SERVICE 6.125.14 E rev.

: - 1997-05-22

Feed Pump Unit

1
2

Introduction
The pump is a screw-type pump with fixed displacement 3
which supplies the feed and control circuits of the
crane. The pump is submerged in the hydraulic oil.
Thus, one pipe only connects the pump to the hydraulic
system.

The pump is separately driven by an electric motor

which is mounted in the oil tank. 5

4 7
To overhaul the pump or the electric motor, the entire
pump unit - motor and pump - should be taken out.

Caution!
Maintain cleanliness throughout! 6

Fig. 1. Tank with feed pump unit

1. Removing and dismantling pump unit
- Park crane jib, stop crane, switch off main switch 1. Air filter with oil dipstick
- Remove tank cover (2) 2. Tank cover
- Loosen the upper end of the hose (5) 3. Oil level and temperature guard
- Disconnect the electric connections to the electric 4. Chain
motor (6) 5. Hose
- Lift electric motor (6) with pump (7), using the chain 6. Electric motor
(4) 7. Pump
- Remove mounting screws holding electric motor (6)
Electric motor
onto the pump (7)
- Withdraw pump (7) from motor (6).

2. Reassembling pump
- Reassemble pump unit in reverse order to
dismantling.
- Replace pump unit. Reinstall and reconnect hydraulic
pipes and components. Reconnect electric motor
power cable.
Pump
- Jog start pump unit to check rotation.
Mounting screws

Fig. 2. Pump with electric motor

1 (1)
SERVICE 6.127.22 E rev.: a 1998-11-03

High Pressure Pumps

General Function checking/Adjusting of “plussing“

All pumps are the straight axial piston type with Hoisting winch
variable displacement controlled by a servo valve - No load on hook.
mounted on the pump housing. - Start the crane.
- Install a pressure gauge 0-400 bar at connection
The pumps are equipped with two adjustments, one 3.1.
for “plussing“ and the other for pressure adjustment - Close valve 1663 (see Fig. 6).
(max. working pressure). “Plussing“ of the pumps is - Move control lever for the hoisting winch to the brake
done to compensate for internal leakage in pumps open position (see Fig. 3).
and motors to prevent load drops (see Fig. 1). - Check the pressure. See hydraulic circuit diagram.
- If the pressure is incorrect, an adjustment must be
made using the “zero setting“ screw (see Fig. 1).
If there is more than one hoisting pump, the lower
pump should be adjusted.
- Stop the crane.
- Open valve 1663.

Zero setting screw

Servo valve

Electrical connector Electrical connector

Pressure cut-off valve

Fig. 1. Pump A4VG 125.

The Original Manufacturer of HÄGGLUNDS Cranes 1 (6)

SERVICE 6.127.22 E rev.: a 1998-11-03

Luffing winch - Close the main switch HA.

- No load on hook. - Reinstall the electrical connectors on the pump.
- Park the crane or move the hook block close to the
jib top.
Installation of a new servo or complete pump
- Stop the crane.
When a new servo unit or a complete pump is installed,
- Open main switch HA.
a function check of the "plussing" has to be carried out.
- Open box MB and pull out the first electronic card
Proceed according to “Function checking/Adjusting of
(see Fig. 2).
“plussing”.
- Close main switch HA.
- Remove the two electrical connectors from the
pump (see Fig. 1).
- Start the crane.
- Install a pressure gauge, 0-400 bar, in outlet 5.1,
(see Fig. 7).
- Close valve 2661 (see Fig. 7).
- Move the control lever for the luffing winch for Pull out
luffing-in (see Fig. 4).
- Check the pressure. See hydraulic circuit diagram.
- If the pressure is incorrect, an adjustment must be
made using the “zero setting“ screw (see Fig. 1).
- Stop the crane.
- Open main switch HA.
- Reinstall the first electronic card (see Fig. 2).
- Close box MB.
- Close the main switch HA.
- Reinstall the electrical connectors on the pump.
- Open valve 2661.

