875 13008-012 . VENTILATION FILTER M18; 0.2 bar

2008-05-13 9.1 625-2205.037 1 (2)
HYDRAULIC MOTOR
391 0458-801
625-2205.037
2008-05-13 9.1 625-2205.037 2 (2)
HYDRAULIC MOTOR
000 1 391 0458-801 HYDRAULIC MOTOR
001 1 489 6331-801 . GASKET SET

2010-03-12 9.1 625-1440.046A 1 (2)
LUFFING WINCH, C
19
15
1
20 19
17 16
163 Nm
189 1625-801
625-1440.046
2010-03-12 9.1 625-1440.046A 2 (2)
LUFFING WINCH, C
000 1 189 1625-801 LUFFING WINCH, C
002 1 189 1622-801 . LUFFING WINCH SEE FIG. 625-1450.056
003 1 289 1639-801 . VALVE UNIT SEE FIG. 625-7207.006
004 1 388 3576-803 . UNLOADING UNIT SEE FIG. 625-7802.004
015 2 2121 2032-469 . SCREW M6S 8 x 90 -8.8 FZB
016 4 2121 2032-471 . SCREW M6S 8 x 100 -8.8 FZB
017 4 2121 2032-630 . SCREW M6S 16 x 50 -8.8 FZB
019 6 2151 2022-164 . WASHER BRB 8.4 x 16 FZB; DIN 125A
020 4 2151 2022-185 . WASHER BRB 17 x 30 FZB

2003-10-22 9.1 625-1450.056A 1 (4)
LUFFING WINCH
2003-10-22 9.1 625-1450.056A 2 (4)
LUFFING WINCH
000 1 189 1622-801 LUFFING WINCH LUFFING
001 22 2121 2030-674 . SCREW M6S 20 x 50 -10.9; DIN 933
002 22 875 13014-023 . WASHER
003 6 2121 2032-628 . SCREW M6S 16 x 40 -8.8 FZB; DIN 933
004 1 875 13009-050 . OIL PIPE, COMPLETE
005 2 875 13016-001 . SPACER
011 18 2121 2032-673 . SCREW M6S 20 x 45 -8.8 FZB; DIN 933
012 18 2121 2032-673 . SCREW M6S 20 x 45 -8.8 FZB; DIN 933
013 1 875 13017-011 . CABLE FIXING
014 5 875 13018-003 . SCREW M 16 x 45; DIN 912
021 1 875 13019-067 . GEAR, COMPLETE Includes item 22-25.
022 1 875 13007-020 .. SHAFT SEALING
023 1 875 13014-017 .. WASHER
024 2 875 13038-001 .. PLUG WITH OIL VALVE
025 2 875 13007-008 .. SEALING
031 1 875 13021-028 . FLANGE, COMPLETE Includes item 32-42.
032 1 875 13026-003 .. FLANGE
033 1 .. FLANGE PLATE Not sold separately. See item 31.
034 1 875 13014-016 .. WASHER
035 1 875 13012-016 .. CIRCLIP
036 1 875 13022-001 .. FELT STRIP L = 400 mm
037 1 875 13011-012 .. BEARING
038 1 875 13023-004 .. COVER
039 1 875 13024-001 .. DRIVER
040 1 2121 2532-468 .. SCREW MC6S 8 x 85 -8.8 FZB; DIN 912
041 2 875 13025-001 .. PIN

2003-10-22 9.1 625-1450.056A 3 (4)
LUFFING WINCH
2003-10-22 9.1 625-1450.056A 4 (4)
LUFFING WINCH
042 1 875 13032-002 .. GREASE NIPPLE M10 x 1; DIN 71412
051 1 875 13004-074 . DRIVE IN, COMPLETE Includes item 52-76.
052 8 875 13001-003 .. MULTIPLE DISC, OUTER Change all 15 discs at the same time.
053 7 875 13001-004 .. MULTIPLE DISC, INNER Change all 15 discs at the same time.
054 14 875 13002-003 .. SPRING Change all 28 springs at the same time.
055 14 875 13002-004 .. SPRING Change all 28 springs at the same time.
056 1 875 13003-008 .. PRESSURE UNIT
057 1 875 13027-001 .. MOTOR FLANGE
058 1 875 13028-001 .. DISC CARRIER
059 1 .. BRAKE FLANGE Not sold separately. See item 51.
060 1 875 13013-019 .. DRIVING SLEEVE Includes item 61-62.
061 1 875 13012-030 ... CIRCLIP
062 24 875 13014-018 ... SHIM
063 1 875 13007-006 .. SHAFT SEALING
064 1 875 13007-005 .. SHAFT SEALING
065 1 875 13011-004 .. BEARING
066 1 875 13012-008 .. CIRCLIP
067 1 875 13012-009 .. CIRCLIP
068 1 875 13015-001 .. O-RING
069 1 875 13015-013 .. O-RING
070 6 2121 2532-559 .. SCREW MC6S 12 x 140-8.8 FZB; DIN 912
071 6 2121 2532-562 .. SCREW MC6S 12x170 -8.8 FZB; DIN 912
072 1 875 13008-011 .. VENTILATION FILTER M 10
073 2 875 13006-012 .. PLUG M 10
074 2 875 13007-007 .. SEALING
075 1 875 13006-006 .. PLUG M 18
076 1 875 13007-008 .. SEALING

2001-01-12 9.1 625-2205.009A 1 (2)
HYDRAULIC MOTOR
2001-01-12 9.1 625-2205.009A 2 (2)
HYDRAULIC MOTOR
001 1 188 1221-801 HYDRAULIC MOTOR LUFFING
002 1 489 6119-801 . GASKET SET

2008-05-14 9.1 625-2250.022 1 (2)
WINCH MOUNTING SET
9 800 Nm
10 4
4
3
800 Nm 9
10
9 800 Nm
289 5365-801
625-2250.022
2008-05-14 9.1 625-2250.022 2 (2)
WINCH MOUNTING SET

000 1 289 5365-801 WINCH MOUNTING SET
003 10 489 5009-010 . WASHER
004 10 488 7386-002 . WASHER
005 16 488 7386-001 . WASHER
006 16 488 7386-005 . WASHER
007 2 489 6415-801 . LIMIT SWITCHES BOX, MOUNT. SEE FIG. 625-6248.001
009 26 2121 2037-737 . SCREW M6S 24 x 160 -10.9 spec.
010 10 2126 2039-126 . NUT M6M 24 -10 spec.

2007-11-23 9.1 625-3254.024A 1 (2)
SLEWING GEAR ASSEMBLY SET
5 6
2 540 Nm
1
3
391 0247-801
625-3254.024
2007-11-23 9.1 625-3254.024A 2 (2)
SLEWING GEAR ASSEMBLY SET

000 1 391 0247-801 SLEWING GEAR ASSEMBLY SET
001 X . SLEWING GEAR See mechanical specification
002 24 2121 2030-678 . SCREW M6S 20 x 70 -10.9; DIN 933
003 24 487 2826-009 . WASHER
005 1 487 7218-002 . NIPPLE
006 1 2152 2151-178 . SEALING

2007-11-22 9.1 625-3254.022A 1 (2)
SLEWING GEAR ASSEMBLY
3 dl
135 Nm 6
1 dl
391 0279-801
625-3254.022
2007-11-22 9.1 625-3254.022A 2 (2)
SLEWING GEAR ASSEMBLY

000 1 391 0279-801 SLEWING GEAR ASSEMBLY
001 X . SLEWING GEAR See mechanical specification
004 4 487 2826-004 . WASHER
006 4 2121 2541-540 . SCREW MC6S 12 x 40 -12.9

2008-06-27 9.1 625-3255.034 1 (2)
SLEWING GEAR
40
360 361 362 363
289 1855-801
625-3255.034 /0
Weight 360 kg
2008-06-27 9.1 625-3255.034 2 (2)
SLEWING GEAR
000 1 289 1855-801 SLEWING GEAR MODULE 16
040 1 875 13004-127 . DRIVE IN, COMPLETE SEE FIG. 625-3256.007
360 1 875 13006-001 . PLUG, MAGNETIC M22
361 1 875 13007-001 . SEALING
362 3 875 13006-002 . PLUG M22
363 3 875 13007-001 . SEALING

2008-09-22 9.1 625-3256.007B 1 (2)
DRIVE IN, COMPLETE
59 7
46 Nm 22
64 65
69
60 61
75 76
95
96
97 98
606 607
80 Nm 20
621 622
1000000081890
50 40 30 41 43 70
Disc arrangement,
item 97 + 98
Motor side
Outer discs
Center line
Inner discs
Gear side
875 13004-127
625-3256.007 /B
Weight 34 kg
2008-09-22 9.1 625-3256.007B 2 (2)
DRIVE IN, COMPLETE

000 1 875 13004-127 DRIVE IN, COMPLETE
007 1 875 13027-006 . MOTOR FLANGE
030 1 875 13011-001 . BEARING
040 1 875 13012-002 . CIRCLIP
041 1 875 13012-001 . CIRCLIP
043 2 875 13012-015 . CIRCLIP
050 1 875 13007-002 . SHAFT SEALING
059 1 875 13015-009 . O-RING 126 x 3.0
060 1 875 13006-003 . PLUG M10
061 1 875 13007-007 . SEALING
064 1 875 13006-004 . PLUG M18
065 1 875 13007-008 . SEALING
069 1 875 13008-001 . VENTILATION FILTER M10; 0.04 bar
070 3 875 13014-012 . SHIM
075 16 875 13002-001 . SPRING Change all springs at the same time
076 16 875 13002-002 . SPRING Change all springs at the same time
095 1 875 13003-011 . PRESSURE UNIT
096 1 875 13028-002 . DISC CARRIER
097 9 875 13001-001 . MULTIPLE DISC, OUTER Change all discs at the same time
098 7 875 13001-002 . MULTIPLE DISC, INNER Change all discs at the same time
606 1 875 13008-018 . OIL DIPSTICK M18; 0.2 bar
607 1 875 13007-008 . SEALING
621 1 875 13006-010 . PLUG M22
622 1 875 13007-001 . SEALING

1998-10-09 9.1 625-2205.010 1 (2)
HYDRAULIC MOTOR
1998-10-09 9.1 625-2205.010 2 (2)
HYDRAULIC MOTOR
001 1 188 1223-801 HYDRAULIC MOTOR SLEWING
002 1 489 6118-801 . GASKET SET

2011-01-03 9.2 625-4935.213 1 (2)
PUMP UNIT
NOTE 12
When replacing electric
motor, also order:
- Centre gearwheel.
- Distance spacer(s).
- Washer.
- Screw.
For ordering article no,
see separate spare part 72 10
illustration for Gear box.
330 Nm
50
49
330 Nm
16
14
8
1 62
52
277 Nm
62
19
277 Nm 52
61
48
1193467
625-4935.213
67 Nm
2011-01-03 9.2 625-4935.213 2 (2)
PUMP UNIT
000 1 1196654 PUMP UNIT
001 2 1202481 . PRESSURE SENSOR
008 1 391 0807-801 . TANDEM PUMP SEE FIG. 625-4944.001
009 1 391 0808-801 . TANDEM PUMP SEE FIG. 625-4944.002
010 1 388 3580-801 . FLUSH AND UNLOADING UNIT SEE FIG. 625-7449
012 1 390 5127-801 . ELECTRIC MOTOR
014 4 391 1219-801 . CONTAMINATION SWITCH
016 1 391 0431-801 . GEAR BOX SEE FIG. 625-4940.033
019 1 391 0571-801 . VANE PUMP SEE FIG. 625-4945.058
048 2 2121 2032-542 . SCREW M6S 12 x 50 -8.8 FZB
049 14 2121 2032-674 . SCREW M6S 20 x 50 -8.8 FZB; DIN 933
050 2 2121 2032-678 . SCREW M6S 20 x 70 -8.8 FZB
052 4 2121 2030-630 . SCREW M6S 16 x 50 -10.9
061 2 2151 2022-178 . WASHER BRB 13 x 24 FZB
062 4 2151 2052-185 . WASHER TBRB 17 x 30 FZB
072 4 2197 2525-055 . RUBBER BUSHING

