Professional Documents
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L9499462 GLB3628 2 28 828gr PDF
L9499462 GLB3628 2 28 828gr PDF
L9499462 GLB3628 2 28 828gr PDF
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
TABLE OF CONTENTS
INSTRUCTION NO. REV NAME OF INSTRUCTION
SERVICE 6
6.1 6.100 E b MEASURES BEFORE STARTING, DURING AND AFTER COMPLETED SERVICE/M
6.106.4 E - TROUBLE-SHOOTING CHART, OVERHEATING
6.117 E b TROUBLE SHOOTING, PUMPS
6.120.18 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
TABLE OF CONTENTS
INSTRUCTION NO. REV NAME OF INSTRUCTION
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
APPENDICES 8
TABLE OF CONTENTS
GROUP DESCRIPTION PART NUMBER FIG
TABLE OF CONTENTS
GROUP DESCRIPTION PART NUMBER FIG
TABLE OF CONTENTS
GROUP DESCRIPTION PART NUMBER FIG
Safety Instructions
1 (14)
GENERAL 1.000.4 E rev.: d 2010-10-07
1. Safety Functions
Regular Care and Control (Maintenance)
a. Maneuvring functions:
This manual contains checklists for regular care and
1. All the crane’s working functions are stopped
control of crane equipment, wire ropes and hydraulic
and the brakes will automatically be activated
filters. These checklists routine contain inspections
when the emergency stop button is pressed.
and maintenance regularly prescribed for safe func-
The buttons are loacated in cabin and on the
tion, e.g.:
CT1-cabinet door. This action activates safety
stops and automatic lock positions.
Chapter 4 contains:
2. The crane has several fail-safe functions for
Safety Precautions Checklist for Single Cranes.
over-ruling or stopping the operator’s maneuvring
in the event that normal hydraulic or electrical
Chapter 5 contains, if applicable:
functions fail, a sudden uncontrolled movement
Inspection of Stressed Components and Structures.
occurs or during overspeed operation (see be-
Lubrication chart; Crane.
low).
Lubrication chart; Cable Winch and Stabilizing Equip-
3. There are limit switches for reducing speed of
ment.
or stopping all dangerous motions.
Lubrication chart; Power Swivel.
Filters. b. Hydraulic functions:
1. Hydraulic valve functions are set for exact pres-
Before maintenance and service work is started, cer- sure. Any change in the settings adversely af-
tain measures and procedures must be done. fects crane operation and must exclusively be
set by professional service personnel (see in-
Chapter 6 contains: structions Hydraulic function and High pressure
Measures before Starting, during and after completed pumps).
Service/Maintenance Work. 2. Hydraulic oil pressure sensor automatically in-
Handling, Installation and Maintenance of Steel Wire dicate an overload. For safe hoisting or lower-
Ropes. ing, the system automatically switch from a high-
Electrical Equipment, General Maintenance. speed movement to a lowspeed movement. If
Emergency Lowering in Case of Complete Power already in lowspeed the hoisting and luffing
Failure, Operation of Crane Using a Hand Pump crane movements stop.
(Optional). 3. In case of a ruptured high-pressure oil pipe/hose
or other feed pressure drops, the oil feed pres-
sure will collapse. A feed pressure switch stops
the crane and the mechanical brakes are auto-
matically applied.
2 (14)
GENERAL 1.000.4 E rev.: d 2010-10-07
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.
c. Firefighting equipment:
A fire extinguisher shall be made available by
owner in the operator’s cabin.
4 (14)
GENERAL 1.000.4 E rev.: d 2010-10-07
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.
5 (14)
GENERAL 1.000.4 E rev.: d 2010-10-07
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.
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
operator’s alarm bell, in the crane operator’s cabin, may be used, preferably.
Attached to surfaces inside the crane house, close to pumps, valves, pipes and manifold blocks.
Also in the foundation close to oil tank and pipes.
PM40 7114-E00 DANGEROUS OIL PRESSURE - BE CAREFUL!
The oil pressure inside oil pressure pipes is 25 - 350 bar.
Under normal working conditions, this exposes no risk for personnel because of rigorous pipe
WARNING SIGN quality control and dimensions and specifications applied to the equipment. For specific ser-vice
work, exchange of parts or equipment, the exposure may be dangerous for unqualified or
uninformed personnel.
Instructions for service must be followed and must be restricted to qualified personnel only.
7 (14)
GENERAL 1.000.4 E rev.: d 2010-10-07
Attached to cooling fans, at the open-air crane top, and at the inside top roof.
PM40 7117-E00 HIGH VOLTAGE INSIDE - DO NOT OPEN! AUTHORIZED PERSONNEL ONLY
High voltage equipment, couplings and boxes are covered and do not expose risk unless co-
vers or hoses are removed. Access is restricted to qualified and authorized personnel only.
DANGER SIGN
Attached to electrical equipment and boxes where 110 V or 440 V is exposed after covers are
removed.
PM40 7118-E00 RISK OF FALLING DOWN - APPLY SAFETY CHAIN!
During any visit to the work platforms, the authorizing officer and the person entering the area
must fully understand the risks involved.
WARNING SIGN The safety chains (at work platforms) must be used to prevent personnel from falling.
Attached to the steel bracket side at the open-air crane top platform, and at the crane work
platforms inside the crane house.
PM40 7119-E00 HIGH VOLTAGE INSIDE - DO NOT OPEN BEFORE MAIN SWITCH (Q1) IS SWITCHED OFF!
AUTHORIZED PERSONNEL ONLY
High voltage equipment, couplings and boxes are covered and do not expose risk unless
covers or hoses are removed. Access is restricted to qualified and authorized personnel only.