Slewing machinery
- No load on hook.
- Stop the crane.
- Open main switch HA.
- Open box MB and pull out the first electronic card
(see Fig. 2).
- Close main switch HA.
- Remove the electrical connectors from the pump
(see Fig. 1).
- Start the crane.
- Move the control lever for the slewing machinery for
slewing left or right (see Fig. 5).
- Ensure that the crane does not move in any direction.
- If the crane does move, an adjustment must be
made using the “zero setting“ screw (see Fig. 1).
- Stop the crane. Fig. 2. MB-Box
- Open main switch HA.
- Reinstall the first electronic card (see Fig. 2).
- Close box MB.

2 (6) The Original Manufacturer of HÄGGLUNDS Cranes

SERVICE 6.127.22 E rev.: a 1998-11-03

Adjustment of cut-off valves
Hoisting pump
- This valve has a setting of 100 - 420 bar. By turning
the adjustment screw 1 revolution the setting is
changed approx. 90 bar.
- Back off the adjustment screw.
- Install a pressure gauge 0-400 bar at connection
3.1.
- Close valve 1663 (see Fig. 6).
- Drive in high speed mode and at max. 25 % speed.
- Adjust the pressure cut-off valve on pump 1111.
See pressure setting list for hydraulic circuit dia-
gram 1111-10.
- Open valve 1663.
With two hoisting pumps
- Turn the valve on pump 1112 to its maximum
setting.
- Adjust valve on pump 1111 as described in above
paragraph "Hoisting pump".
- Adjust valve on pump 1112 by backing off the
setting screw until a little lower pressure can be
read.
- Turn the screw 1/4 revolution.
Luffing pump
- Start the crane.
- Install a pressure gauge, 0-400 bar, in outlet 5.1,
(see Fig. 6).
- Close valve 2661 (see Fig. 7).
- Back off adjustment screw (pressure cut-off valve).
- Drive the crane with 25 % speed (see Fig. 4).
- Adjust pressure cut-off valve 2111-10. See hydrau-
lic circuit diagram for pressure setting.
- Stop the crane.
- Open valve 2661.
Slewing pump
- Start the crane.
- Install a pressure gauge, 0-400 bar, in outlet 6.1 or
6.2.
- Close valve 3661 (see Fig. 8).
- Back off adjustment screw.
- Drive crane with 25 % speed (see Fig. 5).
- Adjust pressure cut-off valve 3111-10, see hydraulic
circuit diagram for pressure setting.
- Stop the crane.
- Open valve 3661.
Installation of a complete new pump
When a new pump is installed, the pressure cut-off
valve has to be adjusted (see “Adjustment of the
pressure cut-off valves”).
N.B. These valves are sealed and the seals must not
be broken.
Adjustment and replacement of these valves must be
done by qualified personnel only.
Contact the Service Department at MacGREGOR
Cranes for information about valve adjustment.

High speed

Fig. 3. Hoisting position. Fig. 4. Luffing position. Fig. 5. Slewing left or right.

The Original Manufacturer of HÄGGLUNDS Cranes 3 (6)

SERVICE 6.127.22 E rev.: a 1998-11-03

(Optional)

Fig. 6. Part of hoisting circuit

4 (6) The Original Manufacturer of HÄGGLUNDS Cranes

SERVICE 6.127.22 E rev.: a 1998-11-03

Valve

Outlet 5.1

Fig. 7. Part of luffing circuit

The Original Manufacturer of HÄGGLUNDS Cranes 5 (6)

SERVICE 6.127.22 E rev.: a 1998-11-03

Valve

Outlet 6.1 Outlet 6.2

Fig. 8. Part of slewing circuit.