2008-05-15 9.2 625-4940.033 1 (2)
GEAR BOX
391 0431-801
625-4940.033 /0
Weight 143 kg
2008-05-15 9.2 625-4940.033 2 (2)
GEAR BOX
000 1 391 0431-801 GEAR BOX

2008-05-14 9.2 625-4944.001 1 (2)
TANDEM PUMP
275 Nm
391 0807-801
625-4944.001
2008-05-14 9.2 625-4944.001 2 (2)
TANDEM PUMP
000 1 391 0807-801 TANDEM PUMP
001 2 289 5330-801 . PUMP SEE FIG. 625-4945.056
002 1 391 0470-801 . DISTANCE PIECE SEE FIG. 625-4963.015

2008-05-14 9.2 625-4944.002 1 (2)
TANDEM PUMP
275 Nm
391 0808-801
625-4944.002
2008-05-14 9.2 625-4944.002 2 (2)
TANDEM PUMP
000 1 391 0808-801 TANDEM PUMP
001 1 289 5879-801 . PUMP SEE FIG. 625-4945.055
002 1 289 5331-801 . PUMP SEE FIG. 625-4945.057

2010-02-08 9.2 625-4945.056A 1 (2)
PUMP
2010-02-08 9.2 625-4945.056A 2 (2)
PUMP
000 1 289 5330-801 PUMP HPV 105
001 1 875 19801-001 . SERVO VALVE SEE FIG. 625-4948.009
002 1 875 19803-001 . PRESSURE RELIEF VALVE 150 bar
004 1 875 19805-001 . RETAINING RING
005 1 875 19806-001 . SEAL KIT Includes item 006-009.
006 1 875 19804-001 .. SHAFT SEALING
007 1 .. O-RING SET
008 2 .. SUPPORT RING
009 2 .. SEALING
2010-02-09 9.2 625-4948.009 1 (2)
SERVO VALVE
2010-02-09 9.2 625-4948.009 2 (2)
SERVO VALVE
000 1 875 19801-001 SERVO VALVE
001 2 875 19802-001 . SOLENOID Includes item 002-004.
002 2 5217 4198-302 .. CONNECTION PLUG
003 2 5217 4198-317 .. GASKET
004 8 2121 2532-305 .. SCREW MC6S 4 x 50 -8.8 FZB; DIN 912
005 2 2152 2118-194 . O-RING Included in seal kit for pump.
006 2 2121 2545-455 . SCREW MC6S 8 x 30 -10.9; DIN 912
007 2 2121 2545-459 . SCREW MC6S 8 x 40 -10.9; DIN 912

2010-02-08 9.2 625-4945.057A 1 (2)
PUMP
2010-02-08 9.2 625-4945.057A 2 (2)
PUMP
000 1 289 5331-801 PUMP HPV 105
004 1 875 19805-001 . RETAINING RING
006 1 875 19804-001 .. SHAFT SEALING
007 1 .. O-RING SET
009 2 .. SEALING
2010-02-08 9.2 625-4945.055A 1 (2)
PUMP
2010-02-08 9.2 625-4945.055A 2 (2)
PUMP
000 1 289 5879-801 PUMP HPV 105
004 1 875 19805-001 . RETAINING RING
006 1 875 19804-001 .. SHAFT SEALING
007 1 .. O-RING SET
009 2 .. SEALING
2008-05-15 9.2 625-4945.058 1 (2)
VANE PUMP
391 0571-801
625-4945.058
2008-05-15 9.2 625-4945.058 2 (2)
VANE PUMP
000 1 391 0571-801 VANE PUMP
001 1 490 4186-801 . GASKET SET

2008-05-13 9.2 625-4963.014 1 (2)
DISTANCE PIECE
391 0469-801
625-4963.014
2008-05-13 9.2 625-4963.014 2 (2)
DISTANCE PIECE
000 1 391 0469-801 DISTANCE PIECE
003 1 391 0469-003 . O-RING 84 x 2
004 1 391 0469-004 . O-RING 106 x 2

2008-05-13 9.2 625-4963.015 1 (2)
DISTANCE PIECE
4
391 0470-801
625-4963.015
2008-05-13 9.2 625-4963.015 2 (2)
DISTANCE PIECE
000 1 391 0470-801 DISTANCE PIECE
003 1 391 0470-003 . O-RING 84 x 2
004 1 391 0470-004 . O-RING 132 x 3
005 2 391 0470-005 . WASHER
006 2 391 0470-006 . SCREW MC6S 16 x 55 -10.9; DIN912
007 4 391 0470-007 . SCREW MC6S 12 x 110 -12.9; DIN912

2009-01-27 9.2 625-5740.031 1 (2)
OIL COOLER
1
2
289 6815-801
625-5740.031 /0
Weight 81 kg
2009-01-27 9.2 625-5740.031 2 (2)
OIL COOLER
000 1 289 6815-801 OIL COOLER
001 1 287 8764-801 . COOLER ELEMENT
002 1 875 18002-003 . ELEMENT COVER
003 1 875 18004-002 . MOTOR COVER
004 1 875 18005-001 . FAN WHEEL
005 1 875 18003-001 . FAN WHEEL COVER
006 1 875 18001-001 . ELECTRIC MOTOR
007 1 490 0197-801 . MOUNTING SET Incl. screws, nuts and washers
008 2 2183 2022-122 . LIFTING EYE BOLT M12; DIN 580

2007-09-25 9.2 625-5740.022 1 (2)
OIL COOLER ASSEMBLY SET
6
5 8
10
10
12
13
4
9
7
1
11
391 0300-801
625-5740.022
2007-09-25 9.2 625-5740.022 2 (2)
OIL COOLER ASSEMBLY SET

000 1 391 0300-801 OIL COOLER ASSEMBLY SET
001 X . OIL COOLER ASSEMBLY See hydraulic specification
004 5 2121 2034-540 . SCREW M6S 12 x 40 -A2-70
005 2 2121 2034-501 . SCREW M6S 10 x 50 -A2-70
006 3 2121 2034-455 . SCREW M6S 8 x 30 -A2-70
007 4 2151 2027-178 . WASHER BRB 13 x 24 -A2
008 6 2151 2027-164 . WASHER BRB 8.4 x 16 -A2
009 1 2151 2054-178 . WASHER TBRSUB 13 x 36 FZB
010 4 2151 2054-173 . WASHER TBRSUB 10.5 x 28 FZV
011 4 2126 2634-122 . LOCKING NUT M6LM 12 - A2-70
012 2 2126 2634-120 . LOCKING NUT M6LM 10 - A2-70
013 3 2126 2634-118 . LOCKING NUT M6LM 8 - A2-70

2009-01-26 9.2 625-5740.032 1 (2)
OIL COOLER ASSEMBLY
391 2766-801
625-5740.032
2009-01-26 9.2 625-5740.032 2 (2)
OIL COOLER ASSEMBLY

000 1 391 2766-801 OIL COOLER ASSEMBLY
001 1 289 6815-801 . OIL COOLER SEE FIG. 625-5740.031
002 2 2528 2512-635 . COUPLING

2006-09-18 9.3 625-5865.033A 1 (2)
OIL TANK ASSEMBLY

2006-09-18 9.3 625-5865.033A 2 (2)
OIL TANK ASSEMBLY

000 1 189 3870-801 OIL TANK ASSEMBLY
004 1 5692 4700-803 . LEVEL AND TEMPERATURE GUARD
005 1 289 1598-801 . DIRECTION VALVE
006 1 390 5254-801 . HEATER
007 1 389 2828-801 . AIR FILTER WITH DIPSTICK
008 1 2529 2563-151 . HOSE CONNECTION
009 1 390 3178-801 . COVER
011 1 5695 1000-063 . THERMOMETER Glued w. Bostic 10 or similar
013 1 490 3471-801 . VALVE PLATE
032 6 2152 2151-228 . SEAL RING
035 1 2515 6044-220 . HYDRAULIC HOSE L= 2200 mm
053 1 2541 2506-117 . VEDGE VALVE 1 1/4"
054 1 2541 4129-113 . BALL VALVE
055 1 2541 4130-050 . BALL VALVE

2010-05-21 9.3 625-6102.520 1 (2)
CRANE HOUSE ASSEMBLY
21
17
16 15
20
18 19
14
13
9
5 6
8
4
10 11
2
7
12
1190634 22
625-6102.520
2010-05-21 9.3 625-6102.520 2 (2)
CRANE HOUSE ASSEMBLY

000 1 1190634 CRANE HOUSE ASSEMBLY
002 X . HOISTING WINCH ASSEMBLY SEE TABLE OF CONTENTS SECTION 9.1
003 X . LUFFING WINCH ASSEMBLY SEE TABLE OF CONTENTS SECTION 9.1
004 1 289 5365-801 . WINCH MOUNTING SET SEE FIG. 625-2250.022
005 1 289 3393-801 . SLACK WIRE DEVICE, MOUNT.
006 1 289 3396-801 .. SLACK WIRE DEVICE SEE FIG. 625-6250.023
007 1 289 5323-801 . LIMIT SWITCHES BOX SEE FIG. 625-6245.635
008 1 289 5449-801 . LIMIT SWITCHES BOX SEE FIG. 625-6245.643
009 X . OIL TANK ASSEMBLY SEE TABLE OF CONTENTS SECTION 9.3
010 X . SLEWING GEAR ASSEMBLY SEE TABLE OF CONTENTS SECTION 9.1
011 2 391 0247-801 . SLEWING GEAR ASSEMBLY SET SEE FIG. 625-3254.024
012 X . JIB BEARING MOUNTING SEE TABLE OF CONTENTS SECTION 9.3
013 X . PUMP UNIT SEE TABLE OF CONTENTS SECTION 9.2
014 1 289 6809-801 . CAB INSTALLATION SEE FIG. 625-6540.040
015 X . OIL COOLER ASSEMBLY SEE TABLE OF CONTENTS SECTION 9.2
016 1 391 0300-801 . OIL COOLER ASSEMBLY SET SEE FIG. 625-5740.022
017 X . CRANE TOP MOUNTING SEE TABLE OF CONTENTS SECTION 9.3
018 X . VENTILATION FAN SEE TABLE OF CONTENTS SECTION 9.3
019 1 289 4601-801 . VENTILATION FAN ASSEMBLY SET SEE FIG. 625-6625.022
020 1 390 3274-801 . COVER MOUNTING SEE FIG. 625-6169.005
021 1 390 7581-801 . PROTECTIVE PLATE MOUNT. SEE FIG. 625-6459.051
022 X . SLEWING BEARING MOUNTING SEE SLEWING SPECIFICATION

2009-01-22 9.3 625-6122.030 1 (2)
SLEWING SPECIFICATION
le
cip
rin
P
CRANE
FOUNDATION
490 6433-801
625-6122.030
2009-01-22 9.3 625-6122.030 2 (2)
SLEWING SPECIFICATION
000 1 490 6433-801 SLEWING SPECIFICATION
001 X . SLEWING BEARING See table of contents section 9.3
004 1 391 0452-801 . SLEWING BEARING MOUNTING
005 1 391 0453-801 . SLEWING BEARING YARD MOUNTING

2011-06-01 9.3 625-6125.001 1 (2)
PROTECTING CUP MOUNTING
391 1210-801
625-6125.001
2011-06-01 9.3 625-6125.001 2 (2)
PROTECTING CUP MOUNTING

000 0 391 1210-801 . PROTECTING CUP MOUNTING
001 120 2522 2515-330 . PROTECTION CUP

2010-05-24 9.3 625-6169.005A 1 (2)
COVER MOUNTING
2010-05-24 9.3 625-6169.005A 2 (2)
COVER MOUNTING
000 1 390 3274-801 COVER MOUNTING
001 1 390 3282-801 . COVER ASSEMBLY SEE FIG. 625-6169.006
002 4 2121 2034-455 . SCREW M6S 8 x 30 -A4 -80
003 4 2151 2027-164 . WASHER RB 8.4 x 16 -A4
004 4 2126 2634-118 . LOCKING NUT M6M 8 -A4-80