DANGER SIGN
Attached to electrical equipment e. g. electric main motor.
PM40 7122-E00 RISK OF BODILY INJURY - SUSPENDED LOAD - WATCH OUT!
The crane operator must ensure that the suspended load does not expose personnel below to
risks of falling material. The crane operator must stop operation and alert personnel.
DANGER SIGN The operator’s alarm bell in the crane operator’s cabin is preferably used.
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 operator’s cabin.
PM40 7125-E00 DANGER - KEEP OUT OF WORKING AREA!
The working area of the crane, over deck as well as over the deck-sides, is dangerous for
personnel, equipment or property. Items lifted or articles dropped may cause death, injury or
DANGER SIGN severe damage.
The crane operator must stop operation and alert personnel.
The operator’s alarm bell must also be used for attention.
Attached on both sides of the crane jib.
PM40 7127-E00 220V INSIDE. DO NOT OPEN! AUTHORIZED PERSONNEL ONLY
This high voltage equipment is covered and does not expose risk unless cover is removed.
The electrical equipment inside cover is powered even if the main switch has shut off other
DANGER SIGN electrical supply.
Access is restricted to qualified and authorized personnel only.
Attached to cooling fans, at the open-air crane top, and at the inside top roof.
PM40 7130-E00 DANGEROUS OIL PRESSURE. BE CAREFUL!
The oil pressure inside oil pressure pipes is 25 - 350 bar.
Under normal working conditions, this exposes no risk for personnel because of rigorous pipe
quality control and dimensions and specifications applied to the equipment. For specific service
WARNING SIGN work, exchange of parts or equipment, the exposure may be dangerous for unqualified or
uninformed personnel.
Instructions for service must be followed and must be restricted to qualified personnel only.
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.
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.
10 (14)
GENERAL 1.000.4 E rev.: d 2010-10-07
11 (14)
GENERAL 1.000.4 E rev.: d 2010-10-07
12 (14)
GENERAL 1.000.4 E rev.: d 2010-10-07
13 (14)
GENERAL 1.000.4 E rev.: d 2010-10-07
14 (14)
GENERAL 1.005 E rev.: e 2003-09-09
Preface
General
Contents list; Safety; Conversion tables; Hydraulic
and electric symbols.
Technical description
Technical data; description of crane design.
Function
Electric and hydraulic functions of the crane.
Operation
Operating instructions; crane operator’s checklist.
Maintenance
Lubricating chart and maintenance instructions.
Service
General service instructions for the hydraulic system,
mechanical, control system and electrical equipment.
Extra equipment
Extra equipment, if any; e.g. cargo handling equip-
ment.
Appendices
Other information, which cannot be referred to any of
the above mentioned sections.
1 (2)
GENERAL 1.005 E rev.: e 2003-09-09
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 0°C = 32°F
1 kpm= 9,80665 Nm 0°C = 273,15 K
1 kpm= 7,23301 lbf · ft 0°F = -17,7778°C
1 Nm = 0,737562 lbf · ft 0°F = 255,3722 K
1 lbf · ft = 0,135582 daNm 0K = -273,15°C
1 lbf · ft = 1,35582 Nm 0K = -459,67°F
1 lbf · ft = 0,13825 kpm
1 daNm = 1,01972 kpm 1
°C = (°F - 32) °F = 1,8 (K - 273,15) + 32
1 daNm = 7,37562 lbf · ft 1,8
1
°F = °C · 1,8 + 32 K= (°F - 32) + 273,15
1,8
Moment of inertia
°C = K - 273,15
1 kg · m 2 = 3417,17 lb · in2
1 lb · in 2 = 0,00029264 kg · m2 K = °C + 273,15
1 (2)
1.102 E rev.: c 1999-09-14
2 (2)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
This section covers a part of the symbols and port markings commonly
used in MacGREGOR (SWE) AB, Service Division hydraulic and electric
circuits, divided into three parts:
3. Electric symbols.
Elektrische Schaltzeichen.
1 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
1. Hydraulic Symbols
Hydraulische Bildzeichen
Pilot line.
Steuerdruckleitung.
Drain line.
Leckölleitung .
Fixed restriction.
Feste Blende, feste Drosselung.
Variable restriction.
Regelblende, regelbare Drosselung.
Flexible hose.
Schlauch, biegsame Leitung.
2 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
Pipe junction.
Leitungsverbindung.
Rotary connection.
Dreh-Verbindung.
Regulation or variability.
Regelbar oder nachstellbar.
Mechanical connection.
Mechanische Verbindung.
3 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
Electric motor.
Elektromotor.
M
Filter.
Filter.
4 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
Air breather.
Luftreiniger.
Non-return valve.
Rückschlagventil.
5 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
Gauge connection.
1
Meßanschluß.
Ventilation valve.
Entlüftungsventil.
Shuttle valve.
Wechselventil.
Brake cylinder.
Bremszylinder.
Pressure gauge.
Manometer.
Thermometer.
Thermometer.
6 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
Oli cooler.
Ölkühler.
Accumulator.
Druckspeicher.
Shut-off valve.
Absperrventil.
7 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
Proportional valve.
Proportionalventil.
Servo valve.
Servoventil.
8 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
Cartridge valve.
Patronenventil.
9 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
10 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
2. Valve Assemblies
Ventil-Baugruppen
11 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
12 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
13 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
14 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
15 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
16 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
17 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
18 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
Flushing valve.
Spülventil.
19 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
20 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
21 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
3. Electric Symbols
Elektrische Schaltzeichen
Make contact.
Arbeitskontakt.
Break contact.
Schaltkontakt.
22 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
Main contact.