6 (6) The Original Manufacturer of HÄGGLUNDS Cranes

SERVICE
Hydraulic Piston Accumulator 388 0362-801, -802, -803
Function
A hydraulic accumulator functions as a source of pres-
surized fluid. Conversely, when the pressure falls off,
the accumulator supplies oil to the hydraulic system.
N.B. - Do not bleed hydraulic accumulators!
Charging equipment
To charge hydraulic accumulators, art. no. 388 0362,
MacGREGOR Cranes supply a charging valve and
associated equipment, Fig. 2, comprising:
- a three-way valve
- a 0-25 bar pressure gauge
- a 1-metre hose with a W24 connector for nitro-
gen cylinder
- two reduction connectors, W24/32M and W24/14D.
Charging pressure for 388 0362-801: 15±1 bar at 20°C.
Charging pressure for 388 0362-802: 28±1 bar at 20°C.
Charging pressure for 388 0362-803: 20±1 bar at 20°C.
New design
Gas valve
Protective cap
Valve guard
Open/close
hexagonal nut
Fig. 1. New design. Piston accumulators 388 0362-801, -802, -803.
6.189 E rev.: e 2003-01-20
Charging hydraulic accumulators with nitrogen (N2)
All crane motors must be immobilized.
1. Dismount valve guard and unscrew the
protective cap from gas valve.
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.
2a. Old design, see Fig. 2. Connect the three-way
valve to the gas valve of the accumulator. The
filling screw of the three-way valve shall be
backed out completely, and the bleed valve
tightly closed.
3. Connect the charging valve, see Fig. 3 to the
reducing valve at the nitrogen cylinder.
4. Back out the adjusting screw of the reducing
valve on the nitrogen cylinder until the valve
spring is unloaded.
5. Open the nitrogen cylinder valve.
6. Adjust the reducing valve to the correct charg-
ing pressure.
Valve guard
Protective cap
Gas valve Open/close
hexagonal nut
1 (3)
SERVICE
7. New design, see Fig. 1. Open the hexagonal nut
on the gas valve counter-clockwise to stop, by
using a 19 mm fork wrench.
7a. Old design, see Fig. 2. Screw in the filling screw
of the three-way valve but not so tightly that the
gas valve of the accumulator is damaged.
8. Fill nitrogen.
9. New design, see Fig. 1. Check the nitrogen
pressure when the temperature and the pressure
of the gas become stable. When the correct
charging pressure has been obtained, close the
gas valve by turning the hexagonal nut clockwise
by use of the 19 mm fork wrench.
9a. Old design, see Fig. 2. Check the nitrogen
pressure when the temperature and the pressure
of the gas have become stable. When the correct
charging pressure has been obtained, again
back out the filling screw of the three-way valve.
Old design
Valve guard
Protective cap Gas valve
Fig. 2. Old design. Piston accumulators 388 0362-801, -802, -803.
2 (3)
6.189 E rev.: e 2003-01-20
10. Close the nitrogen cylinder valve.
11. Open the bleed screw of the three-way valve to
discharge the pressure in the filling hose.
12. Adjust the reducing valve to zero.
13. Unscrew the charging equipment from the nitro-
gen cylinder and from the accumulator.
14. Check tigthness of accumulator gas valve, us-
ing soap water.
N.B. - The protective cap shall be fitted with an
O-ring which must fit correctly into its groove.
15. Screw on protective cap of the gas valve.
16. After charging the accumulator, fit a lable carry-
ing the charging date and signed by the operator.
N.B. For charging, it is not necessary to install a
reducing valve on the nitrogen cylinder.
Valve guard
Gas valve Protective cap
SERVICE 6.189 E rev.: e 2003-01-20

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 (3)
 S E RV I C E I N F O R M AT I O N

625/1531 E rev.:- 1998-10-29

Oil Filling Equipment

The fundamental and foremost rule in all work with Note! Even when filling new oil it is of utmost im-
hydraulic systems and components is absolute portance to connect the equipment to the quick cou-
cleanliness. Every care must be taken to prevent pling on crane's existing filter. Observe minute
external impurities from entering the system. cleanliness when handling all type of quick-release
connectors.
This oil filling equipment, see Fig. 1, is designed for
pumping oil from the ship's deck via existing filter
to tank. Can also be used when draining the oil tank,
by shifting direction of pump rotation and changed
connection to oil tank.

Technical Data:
Quick coupling
Oil Filling Equipment 489 5473-804: Hose length (male type)
Already installed
25 m on existing filter in
Oil Filling Equipment 489 5473-805: Hose length crane
15 m

Pump: Q=35 L/min P=10 bar Temp. range=0-50°

El. motor: P=1,5 kw 3 phase 380/440 V 50/60 Hz

Plug

Connection nipple
(female type)
El. cable

Coupling
Hydraulic hose
L=3m Hydraulic hose
L = 25 m / L = 15 m

Pump motor
unit

489 5473-xxx

Fig. 1 Oil filling equipment

The Original Manufacturer of HÄGGLUNDS Cranes 1 (1)