2003-01-30 9.3 625-6169.006 1 (2)
COVER ASSEMBLY
2003-01-30 9.3 625-6169.006 2 (2)
COVER ASSEMBLY
000 1 390 3282-801 COVER ASSEMBLY
001 1 390 3282-001 . COVER
002 1 389 1581-802 . HANDLE
003 1 1856 2160-001 . SEAL STRIP L= 2010
004 2 389 1903-004 . HINGE
005 6 2121 2034-451 . SCREW M6S 8 x 20 -A4-80
006 6 2151 2027-164 . WASHER RB 8.4 x 16 -A4
007 6 2126 2634-118 . NUT M6M 8 -A4-80

2008-06-16 9.3 625-6170.068 1 (2)
JIB BEARING MOUNTING
8
6
4
3
2
5
391 0467-801
625-6170.068
2008-06-16 9.3 625-6170.068 2 (2)
JIB BEARING MOUNTING

000 1 391 0467-801 JIB BEARING MOUNTING
001 1 289 1905-001 . SHAFT
002 1 391 0468-801 . BEARING HOUSING ASSEMBLY SEE FIG. 625-6170.069
003 12 487 2826-002 . WASHER
004 1 489 6412-001 . COVER
005 1 490 3578-001 . SPACER
006 12 2121 2030-630 . SCREW M6S 16 x 50 -10.9
007 2 2152 2115-529 . O-RING
008 1 2545 2110-003 . GREASE NIPPLE AM 10 x 1 -A2-50

2008-06-16 9.3 625-6170.069 1 (2)
BEARING HOUSING ASSEMBLY
10
4
5
3
1
12 5
4
11 9
6
11
12
2
391 0468-801
625-6170.069
2008-06-16 9.3 625-6170.069 2 (2)
BEARING HOUSING ASSEMBLY

000 1 391 0468-801 BEARING HOUSING ASSEMBLY
001 1 289 5335-001 . BEARING HOUSING
002 2 388 9574-001 . RING
003 2 388 9575-001 . WASHER
004 24 487 2826-002 . WASHER
005 6 489 3362-001 . CLIP
006 1 490 4616-801 . BEARING
009 12 2121 2030-648 . SCREW M6S 16 x 150 -10.9
010 12 2126 2038-124 . NUT M6M 16 -10; 235 Nm
011 2 2152 2115-543 . O-RING
012 2 2186-2187-170 . V-RING V-170A

2010-10-05 9.3 625-6244.073 1 (2)
JIB TOP ASSEMBLY
12
10
22
62 10
10
18
62
9
23
8
23
23
23
9
18
22
1195437
625-6244.073
2010-10-05 9.3 625-6244.073 2 (2)
JIB TOP ASSEMBLY

000 1 1195437 JIB TOP ASSEMBLY
006 1 390 5330-002 . SHAFT
008 2 1185110 . DISTANCE
009 4 489 5334-002 . LOCK WASHER
010 3 490 4086-801 . WIRE SHEAVE
012 1 1185527 . SPACER
018 4 2121 2034-628 . SCREW M6S 16 x 40 -A2-70
022 7 2545 2110-003 . GREASE NIPPLE AM 10 x 1 -A2-50
023 4 490 6143-801 . WIRE SHEAVE

2008-11-28 9.3 625-6245.635A 1 (2)
LIMIT SWITCHES BOX
22
23 24
31
14 15
16 17
32
18 19 20 21
25
289 5323-801
625-6245.635 /A
2008-11-28 9.3 625-6245.635A 2 (2)
LIMIT SWITCHES BOX

000 1 289 5323-801 LIMIT SWITCHES BOX
001 1 875 15017-012 . CAM DISC WITH ARM, COMPLETE 30 - 55
014 6 875 15001-001 . MICRO SWITCH 1A
015 2 875 15001-002 . THREADED STUD WITH NUTS M3. Cut to right length.
016 1 875 15003-023 . COVER, COMPLETE Incl. screws and sealing.
017 1 875 15003-002 .. SEALING L = 2000 mm
018 4 2121 2034-457 .. SCREW M6S 8 x 35 -A2-70
019 4 2126 2034-118 .. NUT M6M 8 - A2-70
020 4 2151 2027-164 .. WASHER BRB 8.4 x 16 -A2
021 4 2126 2432-118 .. CAP NUT MHM 8 -6 FZB
022 1 875 15012-013 . WORM GEAR, COMPLETE Incl. screws. Ratio 50:1.
023 1 875 15006-008 . SHAFT COUPLING, COMPLETE
024 1 875 15008-005 . KEY 4 x 4 x 16
025 2 875 15002-003 . CABLE GLAND WITH NUT
031 1 ENCODER Ordered separately.

2007-12-13 9.3 625-6245.643 1 (2)
LIMIT SWITCHES BOX
22 33
23 24
32
1
14 15
2
16 17 5
8
18 19 20 21
9
289 5449-801 25 31 10
625-6245.643 /0
2007-12-13 9.3 625-6245.643 2 (2)
LIMIT SWITCHES BOX

000 1 289 5449-801 LIMIT SWITCHES BOX
014 10 875 15001-001 . MICRO SWITCH 1A
015 2 875 15001-002 . THREADED STUD WITH NUTS M3. Cut to right length.
016 1 875 15003-028 . COVER, COMPLETE Incl. screws and sealing.
017 1 875 15003-002 .. SEALING L = 2000 mm
018 4 2121 2034-457 .. SCREW M6S 8 x 35 -A2-70
019 4 2126 2034-118 .. NUT M6M 8 - A2-70
020 4 2151 2027-164 .. WASHER BRB 8.4 x 16 -A2
021 4 2126 2432-118 .. CAP NUT MHM 8 -6 FZB
022 1 875 15012-005 . WORM GEAR, COMPLETE Incl. screws. Ratio 50:1.
023 1 875 15006-008 . SHAFT COUPLING, COMPLETE
024 1 875 15008-002 . KEY 4 x 4 x 20
025 2 875 15002-002 . CABLE GLAND WITH NUT
031 1 875 15018-001 . PLAIN BEARING

2009-06-15 9.3 625-6248.001B 1 (2)
LIMIT SWITCHES BOX, MOUNT.

2009-06-15 9.3 625-6248.001B 2 (2)
LIMIT SWITCHES BOX, MOUNT.

000 1 489 6415-801 LIMIT SWITCHES BOX, MOUNT.
002 3 2122 2519-378 . SCREW MSK6SS 6 x 40 -A4
003 3 2151 2027-156 . WASHER BRB 6.7 x 14 -A2
004 3 2126 2034-116 . NUT NYLOC - M6M 6 -A4-80

2004-10-13 9.3 625-6250.023 1 (2)
SLACK WIRE DEVICE

2004-10-13 9.3 625-6250.023 2 (2)
SLACK WIRE DEVICE

000 1 289 3396-801 SLACK WIRE DEVICE
001 1 288 2344-801 . SUPPORT
002 1 288 2345-801 . BRACE
003 1 288 2346-801 . BRACE
004 2 388 3290-004 . LIMIT SWITCH PART
005 2 489 5947-001 . SPRING
006 2 489 4601-001 . SCREW
007 2 489 4604-001 . SPACER
008 18 490 4586-001 . ROLLER
009 4 490 4587-001 . WASHER
010 2 490 4591-001 . SCREW
011 20 488 8518-014 . WASHER
012 2 489 6172-001 . SHAFT
013 2 2184 4024-546 . LINK SCREW M12 x 80 FZB
014 2 2121 2032-544 . SCREW M6S 12 x 60 -8.8 FZB
015 8 2121 2532-339 . SCREW MC6S 5 x 40 -8.8 FZB
016 4 2121 2032-331 . SCREW M6S 5 x 20 -8.8 FZB
017 6 2126 2032-122 . NUT M6M 12 -8 FZB
018 6 2126 2636-124 . LOCKING NUT M6M 16 -8 FZB; DIN 982
019 4 2151 2022-185 . WASHER BRB 17 x 30 FZB
020 8 2151 2022-196 . WASHER BRB 23 x 40 FZB
021 4 2114 2014-201 . SPLIT PIN SP 4 x 40 -A4
022 1 5661 4116-512 . LIMIT SWITCH, HOISTING
023 1 5661 4126-001 . LIMIT SWITCH

2006-03-06 9.3 625-6275.004C 1 (2)
CRANE JIB, YARD MOUNTING

2006-03-06 9.3 625-6275.004C 2 (2)
CRANE JIB, YARD MOUNTING

000 1 489 5409-801 CRANE JIB, YARD MOUNTING
001 8 388 7147-009 . SCREW M6S 30 x 210 -10.9 spec.
002 8 490 3816-008 . WASHER

2010-10-05 9.3 625-6408.115 1 (2)
CRANE JIB ASSEMBLY
1195436
625-6408.115
2010-10-05 9.3 625-6408.115 2 (2)
CRANE JIB ASSEMBLY

000 1 1195436 CRANE JIB ASSEMBLY
003 1 1195437 . JIB TOP ASSEMBLY SEE FIG. 625-6244.073

2010-10-05 9.3 625-6459.071 1 (2)
CRANE TOP ASSEMBLY
25 18 15
13
8
9
2
19
16
7
7
7 8
9
19
16
9
10
17
20
25 12
14 25
19
16
16
19
11
25
1195407
625-6459.071
2010-10-05 9.3 625-6459.071 2 (2)
CRANE TOP ASSEMBLY

000 1 1195407 CRANE TOP ASSEMBLY
001 1 289 1841-001 . SHAFT
002 1 289 1842-001 . SHAFT
007 3 490 4086-801 . WIRE SHEAVE
008 3 490 6143-801 . WIRE SHEAVE
009 3 1184786 . SPACER
010 1 1184788 . SPACER
011 1 490 3620-001 . COVER
012 2 490 3621-001 . COVER
013 1 489 5323-001 . COVER
014 1 489 4345-004 . LOCKING PLATE
015 4 489 5334-001 . LOCK WASHER
016 8 489 5334-002 . LOCK WASHER
017 2 2154 2233-192 . LOCK WASHER
018 4 2121 2034-495 . SCREW M6S 10 x 30 -A4-80
019 8 2121 2034-628 . SCREW M6S 16 x 40 -A4-80
020 2 2121 2034-672 . SCREW M6S 20 x 40 -A4-80
025 8 2545 2110-003 . GREASE NIPPLE A-M 10 x 1 -A2-50

2007-01-17 9.3 625-6459.051 1 (2)
PROTECTIVE PLATE MOUNT.
4 3 2
390 7581-801
625-6459.051
2007-01-17 9.3 625-6459.051 2 (2)
PROTECTIVE PLATE MOUNT.