Hauptkontakt.
Emergency stop.
Notschalter.
Limit switch.
Endschalter.
23 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
Pressostat.
Pressostat. P
Level switch.
Ölstandswächter.
Inductive contact.
Induktiver Geber.
Ammeter.
Strommesser.
A
Voltmeter.
Voltmesser. V
Hour counter.
Stundenzähler. h
24 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
Rectifier.
Gleichrichter.
Frequency converter.
Frequenzumformer.
25 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
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)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
Position encoder.
Drehfeldgeber.
Puls/speed encoder
Geschwindigkeitsgeber
Resistor.
Widerstand.
Resistor, non-linear.
Widerstand, spannungsabhängig.
Variable resistor.
Widerstand, regelbar.
Heater.
Heizkörper.
Motor.
Motor. M
27 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
Condenser.
Kondensator.
Heater, cabin.
Heizkörper in der Fahrerkabine.
Air condition.
Klimaanlageapparat.
VL . . . .
Solenoid valve.
Magnetventil.
28 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
Controller, hoisting.
Steuerknüppel, Lastwinde.
29 (30)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
30 (30)
TECHNICAL DATA
(2.001 E) Project No.: 2/10045.02LMW rev: - 2011-09-15
TECHNICAL DATA
GENERAL
Weight 43 ton
BASIC DATA
Hoisting Hoisting Jib radius Jib radius Hoisting Hoisting Luffing time Slewing speed
capacity capacity Minimum Maximum speed speed Max – min radius
Part SWL low high
(ton) (ton) (m) (m) (m/min) (m/min) (sec) (rev/min)
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
(2.001 E) Project No.: 2/10045.02LMW rev: - 2011-09-15
MAIN SUPPLY
Type of frequency 3 ~ 60 Hz
2 (4)
TECHNICAL DATA
(2.001 E) Project No.: 2/10045.02LMW rev: - 2011-09-15
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
**)
Dimension AT and AL to be measured from the drum flange on empty drum side.
Dimension BT and BL to be measured from the drum flange on full drum side, second layer.
Cams Cam degrees Speed reduce Max jib stop limit Winch angle position Limit values on
luffing out (m) degrees winch drum
Approx. (m) (mm)
E spr E AT BT
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.
3 (4)
TECHNICAL DATA
(2.001 E) Project No.: 2/10045.02LMW rev: - 2011-09-15
One Outreach
4 (4)
TECHNICAL DESCRIPTION 2.007.91 E rev.: - 2008-08-08
Technical Description
Jib top
Protective plate
Lifting block
Pump unit
Luffing winch
Crane jib
Hoisting winch
Slewing gear
1 (4)
TECHNICAL DESCRIPTION 2.007.91 E rev.: - 2008-08-08
MacGREGOR hydraulic deck cranes are self- The hydraulic system is designed for start at a
contained units with all machinery enclosed in the temperature range of from high to lowest ambient
crane house and, thus, well protected against external working temperature for world wide trading according
abuse. to classification societies. For cranes operating in cold
environment an optional oil heater should be installed
When delivered, the cranes are mechanically, in the oil tank. The oil heater is started by using the
hydraulically, and electrically complete in every pushbutton in the CT1 cabinet.
respect and ready to be installed on a suitable
foundation fixed in the ship’s deck or on a crane An oil cooler removes heat developed in the oil during
carriage travelling on deck. its work cycle. If the oil temperature exceeds a certain
level, a thermostat operates a contactor to stop the
main drive electric motor.
Construction
All crane movements - hoisting, luffing, and slewing -
Filters on outlet and inlet to the oil tank ensure
are driven by hydraulic motors. These are supplied
continous cleaning of the oil flow. Two filter indicators,
with high pressure oil by a pump unit comprising
one electric activates a warning lamp in cabin and
separate pumps for each hydraulic circuit and a
one visual indicates when elements need to be
separate feed and control pressure pump. The high
changed.
pressure pumps are mounted in the same pump unit
and are geardriven by a flange mounted electric motor.
Various pressure limits are provided to protect the
Starting of the electric motor is affected by an Y/D
crane against overload. All moving parts in the
starter, giving low starting current.
hydraulic system are lubricated by the hydraulic oil
which minimises mechanical wear and ensures the
The hoisting winch is driven by a hydraulic motor via
added advantage of silent operation.
a planetary gear box. A brake is integrated in the winch
gear set. When the winch is running, the brake is
The crane house is an all-welded structure on a rigid
automatically released by a hydraulic unit. The
baseplate, and encloses all mechanical and
hoisting winch is also provided with a pressure roller
hydraulical machinery and associated electrical
and one layer of wire on the drum.
equipment for adequate protection against rain, sleet,
and waves breaking over the ship. Catwalks, ladders,
Limit switches operate if the wire slackens and to
platforms, and handrails facilitate maintenance of the
preclude the complete unwinding of the wire from the
crane.
wire drums.
The tops of the crane house and of the jib head are
The crane jib is raised and lowered by the luffing winch
fitted with sheaves for the hoisting and luffing wire
whose general design is similar to that of the hoisting
ropes. All sheaves have sealed roller bearings
winch.
mounted on shafts and secured by locking plates.
2 (4)
TECHNICAL DESCRIPTION 2.007.91 E rev.: - 2008-08-08
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)
TECHNICAL DESCRIPTION 2.007.91 E rev.: - 2008-08-08
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
1 (6)
FUNCTION 3.110.122 E rev.: - 2009-02-02
Note!
For exact pressure settings, see pressure list in the
hydraulic diagram.
2 (6)
FUNCTION 3.110.122 E rev.: - 2009-02-02
Introduction
Low speed High speed
The hydrualic circuit diagram shows the following main
hoisting components:
Function Lowering
With the control lever in neutral, Figure 2 or 5, and
the pump running, the hoisting circuit performs no
actual work. A continuous supply of fluid from the
Low speed High speed
feed circuit, flushes the circuit.
3 (6)
FUNCTION 3.110.122 E rev.: - 2009-02-02
Hoisting and lowering, high speed or low speed Fig. 5. Control lever in neutral, hoisting.
Lowering
High speed lowering (optional)
If the crane is designed for high speed lowering the
motor will automatically assume high-speed position
Low speed High speed
when the control lever is moved forward for lowering,
even if the control lever is to the left, for low speed.
Valve 1221 (a) will be actuated.
Hoisting Control lever
4 (6)
FUNCTION 3.110.122 E rev.: - 2009-02-02
Introduction
The hydrualic circuit diagram shows the following main Note!
luffing components: It is not allowed to adjust sealed safety valves without
contacting MacGREGOR Cranes, Service Department.
Variable displacement pump 2111
Hydraulic motor 2141
Brake 2211
The luffing and slewing movements are generally Luffing-out (lowering jib)
operated by a common control lever, Figure 8.
Brake release
Moving the control lever from neutral, eg. backwards
to raise the jib, causes the valves 2221 and 2226 (2226
slightly delayed in relation to 2221) to shift position
and control pressure is admitted to the brake 2211 Luffing-in (raising jib)
and to valve 2127 which shifts position from the
unloading mode.
Fig. 8. Control lever, luffing/slewing.
With the control lever in the brake release position,
the luffing winch should produce a slow movement of
the crane jib, so called plussing. See instruction "High
pressure pumps" in section 6.1.
Safety functions
The luffing winch circuit embodies two safety features:
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.
Brake release
Moving the control lever, eg. to the left for slewing left
(anti-clockwise), will affect valve 3221. The brakes will
be released and the unloading valve 3127-1 will be
blocked.
Safety functions
The slewing circuit embodies one safety feature:
6 (6)
FUNCTION 3.131.29 E rev.: a 2009-02-13
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.
1 (2)
FUNCTION 3.131.29 E rev.: a 2009-02-13
Siren
A pushbutton "SIREN" in the cabin allows the opera-
tor to warn people on deck.
Ventilation fan
For all cranes a ventilation fan is fitted in the crane
house. This is controlled by a +25°C thermostat BT1
which is located in the CT1-cabinet.
2 (2)
FUNCTION 3.142.35 E rev.: b 2009-07-10
General
The following description refers to the microcomputer For detailed information about the control system a
based crane control system CC3000 for complete electric circuit diagram, relating specifically
MacGREGOR Cranes hydraulic deck cranes, single to your crane, will be found in the instruction manual,
crane versions. section "Spare Parts", Group 9.5. Also for detailed
information about the hydraulic system a complete
Minor variations in the use of control system input hydraulic circuit diagram can be found in section
and output signals due to differences in hydraulic and "Spare Parts", Group 9.4.
electric system may occur. The objective of this
description is only to provide a general orientation
concerning the principles of the control system.
MC Hydraulic Hydr.
"SL" pump motor
Fig. 1. Crane control system with interfaces to control levers and hydraulic system.
1 (4)
FUNCTION 3.142.35 E rev.: b 2009-07-10
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.
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.
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
4 (4)
FUNCTION 3.155.3 E rev.: - 2001-08-23
General
Function
With the main switch in position "1" (on-position)
the ventialtion fan starts via a thermostat, positioned
in the CT1-cabinet, see Fig. 2. The thermostat bulb
is situated outside the cabinet.
Thermostat
1 (2)
FUNCTION 3.155.3 E rev.: - 2001-08-23
2 (2)
OPERATION PM40 1879-E00 rev.: - 2011-04-01
S49
Oil temperature
The oil temperature in the oil tank must be at least
+10°C before operation.
If the oil is colder than +10°C, you can start the crane S51
and let it idle to increase the temperature of the hy-
draulic oil until it is +10°C.
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 +10°C. Refer to "Controls and
Indicators" in section 4.
1 (2)
OPERATION PM40 1879-E00 rev.: - 2011-04-01
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.
2 (2)
OPERATION PM40 5500-E00 rev.: b 1996-08-08
OPERATING INSTRUCTION
1 (2)
OPERATION PM40 5500-E00 rev.: b 1996-08-08
2 (2)
OPERATION PM40 6491-E00 rev.: - 2011-03-24
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
Make sure the ship does not trim more than two de-
grees. See Fig. 2.
1 (2)
OPERATION PM40 6491-E00 rev.: - 2011-03-24
STOP
Stop
Press pushbutton “0” (STOP). See Fig 5.
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)
OPERATION PM40 6495-E00 rev.: - 2011-08-30
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
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
0
1
STAB WINCH PAY OUT
1 (4)
OPERATION PM40 6495-E00 rev.: - 2011-08-30
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.
2 (4)
OPERATION PM40 6495-E00 rev.: - 2011-08-30
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)
OPERATION PM40 6495-E00 rev.: - 2011-08-30
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.
4 (4)
OPERATION PM40 7090-E00 rev.: - 2011-09-14
Luffing out
32 31
Lowering
Slew Slew
left Low High
right
Hoisting
1 (8)
OPERATION PM40 7090-E00 rev.: - 2011-09-14
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 150°C.
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
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)
OPERATION PM40 7090-E00 rev.: - 2011-09-14
0 0
1 1
0
1
0
1
0
1
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)
OPERATION PM40 7090-E00 rev.: - 2011-09-14
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.
Speed Speed
max. max.