000 1 390 7581-801 PROTECTIVE PLATE MOUNT.
001 1 390 7582-001 . PROTECTIVE PLATE
002 6 2121 2034-542 . SCREW M6S 12 x 50 -A2 -70
003 6 2151 2054-178 . WASHER TBRSUB 13 x 36 FZB
004 6 2126 2634-122 . NUT M6M 12 -A2 -70

92-02-19 9.3 625-6509A 1 (2)
INCLINOMETER, C
92-02-19 9.3 625-6509A 2 (2)
INCLINOMETER, C
000 1 388 0176-801 INCLINOMETER, C
001 1 488 7233-001 . INCLINOMETER
002 3 2121 2254-378 . SCREW MCS 6 x 40 -5.8 G
003 11 2126 2032-116 . NUT M6M 6 -8 FZB
004 1 488 7511-001 . BRACKET
005 5 2151 2022-153 . WASHER BRB 6.4 x 12 G
006 2 2121 2034-370 . SCREW M6S 6 x 20 -A2-70
007 2 2151 2025-153 . WASHER BRB 6.4 x 12 SSt

2010-05-18 9.3 625-6540.040 1 (2)
CAB INSTALLATION
5
1
3 7 8
289 6809-801
625-6540.040
2010-05-18 9.3 625-6540.040 2 (2)
CAB INSTALLATION
000 1 289 6809-801 CAB INSTALLATION
001 1 190 0115-801 . CAB ASSEMBLY SEE FIG. 625-6545.068
002 3 489 5395-801 . BRACKET
003 3 489 5154-003 . SHAFT
004 1 488 9225-001 . WASHER
005 1 490 6169-001 . RUBBER MOULDING L = 9000 mm
006 1 2121 2034-536 . SCREW M6S 12 x 30 -A4 -80
007 3 2151 2027-192 . WASHER RB 21 x 37 -A4
008 6 2114 2014-201 . SPLIT PIN SP 4 x 40 -A4

2009-04-09 9.3 625-6545.068 1 (2)
CAB ASSEMBLY
190 0115-801
625-6545.068
2009-04-09 9.3 625-6545.068 2 (2)
CAB ASSEMBLY
000 1 190 0115-801 CAB ASSEMBLY
004 1 289 2251-801 . CAB CUPOLA ASSEMBLY SEE FIG. 625-6560.007
005 1 390 8573-801 . CAB DOOR ASSEMBLY SEE FIG. 625-6546.008
013 1 390 4053-801 . EMERGENCY DOOR ASSY SEE FIG. 625-6546.001
016 1 488 3152-801 . VENTILATOR, C
020 2 490 3825-801 . LOCKING PLATE
021 12 489 3492-001 . SHIM
039 12 2121 2550-339 . SCREW MC6S 5 x 40 -A4-80
041 11 2121 2550-370 . SCREW MC6S 6 x 20 -A4 -80
042 6 2121 2550-374 . SCREW MC6S 6 x 30 -A4-80
047 18 2126 2634-114 . LOCKING NUT M6M 5 -A4 -80
048 17 2126 2634-116 . LOCKING NUT M6M 6 -A4-80
056 18 2151 2027-146 . WASHER RB 5.3 x 10 -A4
057 8 2151 2027-156 . WASHER BRB 6.7 x 14 -A4

2009-06-29 9.3 625-6560.007A 1 (2)
CAB CUPOLA ASSEMBLY

2009-06-29 9.3 625-6560.007A 2 (2)
CAB CUPOLA ASSEMBLY

000 1 289 2251-801 . CAB CUPOLA ASSEMBLY
001 1 189 2327-001 . CAB CUPOLA
002 1 387 6167-803 . SLIDE WINDOW
003 1 388 0223-001 . GLASS
004 1 388 0145-002 . GLASS
005 1 388 0145-003 . GLASS
006 2 388 0145-004 . GLASS
007 1 289 2251-007 . RUBBER MOULDING
008 1 289 2251-008 . LOCKING LIST
009 1 488 7400-001 . HOLDER
010 4 488 7601-001 . HOLDER
012 17 2126 2034-116 . NUT M6M 6 -A4-80
013 15 2121 2844-374 . SCREW MVBF 6 x 30 -A4-80
015 X 1236 2273-001 . SEALING

2006-10-30 9.3 625-6546.008 1 (2)
CAB DOOR ASSEMBLY

2006-10-30 9.3 625-6546.008 2 (2)
CAB DOOR ASSEMBLY

000 1 390 8573-801 CAB DOOR ASSEMBLY
001 1 289 4337-001 . DOOR
003 1 390 8574-801 . DOOR LOCK

2002-06-26 9.3 625-6546.001 1 (2)
EMERGENCY DOOR ASSY

2002-06-26 9.3 625-6546.001 2 (2)
EMERGENCY DOOR ASSY

000 1 390 4053-801 EMERGENCY DOOR ASSY
001 1 390 4054-001 . WINDOW
002 2 389 1581-801 . HANDLE
003 2 489 5392-801 . HINGE
004 6 2121 2636-331 . SCREW MFS 5 x 20 -A4-80
005 6 2126 2634-114 . NUT M6M 5 -A4 -80
006 6 2151 2027-146 . WASHER BRB 5.3 x 10 -A4
007 1 489 2006-801 . EYE BOLT WITH WIRE
008 X 1236 2135-021 . SEALING COMPOUND

2005-05-10 9.3 625-6561.001C 1 (2)
WINDSCREEN CLEANER
2005-05-10 9.3 625-6561.001C 2 (2)
WINDSCREEN CLEANER
000 1 387 6227-802 WINDSCREEN CLEANER
010 1 6179 2151-280 . WIPER MOTOR
011 1 387 6227-920 .. MOUNTING SET For shaft 20
012 1 387 6227-916 .. MOUNTING SET For shaft 16
030 1 6179 2153-700 . WIPER BLADE L = 700 mm
090 1 6179 2152-600 . ARM L = 600 mm
101 2 2126 2032-118 . NUT M6M 8 -8 FZB
102 2 2154 2016-164 . SPRING WASHER FBB 8,2 FZB

2007-09-25 9.3 625-6625.022 1 (2)
VENTILATION FAN ASSEMBLY SET
3 4 5 6
2 4 5 6
289 4601-801
625-6625.022
2007-09-25 9.3 625-6625.022 2 (2)
VENTILATION FAN ASSEMBLY SET

000 1 289 4601-801 VENTILATION FAN ASSEMBLY SET
001 X . VENTILATION FAN See table of contents section 9.3
002 1 288 0945-801 . TUB FOR FAN
003 8 2121 2032-459 . SCREW M6S 8 x 40 -8.8 FZB
004 20 2126 2636-118 . LOCKING NUT M6M 8 -8 FZB; DIN 982
005 20 2151 2058-165 . WASHER TBRSB 8.4 x 26 FZB
006 XX 1236 2296-020 . SEAL STRIP 20 x 2

2010-10-22 9.3 625-6625.015A 1 (2)
VENTILATION FAN
388 9464-801
625-6625.015
2010-10-22 9.3 625-6625.015A 2 (2)
VENTILATION FAN
000 1 388 9464-801 VENTILATION FAN

2009-12-07 9.3 625-7013.096A 1 (2)
LIFTING BLOCK
2009-12-07 9.3 625-7013.096A 2 (2)
LIFTING BLOCK
000 1 289 5332-802 LIFTING BLOCK SWL 36 tonnes.
001 1 875 12401-022 . SHEAVE, COMPLETE Incl. bearing and lock rings.
002 1 875 12054-004 .. BEARING
003 2 875 12062-003 .. LOCK RING
004 2 875 12009-011 . SPACER
005 1 875 12404-018 . SHAFT, COMPLETE Incl. retainer, screw, nipple.
007 1 875 12419-002 . SWIVEL, COMPLETE
009 2 875 12073-007 . SHACKLE
010 1 875 12001-015 . HOOK, COMPLETE Incl. safety latch kit.
011 1 875 12064-016 .. SAFETY LATCH KIT Incl. spring, screw, nut.
012 1 875 12408-008 . PROTECTION CAP, COMPLETE Incl. screws.
013 2 875 12406-022 . SPACER, COMPLETE Incl. spacer tube, screw, nut.
014 1 875 12409-010 . CABLE LEADER, COMPLETE
015 4 875 12406-023 . SPACER, COMPLETE Incl. spacer tube, screw, nut.
016 2 2183 2022-126 . LIFTING EYE BOLT M20; DIN 580
017 1 875 12407-002 . CASING, COMPLETE Incl. screws.

2003-03-18 9.4 625-7207.006 1 (2)
VALVE UNIT
2003-03-18 9.4 625-7207.006 2 (2)
VALVE UNIT
000 1 289 1639-801 VALVE UNIT
001 1 189 1665-801 . VALVE BLOCK
002 2 289 1598-801 . DIRECTION VALVE SEE FIG. 625-7322.048
003 1 488 9601-802 . JOINT COUPLING
006 8 2121 2541-341 . SCREW MC6S 5 x 30 -12,9
007 1 2152 2118-217 . O-RING
010 2 2528 2512-615 . COUPLING
011 1 2528 2512-617 . COUPLING
012 1 2528 2512-622 . COUPLING
013 1 2528 2512-623 . COUPLING
014 2 2528 3426-151 . COUPLING
015 1 2528 3632-222 . COUPLING
016 1 2528 3633-215 . COUPLING
017 2 2528 3633-222 . COUPLING
018 1 2528 3634-210 . COUPLING
019 1 2528 3635-151 . COUPLING
020 1 2528 3635-220 . COUPLING
021 1 2529 2558-111 . CONNECTING NIPPLE R 3/8
022 1 2541 4129-113 . BALL VALVE VBS-R 1/2
023 4 2522 2105-018 . PLUG VSTI G1/8-ED

2003-02-06 9.4 625-7207.007 1 (2)
VALVE UNIT
2003-02-06 9.4 625-7207.007 2 (2)
VALVE UNIT
000 1 289 2557-801 VALVE UNIT
001 1 189 1665-001 . VALVE BLOCK
004 1 489 2571-803 . MANOMETER CONNECTION
006 8 2121 2541-341 . SCREW MC6S 5 x 30 -12,9
008 1 2528 2512-609 . COUPLING
009 2 2528 2512-615 . COUPLING
010 1 2528 2512-617 . COUPLING
011 1 2528 2512-623 . COUPLING
012 1 2528 2592-622 . COUPLING
013 1 2528 2592-615 . COUPLING
014 1 2528 3421-150 . COUPLING
015 2 2528 3426-151 . COUPLING
016 1 2528 3426-221 . COUPLING
017 1 2528 3633-215 . COUPLING
018 1 2528 3635-220 . COUPLING
019 1 2529 2558-111 . CONNECTING NIPPLE
020 1 2541 4129-113 . BALL VALVE
024 1 2528 3634-215 . ADJUSTABLE COUPLING

94-09-15 9.4 625-7287C 1 (2)
FLUSHING VALVE
94-09-15 9.4 625-7287C 2 (2)
FLUSHING VALVE
000 1 388 3579-801 FLUSHING VALVE
001 1 489 3705-802 . GASKET SET
002 2 2152 2151-206 .. SEAL RING INCLUDED IN GASKET SET
003 2 2152 2118-406 .. O-RING INCLUDED IN GASKET SET

94-09-15 9.4 625-7291C 1 (2)
UNLOADING UNIT
94-09-15 9.4 625-7291C 2 (2)
UNLOADING UNIT
000 388 3576-801 UNLOADING UNIT
001 1 388 3575-001 . SPRING SLEEVE CAN NOT BE SUPPLIED SEPARATELY
002 1 287 8772-001 . VALVE HOUSING CAN NOT BE SUPPLIED SEPARATELY
003 2 388 3574-001 . PISTON CAN NOT BE SUPPLIED SEPARATELY
004 388 3576-005 . SPRING CAN NOT BE SUPPLIED SEPARATELY
005 1 489 3061-001 . SPRING SEAT CAN NOT BE SUPPLIED SEPARATLY
006 1 2152 2151-215 . SEAL RING
007 1 2522 4502-111 . PLUG
008 1 2522 4502-110 . PLUG
009 1 2522 4502-113 . PLUG

2005-11-22 9.4 625-7314.007A 1 (2)
FILTER UNIT, INLET

2005-11-22 9.4 625-7314.007A 2 (2)
FILTER UNIT, INLET

000 1 189 1558-801 FILTER UNIT, INLET
001 1 . FILTER
002 1 390 2604-001 . BLOCK OUTLET
003 1 . COVER
004 4 . SCREW UC6S 1/2 x 4"
005 1 389 1673-801 . CHECK VALVE 0,2 bar
006 1 . WASHER
007 2 . O-RING
008 1 875 22002-002 . SEAL KIT

2005-11-22 9.4 625-7314.008A 1 (2)
FILTER UNIT OUTLET

2005-11-22 9.4 625-7314.008A 2 (2)
FILTER UNIT OUTLET

000 1 189 1559-801 FILTER UNIT OUTLET
001 1 . FILTER
002 1 390 2689-801 . BLOCK INLET
003 1 390 2691-801 . BLOCK OUTLET
004 1 390 2690-801 . BLOCK PILOT
005 2 . COVER
006 4 . SCREW UC6S 1/2 x 4"
007 4 . SCREW UC6S 1/2 x 1 1/2"
008 4 . SCREW UC6S 1/2 x 7"
009 1 . PRESSURE RELIEF VALVE
010 1 . DIN-CARTRIDGE
011 4 . SCREW UC6S 1/2 x 2"
012 1 389 1673-801 . CHECK VALVE 0,2 bar
013 1 389 1673-802 . CHECK VALVE 7 bar
014 4 . O-RING
015 1 . SEAL
016 1 875 22002-002 . SEAL KIT