Time
Time
2 sec. 2 sec.
2 sec. 2 sec.
Acceleration Retardation
Acceleration Retardation
Fig. 2. Hoisting/lowering.
Fig. 3. Luffing.
4 (8)
OPERATION PM40 7090-E00 rev.: - 2011-09-14
Acceleration Retardation
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.
CT23 Panel
STOP
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)
OPERATION PM40 7090-E00 rev.: - 2011-09-14
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.
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)
OPERATION PM40 7090-E00 rev.: - 2011-09-14
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 +10°C
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 +10°C
set switch to "2" - winter position. Set main switch (Q1)
to position "1" approximately 24 hours before operation.
RGENC
ME Y
E
1 - ON
Starts the power supply to the electric cabinet CT1. 0
7 (8)
OPERATION PM40 7090-E00 rev.: - 2011-09-14
8 (8)
OPERATION PM41 0001-E rev.: - 1994-06-16
1 (2)
OPERATION PM41 0001-E rev.: - 1994-06-16
2 (2)
OPERATION PM41 0014-E00 rev.: a 2010-02-03
Hand rail
1
Deck level
Strops
1 (2)
OPERATION PM41 0014-E00 rev.: a 2010-02-03
2 (2)
OPERATION 4.620.26 E rev.: a 2008-08-20
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 OF JIB
0 0
1 1
Rope connection
Stretching screw
Notice! Hand-tighten
turnbuckle
only to the extent that
Deck the tightening gear is
not slack.
1 (4)
OPERATION 4.620.26 E rev.: a 2008-08-20
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
Rope
2 (4)
OPERATION 4.620.26 E rev.: a 2008-08-20
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
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.
3 (4)
OPERATION 4.620.26 E rev.: a 2008-08-20
Example: Important!
The grab should be lowered to the deck when the Power cable and stabilizing cable should be parked
crane is parked, this to avoid load on the wires. on jib top during sea voyage. Parking on hook block
is for temporary use only.
Turnbuckle
Support Support
SIDE VIEW TOP VIEW
Example: Example:
Fix block
with wire
ropes
Deck Deck
Fig. 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
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
1 (4)
MAINTENANCE 5.005.55 E rev.:g 2010-07-08
Every 500 operating hours or every six - Inspect for any sign of crack
months See "Inspection of Stressed Components and
Structures", section 5.
2 (4)
MAINTENANCE 5.005.55 E rev.:g 2010-07-08
3 (4)
MAINTENANCE 5.005.55 E rev.:g 2010-07-08
4 (4)
MAINTENANCE 5.018 E rev.: b 2004-05-24
Introduction
Stressed parts of the crane structure subjected to This inspection should be performed at intervals ac-
high loads require inspection for signs of cracks and cording to the Maintenance Chart.
other damage at regular intervals.
Note!
Cracks detected at an early stage do not generally Rust on a painted surface does not necessarily
impair the handling safety of the crane unless they mean that there is a crack in the underlying mate-
are not repaired. rial.
Example:
1 (2)
MAINTENANCE 5.018 E rev.: b 2004-05-24
2 (2)
MAINTENANCE 5.025.3 E rev.: - 2009-01-26
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
1 (4)
MAINTENANCE 5.025.3 E rev.: - 2009-01-26
Function
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
LED
2 (4)
MAINTENANCE 5.025.3 E rev.: - 2009-01-26
Maintenance
Operate the crane for another 8-12 hours, and check CONTAMINATION
for contamination indication. (Pilot light)
Check the leakage condition of the pump. Fig. 4. Symbols on the control panel.
3 (4)
MAINTENANCE 5.025.3 E rev.: - 2009-01-26
4 (4)
LUBRICATING CHART PM51 1730-E00 rev.: a 2009-11-09
1 (2)
LUBRICATING CHART PM51 1730-E00 rev.: a 2009-11-09
Red lamp on right control panel in operator’s cab Jib top with lifting block for single crane
CHECK
OIL FILTER
6. Wire ropes
3. Wire sheave
CAUTION!
Renew all filter cartridges 5. Swivel
when this lamp is lit.
17 8. Door hinges
12
Filter
4135 10. Oil tank
11. Air breather cap
2 (2)
LUBRICATING CHART PM51 4200-E00 rev.: - 2008-05-14
1 (2)
LUBRICATING CHART PM51 4200-E00 rev.: - 2008-05-14
2 (2)
LUBRICATING CHART PM51 4300-E00 rev.: - 2008-05-14
1 (2)
LUBRICATING CHART PM51 4300-E00 rev.: - 2008-05-14
2 (2)
MAINTENANCE 5.150.4 E rev.: - 2003-02-19
Contents
1 (17)
MAINTENANCE 5.150.4 E rev.: - 2003-02-19
Door hinges
Grease nipple;
Service door
2 (17)
MAINTENANCE 5.150.4 E rev.: - 2003-02-19
Electric motor
Grease nipple;
Upper bearing
Grease nipple;
Lower bearing
3 (17)
MAINTENANCE 5.150.4 E rev.: - 2003-02-19
Slewing bearing
4 (17)
MAINTENANCE 5.150.4 E rev.: - 2003-02-19
Jib bearing
Grease nipple;
Inside crane house
5 (17)
MAINTENANCE 5.150.4 E rev.: - 2003-02-19
6 (17)
MAINTENANCE 5.150.4 E rev.: - 2003-02-19
Grease nipple
7 (17)
MAINTENANCE 5.150.4 E rev.: - 2003-02-19
Grease nipple
8 (17)
MAINTENANCE 5.150.4 E rev.: - 2003-02-19
9 (17)
MAINTENANCE 5.150.4 E rev.: - 2003-02-19
Lifting equipment
10 (17)
MAINTENANCE 5.150.4 E rev.: - 2003-02-19
Oil tank
11 (17)
MAINTENANCE 5.150.4 E rev.: - 2003-02-19
Oil filter
12 (17)
MAINTENANCE 5.150.4 E rev.: - 2003-02-19
13 (17)
MAINTENANCE 5.150.4 E rev.: - 2003-02-19
Wire ropes
Grease
14 (17)
MAINTENANCE 5.150.4 E rev.: - 2003-02-19
Grease nipple
Oil outlet
15 (17)
MAINTENANCE 5.150.4 E rev.: - 2003-02-19
16 (17)
MAINTENANCE 5.150.4 E rev.: - 2003-02-19
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. 45°C. Upon reaching a certain degree of clogging, a
red indication can be seen on the top of the filter
Filter indicators indicator. Replace both filter cartridges in the system
when the red indication shows.
The filter indicators operate only when the crane
starts.
Replacement filter cartridges
Filter 4135 has two filter indicators. One indicator is You must replace both cartridges (see Fig. 3) in the
electric and operates a warning lamp placed on the crane at the same time. Flush all other parts of the
control panel in the cabin (see Fig. 4a and 4b). filters with white spirit when you replace the cartridges.
Use new seals. Reassemble the filters.
4101 4102
Electric indicator
Visual
indicator
Oil filling
Filter Filter
4135 4136
Filter cartridge
1 (2)
MAINTENANCE 5.301.13 E rev.: a 2009-04-20
2 (2)
MAINTENANCE 5.302.24 E rev.: - 2003-06-23
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
1 (2)
MAINTENANCE 5.302.24 E rev.: - 2003-06-23
Filling oil
Oil is filled at an ”aero-quip” type quick-release coupling,
placed on the filter unit, see Fig. 2. When filling oil the
hydraulic system must be at rest and the electric
power switched off.
Fill oil to just under the MAX mark on the dipstick. Use
oil according to the ”Lubricating Chart”.
Fill oil to just under the MAX mark on the dipstick. Use
oil according to the ”Lubricating chart”.
2 (2)
MAINTENANCE 5.315 E rev.: b 2010-09-03
Pump Hose
1 (2)
MAINTENANCE 5.315 E rev.: b 2010-09-03
Number of particles equal to or larger than 4 µm(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 µm(c), 25 160 000 320 000
not to exceed code 17. 24 80 000 160 000
Number of particles equal to or larger than 14 µm(c), 23 40 000 80 000
not to exceed code 14. 22 20 000 40 000
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 µm, 16 320 640
not to exceed code 17. 15 160 320
Number of particles equal to or larger than 15 µm, 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.
2 (2)
MAINTENANCE 5.421.40 E rev.: d 2008-05-14
The oil shall be refined oil containing additives against Cable winch, turbo coupling (if applicable)
oxidation, rust and foaming, as well as wear inhibitor Viscosity 22 cSt/40°C (ISO VG 22).
and/or EP additives. Example: SHELL MORLINA.
1 (2)
MAINTENANCE 5.421.40 E rev.: d 2008-05-14
B. GREASES
Roller/ball bearings
Grease with EP additives.
Must withstand wet conditions.
Example: SHELL Alvania EP (LF) 2 (-20 to +130°C).
Arctic climate: SHELL Albida PPS2.
Ropes
Grease resistant to salt water and with antirust
properties. (Very thin.)
Temperature range -30 to +100°C.
Viscosity 9.8 cSt/40°C.
Example: FUCHS Cedracon.
Arctic climate: FUCHS Ceplattyn.
2 (2)
How to order
Cargotec Sweden AB
MacGregor Cranes spare parts 6.0
Sjögatan 4G
SE-891 85 ÖRNSKÖLDSVIK, Sweden
Telephone: 46 - 660 - 29 40 00
Telefax: 46 - 660 - 139 77
www.cargotec.com
SERVICE
Mechanical
equipment 6.2
Electrical
6.3
equipment
SERVICE 6.000 E rev.: e 2010-09-08
Please send your inquiry or order to closest MacGregor global service station, see instruction "MacGregor Global
Services", 6.004.1 E.
Part description
Quantity required
When you order a wire rope or lifting block, please specify which certificate is needed.
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
SE-891 85 ÖRNSKÖLDSVIK, Sweden
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: ................................................
Confirmation of
phone call/conv.
6. See enclosure
............................................................................................................
............................................................................................................
...................................................................................................................
Name/ Title/
SERVICE 6.000.1 E rev.: c 2007-01-08
Paragraph A.1.2 stipulates that the following MacGREGOR (SWE) AB, Örnsköldsvik
exceptions to the requirements of paragraph A.1.1 Quality Department
may nevertheless be allowed:
Section B
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
1) the part
2) from where it has been taken and
3) why it is returned.
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.:
Ship’s name:
IMO no.:
Returned part’s
drawing or article
no, serial no.:
Part description:
*) Please note: To be filled in with short but specific details. “Faulty“ is not enough, a much better
description is “leaking“, “not adjustable“, “cracked“, “earthing fault“, “short circuit“ if the reason is obvious,
or, a circumstantial evidence pointing to the returned part as the reason for malfunction, like “luffing
movement too slow in one direction“.
2 (2)
SERVICE & PARTS 6.004.1 E rev.: bc 2011-06-21
1 (2)
SERVICE & PARTS 6.004.1 E rev.: bc 2011-06-21
2 (2)
SERVICE 6.005.7 E rev.: - 2003-02-12
Introduction
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.