2003-02-11 9.4 625-7322.047 1 (2)
DIRECTION VALVE
2003-02-11 9.4 625-7322.047 2 (2)
DIRECTION VALVE
001 1 289 1597-801 DIRECTION VALVE
002 2 490 3450-801 . COIL
003 1 490 3452-801 . GASKET SET

2003-02-11 9.4 625-7322.048 1 (2)
DIRECTION VALVE
2003-02-11 9.4 625-7322.048 2 (2)
DIRECTION VALVE
001 1 289 1598-801 DIRECTION VALVE
002 1 490 3450-801 . COIL
003 1 490 3452-801 . GASKET SET

1996-09-30 9.4 625-7449B 1 (2)
FLUSH AND UNLOADING UNIT

1996-09-30 9.4 625-7449B 2 (2)
FLUSH AND UNLOADING UNIT

000 1 388 3580-801 FLUSH AND UNLOADING UNIT
001 1 388 3579-801 . FLUSHING VALVE SEE FIG 625-7287
002 1 388 3576-801 . UNLOADING UNIT SEE FIG 625-7291
003 4 2121 2541-497 . SCREW MC63 10 x 35 -12.9
004 1 2521 2135-205 . COUPLING
005 1 2152 2151-194 . SEAL RING INCLUDED IN GASKET SET
006 1 2152 2151-181 . SEAL RING INCLUDED IN GASKET SET
007 1 489 3059-801 . CHECK-RESTRICTION VALVE
008 1 2528 2512-610 . COUPLING
009 1 2522 4506-191 . PROTECTIVE PLUG
010 1 489 3705-803 . GASKET SET

1999-04-22 9.4 625-7802.004 1 (2)
UNLOADING UNIT
1999-04-22 9.4 625-7802.004 2 (2)
UNLOADING UNIT
000 1 388 3576-803 UNLOADING UNIT
001 1 388 3575-001 . SPRING SLEEVE CAN NOT BE SUPPLIED SEPARATELY
002 1 287 8772-001 . VALVE HOUSING CAN NOT BE SUPPLIED SEPARATELY
003 1 388 3574-001 . PISTON CAN NOT BE SUPPLIED SEPATATELY
004 1 388 3576-005 . SPRING CAN NOT BE SUPPLIED SEPARATELY
005 1 489 3061-001 . SPRING SEAT CAN NOT BE SUPPLIED SEPARATELY
006 1 2152 2151-215 . SEAL RING
007 2 2522 4502-111 . PLUG
008 1 2522 4502-110 . PLUG
009 1 2521 2135-205 . COUPLING
010 1 2152 2151-194 . SEAL RING
011 1 2152 2151-181 . SEAL RING
012 1 489 3059-801 . CHECK-RESTRICTION VALVE
013 1 2528 2512-610 . COUPLING
014 1 2522 4506-191 . PROTECTIVE PLUG

2007-08-06 9.4 625-7951.005 1 (2)
ACCUMULATOR
Old design
New design
1 2
388 0362-803
625-7951.005
2007-08-06 9.4 625-7951.005 2 (2)
ACCUMULATOR
000 1 388 0362-803 ACCUMULATOR Charge Press. 2.0 MPa (20 bar)
001 1 488 7888 . GASKET SET Valid for old design
002 1 490 3956 . GASKET SET Valid for new design

2003-06-10 9.4 625-7970G 1 (2)
HYDRAULIC HOSES
When ordering hydraulic hoses, see marking on each

hose
Article number for hydraulic hoses
Quality demands hydraulic hoses, see page 2

2003-06-10 9.4 625-7970G 2 (2)
HYDRAULIC HOSES
MacGREGOR Cranes
Quality and Manufacturing Demands - Hydraulic Hoses
MacGREGOR Cranes are certified holders according to ISO 9001, and therefore the
hydraulic hoses with couplings supplied by us must have type approval on all ma-
terial.
Standard rubber hose for our 1" high pressure hoses are made for a working
pressure of 380 bar.
The hoses are pressure-proof tested according to the DIN norms.
100% of the high pressure hoses are proof tested and leakage tested at 450 bar
during minimum 30 seconds and maximum 60 seconds. This pressure corresponds
to 1.3 times the working pressure.
100% of the hoses are marked with MacGREGOR Cranes part numbers, for quick
and correct identification.
100% of all high pressure hoses are, furthermore, marked with manufacturing date.
100% of all hoses are carefully cleaned after testing. They are cleaned by means of
cavitation with a mixture of water and an anti-corrosive agent.
The cleanliness after washing is equal to, or better than, class 9 according to NAS
norm 1638.
Factors Influencing the Lifetime of Hydraulic HOSES

Pressure - temperature - bending radius - damage caused by outside factors.
Sunlight and artificial light are also harmful to hydraulic hoses.

2011-01-21 9.4 625-7994.001 1 (2)
PRES. SWITCHES EXTRA OVERLOAD
288 1436-801
625-7994.001
2011-01-21 9.4 625-7994.001 2 (2)
PRES. SWITCHES EXTRA OVERLOAD

000 1 288 1436-801 PRES. SWITCHES EXTRA OVERLOAD
001 2 388 3600-801 . PRESSURE SWITCH, C

2009-09-03 9.5 625-8563.059 1 (2)
DRIVERS DESK
7 8
14 72 73 9 10
15 74
11 12
13
124 0827-801
625-8563.059
2009-09-03 9.5 625-8563.059 2 (2)
DRIVERS DESK
000 1 124 0827-801 DRIVERS DESK
002 1 390 8558-001 . DRIVER SEAT
003 1 224 0483-801 . CONTROL PANEL RIGHT CT3
004 1 414 6792-801 . CONTROLLER SEE FIG. 625-8596
006 1 314 3980-801 . SIREN
007 1 5915 4262-002 . ARMATURE 60 W
008 1 5911 4145-060 . LAMP BULB 220 V 60 W E27
009 1 387 6227-802 . WINDSCREEN CLEANER SEE FIG. 625-6561.001
010 1 388 9799-001 . COVER
011 3 5217 4837-240 . SCREW CONNECTION
012 3 5217 4838-240 . BULKHEAD HOUSING
013 1 314 4244-801 . CABIN HEATER
014 1 287 4867-002 . ARM REST
015 1 288 1058-001 . ARM REST
072 1 488 7461-001 . SIGN
073 1 488 6906-001 . SIGN
074 1 490 6220-001 . SIGN

2008-06-27 9.5 625-8567.049 1 (2)
EL.INST.JIB LIGHT (CRANE)
124 0760-801
625-8567.049
2008-06-27 9.5 625-8567.049 2 (2)
EL.INST.JIB LIGHT (CRANE)

000 1 124 0760-801 EL.INST.JIB LIGHT (CRANE)
001 1 1684 2126-301 . CABLE MPRX 3 x 1.5 L=7m
002 2 2121 2550-370 . SCREW MC6S 6 x 20 -A2-70
003 2 2126 2634-116 . LOCKING NUT M6LM 6 - A2-70
004 2 2151 2027-156 . WASHER BRB 6.7 x 14 -A2
005 1 2166 2051-823 . CABLE GLAND Pr 22.5
007 1 5388 4121-002 . CONNECTION BOX

2008-06-27 9.5 625-8567.050 1 (2)
EL. INST. JIB LIGHT (PACKING)
25 26
124 0761-801 2 14 13 12
625-8567.050
2008-06-27 9.5 625-8567.050 2 (2)
EL. INST. JIB LIGHT (PACKING)

000 1 124 0761-801 EL. INST. JIB LIGHT (PACKING)
002 2 490 5473-001 . SCREW
005 1 1684 2125-402 . CABLE L=40m
012 2 2126 2634-122 . LOCKING NUT M6LM 12 - A2-70
013 2 2151 2027-178 . WASHER BRB 13 x 24 -A2
014 2 2151 2027-185 . WASHER BRB 17 x 30 -A2
025 2 5911 4529-410 . HALOGEN LAMP 1000W
026 2 5921 2141-101 . FLOOD LIGHT

91-12-10 9.5 625-8591C 1 (2)
CONTROLLER, HOISTING
91-12-10 9.5 625-8591C 2 (2)
CONTROLLER, HOISTING
000 1 314 2005-802 CONTROLLER, HOISTING
001 1 414 5396-801 . POTENTIOMETER WITH CARD
002 1 414 2081-801 BELLOWS WITH BRACE SPARE PART NO: 662 0034-000
91-11-14 9.5 625-8592C 1 (2)
CONTROLLER, LUFFING/SLEWING
91-11-14 9.5 625-8592C 2 (2)
CONTROLLER, LUFFING/SLEWING
000 1 314 2006-802 CONTROLLER, LUFFING/SLEWING
001 2 414 5396-801 . POTENTIOMETER WITH CARD
002 1 414 2081-801 BELLOWS WITH BRACE SPARE PART NO: 662 0034-000
1997-10-07 9.5 625-8596 1 (2)
CONTROLLER
1997-10-07 9.5 625-8596 2 (2)
CONTROLLER
000 1 414 6792-801 CONTROLLER
001 1 414 7054-001 . COVER
002 1 314 2006-802 . CONTROLLER, LUFFING/SLEWING SEE FIG. 625-8592
003 1 2152 2067-018 . COVER PLATE
004 1 2121 2550-331 . SCREW MC6S 5 x 20 A4-80
005 2 2126 2634-114 . NUT M6M 5 -A4 -80
006 1 2151 2027-146 . WASHER RB 5.3 x 10 -A4

2008-12-04 9.5 625-8597.041 1 (4)
CONTROL PANEL RIGHT CT3
224 0483-801
625-8597.041
2008-12-04 9.5 625-8597.041 2 (4)

000 1 224 0483-801 CONTROL PANEL RIGHT CT3
001 1 224 0206-001 . COVER
002 1 314 2005-802 . CONTROLLER, HOISTING SEE FIG. 625-8591
005 1 424 0640-801 . SWITCH WITH KEY
006 1 424 0641-801 . SWITCH WITH HANDLE
011 1 424 0643-001 . LENS WITH SYMBOL
012 1 424 0643-002 . LENS WITH SYMBOL
013 1 424 0643-003 . LENS WITH SYMBOL
014 1 424 0643-004 . LENS WITH SYMBOL
015 1 424 0643-005 . LENS WITH SYMBOL
016 1 424 0643-006 . LENS WITH SYMBOL
018 1 424 0643-022 . LENS WITH SYMBOL
028 1 424 0646-001 . SIGN
030 1 424 0644-002 . SIGN
032 1 424 0644-005 . HEADLINE SIGN
033 1 424 0644-006 . HEADLINE SIGN
038 7 5298 2070-100 . PILOT LAMP RED
045 1 5372 2206-003 . CONTACT BLOCK
046 1 5372 2206-002 . CONTACT BLOCK
048 1 5372 2203-001 . PUSH BUTTON
049 1 5372 2204-102 . PUSH BUTTON
050 1 5372 2202-101 . EMERGENCY STOP
053 2 5375 4340-102 . SWITCH
056 1 5375 4341-112 . SWITCH WITH KEY

2008-12-04 9.5 625-8597.041 3 (4)
224 0483-801
625-8597.041
2008-12-04 9.5 625-8597.041 4 (4)

058 1 5672 4245-002 . CIRCUIT BREAKER
062 11 2152 2069-225 . BLANKING PLUG
063 1 2152 2067-018 . COVER PLATE
064 1 2121 2550-331 . SCREW MC6S 5 x 20 -A4-80
066 2 2126 2634-114 . LOCKING NUT M6M 5 -A4 -80
068 1 2151 2027-146 . WASHER RB 5.3 x 10 -A4

2011-01-26 9.5 625-8597.061 1 (2)
EL. INST JIB LIGHT (CABIN)
324 2043-801
625-8597.061
2011-01-26 9.5 625-8597.061 2 (2)
EL. INST JIB LIGHT (CABIN)

000 1 324 2043-801 EL. INST JIB LIGHT (CABIN)
001 1 5372 2207-011 . CONTACT BLOCK
003 1 5372 2205-142 . PUSH BUTTON

2011-01-27 9.5 625-8597.063 1 (2)
EL. INST. FORCE LIMIT GRAB (CA
324 1724-801
625-8597.063
2011-01-27 9.5 625-8597.063 2 (2)
EL. INST. FORCE LIMIT GRAB (CA