2 (2)
SERVICE 6.100 E rev.: b 1998-10-22
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.
1 (2)
SERVICE 6.100 E rev.: b 1998-10-22
2 (2)
SERVICE 6.106.4 E rev.: - 2003-02-03
A. Overheating in hydraulic sys- Oil cooler fan motor not working. Check connections, contactor,
tem. effect repairs as required.
Oil cooler flanges loaded with dirt. Dismantle and clean cooler.
N.B.
When the hydraulic system is overheated thermostat BT2 (+85oC) opens
and crane stops.
To cool the system press the "Start" button to start main electric motor in
idling while the control system is switched off. The control system will then
start automatically when thermostat BT2 closes.
1 (1)
SERVICE 6.117 E rev.: b 1999-12-21
Pumps, general
A. Pump not supplying any fluid. Servo error. Contact MacGREGOR Cranes
B. Excessive wear of the pump. Hydraulic fluid contains abra- Check filters. Change cartridge,
sive particles. if necessary. Analyze sample
of the fluid.
C. Fracture of parts in the pump. Pressure shocks. Check valve functions and valve
settings.
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
Technical description
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.
Brake
Maintenance
The brake is self-adjusting.
Trouble-shooting
a. Braking torque insufficient
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
Technical description
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.
Inspect oil level when the gear is at rest with the brake
engaged.
Caution!
C-00116
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 µ). 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 µ) 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
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
1 (8)
SERVICE 6.120.64 E rev.: o 2011-04-27
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
2 (8)
SERVICE 6.120.64 E rev.: o 2011-04-27
Displacement: 40 cm3/rev.
Pre-filling volume: 1.0 litre (approx.)
Oil filling
Drain connection
Oil filling
Hydraulic motor 189 3383-801
Drain connection
Oil filling
Drain connection
3 (8)
SERVICE 6.120.64 E rev.: o 2011-04-27
Oil filling
Drain connection
Oil filling
Drain connection
4 (8)
SERVICE 6.120.64 E rev.: o 2011-04-27
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
5 (8)
SERVICE 6.120.64 E rev.: o 2011-04-27
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
6 (8)
SERVICE 6.120.64 E rev.: o 2011-04-27
Oil filling
Drain connection
Oil filling
Drain connection
Oil filling
Drain connection
7 (8)
SERVICE 6.120.64 E rev.: o 2011-04-27
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
1 (4)
SERVICE 6.120.108 E rev.: b 2009-11-06
2 (4)
SERVICE 6.120.108 E rev.: b 2009-11-06
Trouble-shooting
Braking torque insufficient
Brake heats
Check the hydraulic pressure to make sure that it is
sufficient in order to disengage the brake completely.
Connect
pressure oil
Leakage oil
Gear side
3 (4)
SERVICE 6.120.108 E rev.: b 2009-11-06
1. Pressure roller
2. Adjusting nut
3. Locking nut
4 (4)
SERVICE 6.121.3 E rev.: a 1999-03-16
The motor does not run. Mechanical stop in the drive. Check system pressure. If the pres-
sure has risen to the relief valve set-
ting, remove the load from the drive.
The motor does not deliver enough Investigate the pressure level in the
torque because the pressure differ- system and correct the setting of the
ence across the motor is not great pressure limiting valve if necessary.
enough for the load.
Motor rotates in wrong direction. Oil supply connections to motor in- Connect the oil supply correctly.
correctly connected.
Motor runs jerkily. Pressure or flow fluctuations in the Find the cause in the system or in
hydraulic system. the driven unit.
Noise in the motor. The motor is being operated with the Adjust the charge pressure to the
charge pressure too low. correct level. See Hydraulic Circuit
- gauge connection 1.
External oil leakage on the motor. The radial lip seal is worn. Replace the radial lip seal.
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.
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.
2 (2)
SERVICE 6.127.50 E rev.: b 2010-10-25
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
1 (8)
SERVICE 6.127.50 E rev.: b 2010-10-25
Servo valve
*)
Locking nut
2 (8)
SERVICE 6.127.50 E rev.: b 2010-10-25
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 40°C.
- 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
3 (8)
SERVICE 6.127.50 E rev.: b 2010-10-25
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 40°C. 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.
"Plussing" screw
Operate
5 (8)
SERVICE 6.127.50 E rev.: b 2010-10-25
Slewing machinery
B-0020
6 (8)
SERVICE 6.127.50 E rev.: b 2010-10-25
Servo valve
XX*)
Locking nut
7 (8)
SERVICE 6.127.50 E rev.: b 2010-10-25
Slewing machinery
Operate
8 (8)
SERVICE 6.132.18 E rev.: a 2010-10-07
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.
Pump unit
Suction hose
Oil tank
1 (2)
SERVICE 6.132.18 E rev.: a 2010-10-07
2 (2)
SERVICE 6.142.5 E rev.: a 2002-01-09
Hydraulic hoses assembled inside crane house If the rubber in the hose is damaged so that the steel
should be inspected for damage every five (5) years, core can be exposed to corrosion the hose should be
see Maintenance Chart in section 5. replaced.
If the rubber in the hose is damaged so that the steel The hose couplings should also be inspected for
core can be exposed to corrosion the hose should leakage and damage of the corrosion protective Den-
be replaced. syl tape. If the corrosion protection is damaged so
The hose couplings should also be inspected for that the coupling can be exposed to corrosion the
damage and leakage. If the coupling is damaged or corrosion protection should be removed and the
severely corroded the hose should be changed. coupling inspected for damage and severe corrosion.