000 1 324 1724-801 EL. INST. FORCE LIMIT GRAB (CA
001 1 5375 4340-131 . SWITCH
002 1 424 0644-014 . SYMBOL

2011-01-28 9.5 625-8597.064 1 (2)
EL. INST. PMS (CABIN)
324 1723-801
625-8597.064
2011-01-28 9.5 625-8597.064 2 (2)
EL. INST. PMS (CABIN)

000 1 324 1723-801 EL. INST. PMS (CABIN)
001 1 5372 2207-003 . CONTACT BLOCK
003 1 5372 2205-112 . PUSH BUTTON

2011-03-28 9.5 625-8597.070 1 (2)
EL. INST. DECK LIGHT (CABIN)
2 3
14 15
324 1777-801
625-8597.070
2011-03-28 9.5 625-8597.070 2 (2)
EL. INST. DECK LIGHT (CABIN)

000 1 324 1777-801 EL. INST. DECK LIGHT (CABIN)
002 1 5372 2205-143 . PUSH BUTTON
003 1 5372 2207-011 . CONTACT BLOCK
014 1 5921 2141-101 . FLOOD LIGHT
015 1 5911 4529-410 . HALOGEN LAMP 1000W

2011-03-28 9.5 625-8597.071 1 (2)
EL. INST. RESET EMERG.STOP (CABIN)
1 3
324 1819-801
625-8597.071
2011-03-28 9.5 625-8597.071 2 (2)
EL. INST. RESET EMERG.STOP (CABIN)

000 1 324 1819-801 EL. INST. RESET EMERG.STOP
001 1 5372 2207-004 . CONTACT BLOCK
003 1 5372 2205-122 . PUSH BUTTON Yellow

2011-03-28 9.5 625-8597.072 1 (2)
ELECTRICAL VENT. FAN ASSY.
1, 2
1202310-801
625-8597.072
2011-03-28 9.5 625-8597.072 2 (2)
ELECTRICAL VENT. FAN ASSY.

000 1 1202310 ELECTRICAL VENT. FAN ASSY.
001 1 5375 4340-102 . SWITCH
002 1 424 0644-008 . SIGN
003 1 414 4354-002 . VENTILATOR

2011-03-29 9.5 625-8597.073 1 (2)
EL.INST.HOIST/LUFF LIMIT (CAB)
1205863
625-8597.073
2011-03-29 9.5 625-8597.073 2 (2)
EL.INST.HOIST/LUFF LIMIT (CAB)

000 1 1205863 EL.INST.HOIST/LUFF LIMIT (CAB)
001 1 424 0643-012 . LENS WITH SYMBOL
002 1 424 0643-013 . LENS WITH SYMBOL
004 1 5298 2070-102 .. PILOT LAMP YELLOW

2011-03-30 9.5 625-8597.074 1 (2)
EL INST AIR CIRCUL FAN (CABIN)
1 12
324 1848-801
625-8597.074
2011-03-30 9.5 625-8597.074 2 (2)
EL INST AIR CIRCUL FAN (CABIN)

000 1 324 1848-801 EL INST AIR CIRCUL FAN (CABIN)
001 1 5375 4340-102 . SWITCH
004 1 6480 2150-024 . FAN
012 1 424 0644-008 . SIGN

2011-04-04 9.5 625-8597.075 1 (2)
EL.INST. EXTRA CABLE (CABIN)
S
P
3 1
3
3
3
2 P
S
4
324 1236-801
625-8597.075
2011-04-04 9.5 625-8597.075 2 (2)
EL.INST. EXTRA CABLE (CABIN)

000 1 324 1236-801 EL.INST. EXTRA CABLE (CABIN)
001 1 5217 4837-240 . SCREW CONNECTION Male
003 4 5217 4839-116 . CODING SET Includes 1 pcs (S) + 1 pcs (P)
004 4 2121 2550-291 . SCREW MC6S 4 x 12 -A2-70

2011-04-04 9.5 625-8597.076 1 (2)
EL. INST. CONTAM. SWITCH (CAB)
2 3
324 1864-801
625-8597.076
2011-04-04 9.5 625-8597.076 2 (2)
EL. INST. CONTAM. SWITCH (CAB)

000 1 324 1864-801 EL. INST. CONTAM. SWITCH (CAB)
001 1 5931 4108-828 . BUZZER
002 1 5298 2070-100 . PILOT LAMP RED
003 1 424 0643-014 . LENS WITH SYMBOL

2011-09-02 9.5 625-8597.089 1 (2)
CONTROL PANEL, GRAB (CT23)
26 10
6 8
7 10
9
11 12
18
12 21
19
12 14
13
23
23
P
22 S
24
1214847
625-8597.089
2011-09-02 9.5 625-8597.089 2 (2)
CONTROL PANEL, GRAB (CT23)

000 1 1214847 CONTROL PANEL, GRAB (CT23)
001 1 324 0059-801 . CONNECTION BOX
006 1 424 0644-017 . SIGN
007 1 424 0644-018 . SIGN
008 1 1215743 . SWITCH
009 1 424 0644-007 . SIGN
010 2 5375 4341-112 . SWITCH WITH KEY
011 1 5372 2205-102 . PUSH BUTTON
012 3 1216007 . CONTACT BLOCK
013 1 1214878 . PUSH BUTTON
014 1 1214879 . PUSH BUTTON
018 28 2663 4382-025 . TERMINAL BLOCK
019 2 2647 4155-040 . EARTH TERMINAL
021 1 5217 4837-240 . SCREW CONNECTION Male
024 4 2121 2550-291 . SCREW MC6S 4 x 12 -A2-70
026 1 1203725 . CABLE L=6m

2011-03-29 9.5 625-8598.121 1 (4)
EL. CABINET (CT1/CT2)
1198703
625-8598.121
2011-03-29 9.5 625-8598.121 2 (4)

000 1 1198703 EL. CABINET (CT1/CT2)
001 1 224 0351-801 . CABINET BASIC
002 1 4762 4221-200 . POWER SUPPLY
003 1 4762 4202-102 . POWER SUPPLY
004 1 324 1165-801 . TRANSFORMER 1-PHASE
006 1 324 1682-801 . ASSEMBLY CT2 PLATE SEE FIG. 625-8607.011
008 1 2152 2069-225 . BLANKING PLUG
010 1 414 1941-801 . THERMISTOR
012 1 5639 4161-202 . IMPULSE RELAY
013 2 2638 3100-160 . COPPER BRAID
014 2 2638 3100-224 . COPPER BRAID
015 2 2638 3100-288 . COPPER BRAID
019 6 2121 2550-329 . SCREW MC6S 5 x 16 -A2-70
020 4 2121 2032-453 . SCREW M6S 8 x 25 -8.8 FZB
024 4 2126 2032-118 . NUT M6M 8 -8 FZB
028 4 2151 2022-164 . WASHER BRB 8.4 x 16 FZB; DIN 125A
029 4 2151 2027-146 . WASHER BRB 5.3 x 10 -A2
032 1 5632 4209-003 . TIME RELAY
036 1 2663 4660-001 . CONNECTION PLINTH
040 5 2669 4160-015 . END HOLDER
044 2 5218 3107-111 . AUXILIARY CONTACT
047 4 5354 4130-220 . CONTACTOR RELAY
050 1 5237 4190-035 . FLANGE
054 1 5340 2011-501 . CIRCUIT BREAKER
058 1 5349 2002-105 . CONNECTOR
062 1 5349 2011-105 . COVER

2011-03-29 9.5 625-8598.121 3 (4)
1198703
625-8598.121
2011-03-29 9.5 625-8598.121 4 (4)

066 2 5354 4130-400 . CONTACTOR RELAY
070 5 5354 4137-501 . AUXILIARY CONTACT BLOCK
074 3 5354 4273-009 . CONTACTOR
080 1 5372 2202-101 . EMERGENCY STOP
082 1 5381 4280-001 . ELECTRICAL OUTLET
083 2 5672 4212-140 . FUSE
084 1 5572 4105-063 . MOTOR SWITCH
085 1 5572 4105-400 . MOTOR SWITCH
086 3 2669 4180-060 . FUSE TERMINAL
087 1 5672 4212-120 . FUSE 5x20 2A
090 1 5591 2153-200 . STAR DELTA STARTER
091 2 5347 4262-116 . CIRCUIT BREAKER
092 1 5632 4209-002 . TIME RELAY
093 1 5632 4209-004 . TIME RELAY
095 1 5347 4262-106 . CIRCUIT BREAKER
096 1 5347 4262-202 . CIRCUIT BREAKER
097 1 5347 4262-306 . CIRCUIT BREAKER
099 1 7635 4113-200 . THERMOSTAT
101 1 5349 2021-102 . KNOB
103 1 5692 4740-024 . HOUR METER
105 3 2689 4121-009 . SLEEVE

2011-09-05 9.5 625-8598.132 1 (4)
EL. CABNET (CT19)
1215193
625-8598.132
2011-09-05 9.5 625-8598.132 2 (4)
EL. CABNET (CT19)

000 1 1215193 EL. CABNET (CT19)
001 1 1212474 . CABINET BASIC
002 1 5572 4103-190 . MOTOR SWITCH
003 2 5354 4273-114 . CONTACTOR
004 1 5572 4105-910 . MOTOR SWITCH
005 2 1196897 . CONTACTOR
006 8 2669 4160-015 . END HOLDER
007 4 2121 2532-295 . ALLEN SCREW
008 1 5572 4105-630 . MOTOR SWITCH
009 7 1196894 . AUXILARY CONTACT
011 3 2641 2101-355 . CABLE TERMINAL
012 1 1202921 . CABLE
013 1 1186616 . CABLE
014 1 1186619 . CABLE
015 1 1192204 . CABLE
016 1 1186625 . CABLE
017 2 1196896 . CONTACTOR
018 1 1196890 . RELAY
019 4 1196887 . RELAY
020 1 5632 4209-003 . TIME RELAY
021 1 5632 4209-002 . TIME RELAY
022 1 1197825 . MOUNTING RAIL

2011-09-05 9.5 625-8598.132 3 (4)
EL. CABNET (CT19)
1215193
625-8598.132
2011-09-05 9.5 625-8598.132 4 (4)
EL. CABNET (CT19)

024 2 2124 2550-228 . SCREW
025 2 2663 4660-001 . CONNECTION PLINTH
026 1 1189888 . CABLE
027 1 1194937 . CABLE TERMINAL

2000-03-28 9.5 625-8599.020 1 (2)
RELAY CARD WITH LEDs

2000-03-28 9.5 625-8599.020 2 (2)
RELAY CARD WITH LEDs

000 1 324 0089-801 RELAY CARD WITH LEDs
006 4 414 4667-007 . SPACER
007 4 2121 2254-220 . SCREW MCS 3 x 6 -5.8 FZB
008 4 2126 2636-110 . NUT NYLOC-M6M 3 -8 FZB
009 4 2154 2022-124 . WASHER AZ 3.2 FZB

2009-10-02 9.5 625-8607.011A 1 (2)
ASSEMBLY CT2 PLATE
6 4 3
50 50
50
459
458 457
455 453
451 449
Hardware Hardware Hardware Hardware 448 438
xxx xxxx-xxx xxx xxxx-xxx xxx xxxx-xxx xxx xxxx-xxx 437 436
435 434
Error MP SP Error MP SP Error MP SP Error MP SP 433 432
431 430
Input Output Input Output Input Output Input Output
07 18 27 33 36 33 36 33 36 429 427
07 07 07 426 425
08 19 28 39 43 39 43 39 43
09 20 29 34 37 34 37 34 37 420 419
08 08 08 418 417
10 26 30 40 45 40 45 40 45
415 414
11 49 31 09 31 09 31 09 31
30 30 30 412 411
12 51 32 10 32 10 32 10 32
408 407
13 56 33 19 Sw19 19 Sw19 19 Sw19
404 403
Encoder 14 57 34 20 Sw20 55 20 Sw20 55 20 Sw20 55
402 401
15 58 35 11 14 Sw14 11 14 Sw14 11 14 Sw14
calibration
16 59 36 56 Sw56 56 Sw56 56 Sw56
17 60 37 12 15 Sw15 12 15 Sw15 12 15 Sw15
50 50
24V 38 26 27 26 27 26 27
42 359
Com 39 58 59 58 59 58 59
358 357
C1 R1 40 49 17 29 49 17 29 49 17 29
356 355
C2 R2 53 51 18 53 51 18 53 51 18 53
353 349
C3 R3 61 52 54 52 54 52 54
348 338
C4 MP 57 C1 R1 57 C1 R1 57 C1 R1
337 336
C2 MP C2 MP C2 MP
335 334
Com Com Com
333 332
331 330
CC MC MC MC
329 327
326 325
320 319
318 317
315 314
Sc Ho Lu Sl
312 311
308 307
Select / Info Select / Info Select / Info Select / Info 304 303
302 301
Up Up Up Up
Down / Exit Down / Exit Down / Exit Down / Exit
50 50
50 50
259 258
257 256
50 42
255 254
PC COM PC COM PC COM PC COM 50 42
253 252
50 42
251 249
50 42
248 247
50 42
Software Software Software Software 245 243
98 97
241 240
96 95
239 238
94 93
237 236
92 91
235 234
90 89
233 232
SC IO SC Supervisory HO Hoisting LU Luffing SL Slewing AU Auxiliary IO Input/Output 88 87
231 230
C28
C36
C44
C52
C17
C6
86 85
C3 C3 A1 C1 A1 C1 A1 C1 A1 C1 A1 C1 A1 C1 229 227
SC_C3 1
IO_C3 1
SC_C1 1
HO_C1 1
LU_C1 1
SL_C1 1
AU_C1 1
IO_C1 1
84 83
226 225
82 81
HO_A1
AU_A1
SC_A1
LU_A1
SL_A1
IO_A1
220 219
80 79
218 217
78 77
P115 P1115 P108 P208 P308 P408 P508 P1108 215 214
76 75
P101 P201 P301 P401 P501 P1101 212 211
C29
C37
C45
C53
C18
74 73
C7
C4 C4 A2 C2 A2 C2 A2 C2 A2 C2 A2 C2 A2 C2 210 209
72 71
1
SC_C2 1
HO_C2 1
LU_C2 1
SL_C2 1
AU_C2 1
IO_C2 1
208 207
70 69
HO_A2
SC_C4
AU_A2
SC_A2
LU_A2
SL_A2
IO_C4
IO_A2
204 203
68 67
202 201
66 65
P109 P209 P309 P409 P509 P1109 50 50
64 63
P116 P1116 P102 P202 P302 P402 P502 P1102 50 50
62 61
485.2 485.2 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1 42 42
60 23
SC_485.2 1
IO_485.2 1
SC_485.11
HO_485.11
LU_485.11
SL_485.11
AU_485.11
IO_485.1 1
42 42
22 21
HO_A3
AU_A3
SC_A3
LU_A3
SL_A3
161 160
IO_A3
20
158 157
19
P103 P110 P210 P310 P403 P410 P510 P1110 153 151
P203 P303 P503 P1103 18
149 143
P117 P1117
C12
C34
C33
C42
C41
C50
C49
C58
C57
C23
C22
C11
17
141 137
485.3 485.3 Sp SSI Sp SSI Sp SSI Sp SSI Sp SSI Sp SSI 16
SC_485.3 1
IO_485.3 1
136 135
15
134 133
14 13
HO_SSI
AU_SSI
SC_SSI
LU_SSI
SL_SSI
HO_Sp
IO_SSI
132 131
AU_Sp
SC_Sp
LU_Sp
SL_Sp
IO_Sp
12 11
130 128
10 9
127 126
P118 P1118 8 7
125 119
6 5
118 117
P107 P106 P207 P206 P307 P306 P407 P406 P507 P506 P1107 P1106 4 3
116 115
2 1
114 113
112 111
110 109
108 107
104 103
102 101
324 1682-801
625-8607.011
2009-10-02 9.5 625-8607.011A 2 (2)
ASSEMBLY CT2 PLATE

000 1 324 1682-801 ASSEMBLY CT2 PLATE
003 3 . MC-CARD See table of cont. section 9.5
004 1 . CC-CARD See table of cont. section 9.5
006 1 324 1663-X . MEMORY CARD X = Crane manufacturing No.

2010-10-08 9.5 625-8650.001 1 (2)
EL. INST. IMPULS RELAY
224 0116-801
625-8650.001
2010-10-08 9.5 625-8650.001 2 (2)
EL. INST. IMPULS RELAY

000 1 224 0116-801 EL. INST. IMPULS RELAY
002 1 5639 4161-202 . IMPULSE RELAY

2011-01-31 9.5 625-8650.003 1 (2)
EL. INST. PMS ELECTRIC CABINET
2 6
224 0119-801
625-8650.003
2011-01-31 9.5 625-8650.003 2 (2)
EL. INST. PMS ELECTRIC CABINET

000 1 224 0119-801 EL. INST. PMS ELECTRIC CABINET
002 1 5354 4130-220 . CONTACTOR RELAY
006 1 2669 4160-015 . END HOLDER

2011-02-01 9.5 625-8650.004 1 (2)
EL.INST.OIL TANK HEATER (CT1)
15
3
14
2 15
224 0474-801
625-8650.004
2011-02-01 9.5 625-8650.004 2 (2)
EL.INST.OIL TANK HEATER (CT1)

000 1 224 0474-801 EL.INST.OIL TANK HEATER (CT1)
001 1 5354 4273-009 . CONTACTOR
002 1 5354 4130-220 . CONTACTOR RELAY
003 1 5572 4105-250 . MOTOR SWITCH
015 2 2669 4160-015 . END HOLDER

2011-02-02 9.5 625-8650.005 1 (2)
EL. INST. FORCE LIMIT GRAB CT1
1, 2
4
224 0547-801
625-8650.005
2011-02-02 9.5 625-8650.005 2 (2)
EL. INST. FORCE LIMIT GRAB CT1

000 1 224 0547-801 EL. INST. FORCE LIMIT GRAB CT1
001 1 5354 4133-221 . CONTACTOR RELAY
002 1 7426 4200-050 . SURGE SUPPRESSOR
004 1 2669 4160-015 . END HOLDER

2011-03-28 9.5 625-8650.010 1 (2)
EL. INST. POWER SUPPLY (CT1)
1, 2
224 0506-801
625-8650.010
2011-03-28 9.5 625-8650.010 2 (2)
EL. INST. POWER SUPPLY (CT1)

000 1 224 0506-801 EL. INST. POWER SUPPLY (CT1)
001 1 2669 4180-060 . FUSE TERMINAL
002 1 5672 4212-140 . FUSE
003 1 4762 4201-100 . POWER SUPPLY
005 1 2669 4160-015 . END HOLDER

2011-03-30 9.5 625-8650.011 1 (2)
EL. INST. CARD RELAY (CT2)
224 0154-801
625-8650.011
2011-03-30 9.5 625-8650.011 2 (2)
EL. INST. CARD RELAY (CT2)

000 1 224 0154-801 EL. INST. CARD RELAY (CT2)
001 2 324 0089-801 . RELAY CARD WITH LEDS SEE FIG. 625-8599.020
2011-03-31 9.5 625-8650.012 1 (2)
EL. INST. SAFETY RELAY (CT1)
224 0249-801
625-8650.012
2011-03-31 9.5 625-8650.012 2 (2)
EL. INST. SAFETY RELAY (CT1)

000 1 224 0249-801 EL. INST. SAFETY RELAY (CT1)
001 1 5638 1000-230 . SAFETY RELAY

2011-03-31 9.5 625-8650.013 1 (2)
EL.INST.CONT.SWITCHES CT1/CT2
224 0429-801
625-8650.013
2011-03-31 9.5 625-8650.013 2 (2)
EL.INST.CONT.SWITCHES CT1/CT2
000 1 224 0429-801 EL.INST.CONT.SWITCHES CT1/CT2
003 1 5632 4209-002 . TIME RELAY
005 1 324 0089-801 . RELAY CARD WITH LEDS SEE FIG. 625-8599.020
2011-03-31 9.5 625-8650.014 1 (2)
EL.INST. VENTILATION FAN (CT1)
224 0505-801
625-8650.014
2011-03-31 9.5 625-8650.014 2 (2)
EL.INST. VENTILATION FAN (CT1)

000 1 224 0505-801 EL.INST. VENTILATION FAN (CT1)
003 1 6480 2160-101 . FAN

2011-04-04 9.5 625-8650.015 1 (2)
EL. INST. AUX RELAY (CT1)
224 0548-801
625-8650.015
2011-04-04 9.5 625-8650.015 2 (2)
EL. INST. AUX RELAY (CT1)

000 1 224 0548-801 EL. INST. AUX RELAY (CT1)
001 1 5354 4133-221 . CONTACTOR RELAY
005 1 7426 4200-050 . SURGE SUPPRESSOR

2011-04-05 9.5 625-8650.016 1 (2)
EL.INST.EXTRA CABLE (CT1/CT2)
3
5 6
S
P
1
1
1
1
P
S
124 0524-801
625-8650.016
2011-04-05 9.5 625-8650.016 2 (2)
EL.INST.EXTRA CABLE (CT1/CT2)

000 1 124 0524-801 EL.INST.EXTRA CABLE (CT1/CT2)
003 2 2166 1901-140 . CABLE GLAND M40
005 1 5217 4833-241 . PLUG HOOD
006 1 5217 4834-240 . SCREW CONNECTION Female

2011-02-03 9.5 625-8655.001 1 (2)
CABIN DISPLAY
424 0715.801
625-8655.001
2011-02-03 9.5 625-8655.001 2 (2)
CABIN DISPLAY
000 1 424 0715-801 CABIN DISPLAY
001 1 5730 1003-101 . DISPLAY
002 1 424 0632-801 . USB CABLE
003 1 424 0786-801 . BUZZER CABLE

2011-04-19 9.5 625-8750.005D 1 (2)
SLIPRING UNIT
2011-04-19 9.5 625-8750.005D 2 (2)
SLIPRING UNIT
000 1 314 3985-801 SLIPRING UNIT
011 20 875 17202-001 . SIGNAL BRUSH, COMPLETE 20 A
012 22 875 17203-001 . HOLDER
021 3 875 17201-001 . POWER BRUSH, COMPLETE 400 A
022 1 875 17201-002 . POWER BRUSH, COMPLETE 400 A, earth
101 1 875 17207-006 . POWER CABLE Slipring #101, earth
102 1 875 17207-001 . POWER CABLE Slipring #102

2011-06-27 9.5 625-9597.081 1 (2)
CABIN DISPLAY ASSEMBLY
1182879
625-9597.081
2011-06-27 9.5 625-9597.081 2 (2)
CABIN DISPLAY ASSEMBLY

000 1 1182879 CABIN DISPLAY ASSEMBLY
004 1 1183160 . CABLE

2010-03-15 9.7 624-2145.009A 1 (2)
CABLE WINCH ASSEMBLY
324 1956-801
624-2145.009
2010-03-15 9.7 624-2145.009A 2 (2)
CABLE WINCH ASSEMBLY

000 1 324 1956-801 CABLE WINCH ASSEMBLY
002 1 387 7990-801 . CABLE WINCH SEE FIG. 624-2158
003 1 1684 2125-425 . CABLE L = 17 m
004 1 1689 2133-425 . CABLE L = 90 m
005 1 1684 2125-402 . CABLE L = 17 m
006 1 324 1955-801 . SOCKET PLUG
008 1 487 5325-803 . CABLE LAYING
009 2 2529 2134-040 . HOSE CLIP

2006-10-02 9.7 624-2158E 1 (2)
CABLE WINCH
2006-10-02 9.7 624-2158E 2 (2)
CABLE WINCH
000 1 387 7990-801 CABLE WINCH 4 x 25 mm2
001 1 875 20001-003 . ELECTRIC MOTOR 3.6 kW
002 2 875 20002-001 . V-BELT L = 1212 mm
003 1 875 20003-004 . V-BELT SHEAVE D = 155 mm
004 1 875 20003-002 . V-BELT SHEAVE D = 250 mm
005 1 875 20007-001 . PROTECTIVE DEVICE
010 1 875 20004-001 . TURBO COUPLING, COMPLETE Incl. item 11-13.
011 1 875 20004-003 .. SEAL KIT
012 1 875 20005-001 .. OIL FILLING PLUG M 42
013 1 875 20005-002 .. SAFETY PLUG 140 C
014 1 875 20004-002 . COVER
015 1 875 20012-001 . SEALING
019 1 875 20015-001 . SLIPRING ASSEMBLY, COMPLETE Incl. item 20-25.
020 1 875 20008-005 .. HOUSING
021 1 875 20008-001 .. COVER
022 1 875 20008-003 .. GASKET
023 1 875 20008-004 .. CLAMP
024 1 875 20010-003 .. BRUSHHOLDER, EARTH 150 A
025 3 875 20010-004 .. BRUSHHOLDER, PHASE 150 A
031 1 875 20006-001 . BRAKE, COMPLETE
032 1 875 20006-002 . COVER
033 2 875 20011-001 . PLUG
034 1 875 20011-002 . OIL SIGHT GLASS
035 1 875 20011-003 . AIR VENTILATION PLUG

2011-04-21 9.7 624-2420.001B 1 (2)
STABILIZATION WINCH
Note.
For wire, see Mounting stab and cable wheel.
180
170
310
60
110
324 1401-801
624-2420.001 /B
Weight 190 kg
2011-04-21 9.7 624-2420.001B 2 (2)
STABILIZATION WINCH
000 1 324 1401-801 STABILIZATION WINCH
060 1 875 20017-003 . GEARBOX, COMPLETE
110 1 875 20001-007 . ELECTRIC MOTOR
170 1 875 20004-001 . TURBO COUPLING, COMPLETE
180 1 875 20006-004 . BRAKE, COMPLETE
310 2 875 20002-003 . V-BELT L = 1287 mm

2009-02-03 9.7 624-2435.010 1 (2)
MOUNT. STAB. AND CABLE WHEEL
3
1 2
18 17
9, 13, 14, 15 6
4
5
189 7669-801
624-2435.010
2009-02-03 9.7 624-2435.010 2 (2)
MOUNT. STAB. AND CABLE WHEEL

000 1 189 7669-801 MOUNT. STAB. AND CABLE WHEEL
001 X . STAB WINCH SEE TABLE OF CONTENTS SECTION 9.7
002 X . CABLE WINCH
003 1 189 7420-801 . STAB WIRE SHEAVE ASSY SEE FIG 624-2162.011
004 1 289 3307-801 . BRACKET WITH SHEAVE
005 1 189 3997-801 . CABLE WHEEL ASSEMBLY
006 2 189 3916-801 . CABLE WHEEL ASSEMBLY
009 8 2126 2634-126 . LOCKING NUT M6LM 20 - A2-70
013 4 2121 2034-676 . SCREW M6S 20 x 60 -A2-70
014 4 2151 2054-192 . WASHER TBRSUB 21 x 52 FZV
015 4 2151 2027-192 . WASHER BRB 21 x 37 -A2
017 1 487 3908-802 . SLING ASSEMBLY
018 1 487 4484-807 . STEEL WIRE W. THIMBLE

2011-09-01 9.7 624-2492C 1 (2)
HAND PUMP
50
22 13
9
49
8
6
19
27
2
28
21
52
7
3 10
20
36
189 1952-801
624-2492
2011-09-01 9.7 624-2492C 2 (2)
HAND PUMP
000 1 189 1952-801 HAND PUMP
002 1 389 1507-801 . SINGLE ACTING PUMP
003 1 389 3862-801 . RELIEF VALVE
004 1 389 3864-801 . NEEDLE VALVE
006 1 489 3126-801 . FLOW CONTROL VALVE
008 1 489 5662-801 . NEEDLE VALVE
009 1 489 5663-001 . BUSHING
010 1 489 5901-801 . COUPLING
013 1 2121 2033-463 . SCREW M6S 8 x 60 H -8.8 FZB
027 1 2528 2773-100 . NUT
028 1 2528 2763-100 . PLUG
036 1 2522 2170-100 . PLUG
049 1 2529 2458-111 . QUICK COUPLING G 3/8"
050 1 2529 2458-116 . QUICK COUPLING G 1"
052 1 5693 4121-060 . MANOMETER

2010-08-13 9.7 624-2524A 1 (2)
FIRE EXTINGUISHER, MOUNT
490 4074-801
624-2524
2010-08-13 9.7 624-2524A 2 (2)
FIRE EXTINGUISHER, MOUNT

000 1 490 4074-801 FIRE EXTINGUISHER, MOUNT
003 1 6956 2020-060 . FIRE EXTINGUISHER POWDER

2009-02-02 9.7 624-2162.011 1 (2)
STAB WIRE SHEAVE ASSY
10 5 6
9
11
7
4
10
189 7420-801
624-2162.011
2009-02-02 9.7 624-2162.011 2 (2)
STAB WIRE SHEAVE ASSY

000 1 189 7420-801 STAB WIRE SHEAVE ASSY
001 1 390 6516-801 . SHEAVE ASSY.
002 2 391 1441-801 . GUIDE RING
003 1 391 1457-001 . SHAFT
004 1 490 6836-001 . SPACER RING
005 2 490 6839-001 . SPACER TUBE
006 2 490 6840-001 . BAR
007 2 2126 2034-128 . NUT M6M 24 - A2-70
008 1 2126 2532-128 . CASTLE NUT MKM 24 - 8 FZB
009 1 2114 2014-218 . SPLIT PIN SP 5 x 50 -A2
010 2 2114 2014-199 . SPLIT PIN SP 4 x 32 -A2
011 2 2119 4122-040 . HAIR PIN

2010-11-12 9.7 624-2147.002 1 (2)
EL. INST. HEAT. SLIPR. DEVICE
324 2274-801
624-2147.002
2010-11-12 9.7 624-2147.002 2 (2)
EL. INST. HEAT. SLIPR. DEVICE

000 1 324 2274-801 EL. INST. HEAT. SLIPR. DEVICE

2008-10-30 9.7 624-2180.014 1 (2)
MOUNTING ENCODER
390 9851-801
624-2180.014
2008-10-30 9.7 624-2180.014 2 (2)
MOUNTING ENCODER
000 1 390 9851-801 MOUNTING ENCODER
001 1 490 4982-001 . TORQUE ARM
002 3 2121 2550-220 . SCREW MC6S 3 x 6 -A2-70

2008-10-30 9.7 624-2180.015 1 (2)
MOUNTING ENCODER
390 9852-801
624-2180.015
2008-10-30 9.7 624-2180.015 2 (2)
MOUNTING ENCODER
000 1 390 9852-801 MOUNTING ENCODER
001 1 490 4982-001 . TORQUE ARM
002 3 2121 2550-220 . SCREW MC6S 3 x 6 -A2-70

2010-12-30 9.7 624-2195.013 1 (2)
SENSOR ASSEMBLY
1
4
7
17
5
2
7
17
1196357
624-2195.013
2010-12-30 9.7 624-2195.013 2 (2)
SENSOR ASSEMBLY
000 1 1196357 SENSOR ASSEMBLY
001 1 324 1408-801 . ABSOLUTE SINGLETURN ENCODER
002 1 324 1409-801 . INCREMENTAL ENCODER 5000
004 1 390 9852-801 . MOUNTING ENCODER SEE FIG. 624-2180.015
005 1 390 9851-801 . MOUNTING ENCODER SEE FIG. 624-2180.014
007 2 2623 4130-102 . SENSOR CABLE
017 2 424 0756-801 . CONNECTOR 6-POL

2011-01-24 9.7 624-2196.006 1 (2)
EL. INST. EMERG. STOP PEDESTAL
124 0335-801
624-2196.006
2011-01-24 9.7 624-2196.006 2 (2)
EL. INST. EMERG. STOP PEDESTAL

000 1 124 0335-801 EL. INST. EMERG. STOP PEDESTAL
001 1 5372 2444-105 . EMERGENCY STOP

L9499462 GLB3628-2 - 28.828gr

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L9499462 GLB3628-2 - 28.828gr

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INSTRUCTION MANUAL Project No.

GENERAL 1 1.000.4 E d SAFETY INSTRUCTIONS

TECHN. DESCRIP. 2 2/10045.02LMW - TECHNICAL DATA

FUNCTION 3 3.110.122 E - HYDRAULIC FUNCTION

OPERATION 4 PM40 1879-E00 - CREW CHECKLIST BEFORE AND AFTER OPERATION

MAINTENANCE 5 5.005.55 E g MAINTENANCE CHART

MAINTENANCE 5 5.018 E b INSPECTION OF STRESSED COMPONENTS AND STRUCTURES

6.0 6.000 E e HOW TO ORDER SPARE PARTS

6.3 6.303.49 E e TROUBLESHOOTING, CRANE CONTROL SYSTEM CC3000, GLB-CRANE

EXTRA EQUIPMENT 7 7.003.2 E c CABLE WINCH, TYPE KFM

SPARE PARTS 9 SEE SEPARATE TABLE OF CONTENTS

9.0 HOW TO ORDER SPARE PARTS e 6.000 E

9.1 HOISTING WINCH COMPLETE 189 6696-801 C/ 625-1440.147A

9.2 PUMP UNIT 1196654 A/ 625-4935.213

9.3 OIL TANK ASSEMBLY 189 3870-801 -/ 625-5865.033A

9.3 CRANE TOP ASSEMBLY 1195407 -/ 625-6459.071

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

9.5 DRIVERS DESK 124 0827-801 A/ 625-8563.059

9.5 EL.INST. EXTRA CABLE (CABIN) 324 1236-801 A/ 625-8597.075

9.7 CABLE WINCH ASSEMBLY 324 1956-801 D/ 624-2145.009A

Cargo Handling Equipment

Supervision, Instructions, Signs and Warnings

Preparation for Use and Operation According to Improper Use

MacGREGOR are available for full service of this cargo

Functions, Installations and Equipment Safety Functions and Equipment

General Specific safety equipment is installed and delivered

4. If there is a multiple-disc failure caused by worn d. Mechanical functions:

b. Safety belt, rescue line, safety chains:

Danger, Warning, Caution and Notice

Principles of Risk Classification

Those risks classified as DANGER sign are pre-

2. WARNING SIGNS are attached to equipment or

The danger does not exist unless protection instal-

3. CAUTION SIGNS are attached to equipment or

Any person should be able to avoid the danger.

4. NOTICE SIGNS are attached to equipment and

Responsible officers onboard must ensure that the

Alert / Warning signs

PM40 7101-E00 REPORT TO SUPERINTENDENT OR OPERATORS ROOM FOR PERMIT TO ENTER

This sign is at the bottom entrance to the crane foundation.

This sign is at the bottom entrance to the crane foundation.

This sign is at the bottom entrance to the crane foundation.

This sign is at the bottom entrance to the crane (twin) platform.

Attached to the crane wall surfaces close to winches.

Attached to brackets and walls of work platforms inside crane

Attached on the wall side of the crane operators cabin.

Attached to surfaces close to pipes inside the crane house.

PM40 7115-E00SLIPPERY SURFACES - WATCH OUT!

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

Applied on the wall side of the crane operators cabin.

Attached outside and inside the cabin.

Attached to surfaces close to pipes inside the crane house.

Attached to brackets and walls of work platforms inside the crane.

Attached to the crane wall surfaces close to winches.

Attached to brackets and walls of work platforms inside the crane.

Attached to the cover of slipring device in the foundation.

Fig. 1. PM40 7101-E00 Fig. 2. PM40 7102-E00

Fig. 3. PM40 7103-E00 Fig. 4. PM40 7104-E00

Fig. 5. PM40 7105-E00 Fig. 6. PM40 7106-E00

Fig. 7. PM40 7108-E00 Fig. 8. PM40 7109-E00

Fig. 9. PM40 7111-E00 Fig. 10. PM40 7112-E00

Fig. 11. PM40 7113-E00 Fig. 12. PM40 7114-E00

Fig. 13. PM40 7115-E00 Fig. 14. PM40 7116-E00