If the coupling is leaking the coupling should be tighte- If the coupling is damaged or severely corroded the
ned at first. If tightening does not help, the hose and hose should be changed.
the mating couplings should be changed, see Fig. 1. If the coupling is leaking the coupling should be tighte-
If the coupling is of flange type the O-ring and screws ned at first. If tightening does not help, the hose and
should be changed, see Fig. 2. the mating couplings should be changed, see Fig. 1.
If the coupling is of flange type the O-ring and screws
Hydraulic hoses and couplings should be changed, see Fig. 2.
assembled on outside of crane house
Replacement of hydraulic hoses
Hydraulic hoses assembled on outside of crane house
should be inspected for damage every two (2) years, All hydraulic hoses assembled inside crane house
see Maintenance Chart in section 5. should be replaced after ten (10) years due to safety
reasons.
All hydraulic hoses assembled on outside of crane
house should be replaced after five (5) years due to
safety reasons.
Hose coupling
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
New design
Valve guard
Protective
Gas valve cap
Protective cap Gas valve Open/close
Valve guard hexagonal nut
Open/close
hexagonal nut
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
2 (4)
SERVICE 6.189 E rev.: f 2007-04-11
Filling screw, to be
used for old design
Pressure gauge
Bleed valve connection
Hose
3 (4)
SERVICE 6.189 E rev.: f 2007-04-11
4 (4)
SERVICE 6.209.15 E rev.: - 2004-04-28
Max. 10 mm Max. 8 mm
1 (1)
THIS PAGE IS INTENTIONALLY LEFT BLANK
SERVICE 6.214 E rev.: i 2007-03-02
Tightening Torques
Studs/Screws and Bolts
Introduction
Phosphatized bolts greased with Molykote R 1000 Untreated bolts greased with Molykote R 1000
(Also valid for bolts greased with Loctite 243 or oil.) (Also valid for bolts greased with Loctite 243 or oil.)
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 class Min. ultimate strength Min. tensile strength Corresponding strength
N/mm2 (kp/mm2) N/mm2 (kp/mm2) class of nuts
Examples of markings:
Hexagonal screw Allen screw
Strength class 4.6: Strength class 12.9:
BH 12 9 M
Hexagonal nut
Strength class 8:
3 (4)
SERVICE 6.214 E rev.: i 2007-03-02
Tightening Torques
Hydraulic Couplings
Example: GE 10 - LM
Table 1. Sealing
d = 10
Fitting
Sealing cone
Insert the sealing cone into the 24-degree coupling
fitting, firmly tighten the coupling by hand. Using a
wrench, tighten the coupling nut another 1/4 to 1/2
turn. The O-ring should preferably be oiled.
4 (4)
SERVICE 6.215.21 E rev.: b 2007-06-08
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
2 (2)
SERVICE 6.216.83 E rev.: a 2003-03-11
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
1 (3)
SERVICE 6.216.83 E rev.: a 2003-03-11
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
After replacement of wire the pressure roller on the - Tighten adjusting nut 12 turns to get correct spring
hoisting winch must be re-adjusted. force. Adjustment shall be done at full drum
condition.
- Tighten adjusting nut carefully until the pressure - Secure with the locking nut.
roller touches the hoisting wire on the drum.
- Check that the play (approx. 2 mm) between wire
and pressure roller corresponds to Fig. 4. Adjust if
necessary by changing location (rotation) of frame
bearings, see Fig. 4.
Approx. 2 mm
Full drum
Empty drum
Pressure roller
Frame
Locking nut
3 (3)
THIS PAGE IS INTENTIONALLY LEFT BLANK
6.216.101 E rev.: - 2009-03-05
1 2 3 4
1 2
Fig. 2. Parking position of power cable and stabilizing wire during sea voyage.
1. Stabilizing wire.
2. Power cable from cable winch.
1 (2)
6.216.101 E rev.: - 2009-03-05
1
2
Fig. 3. Prepared for rigging of grab, and temporarily parking position of power cable and stabilizing wire.
1. Stabilizing wire.
2. Power cable from cable winch.
1. Stabilizing wire.
2. Power cable from cable winch.
2 (2)
SERVICE 6.222.1 E rev.: a 1998-04-17
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.
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.
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 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.
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 block´s
sheaves. If the new rope is pulled in with help of the used
one, the two rope ends are often buttwelded to-
gether. A connection of that kind can transfer the
Winding the steel wire rope from the reel twist of the old rope, built up in the reeving system,
onto the drum into the new rope. By that method of installation the
new rope may be extremely damaged.
During the manufacturing process every steel wire
rope receives its preferred bending direction when There are even more reasons why that procedure
being drawn from the wire rope closer by means of is highly problematic: It is true, that when using spe-
a capstan. When delivered to the customer the rope cial electrodes the welded connection presents
is bent in that direction. Make certain that it bends acceptable results in a pull test with a straight rope;
in the same direction when it is wound from the reel but because of the great length of rigid connection
onto the drum. zone the very same connection could break due to
the enormous bending stresses when running over
sheaves.
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.
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
7 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
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
9 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
Severe corrosion.
10 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
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
11 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
12 (12)
SERVICE 6.223.20 E rev.: c 2011-02-07
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
2 (6)
SERVICE 6.223.20 E rev.: c 2011-02-07
Note!
To adjust the pressure roller on winch see instruction
"Rope Reeving Diagram ..." in section 6.2 in the
instruction and spare parts manual.
3 (6)
SERVICE 6.223.20 E rev.: c 2011-02-07
New pin
New pin
4 (6)
SERVICE 6.223.20 E rev.: c 2011-02-07
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
Load cell
6 (6)
S E RV I C E I N F O R M AT I O N
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.
t a
max
16 3
12 3
10 2.5
8 2
6 1.5
1 (2)
S E RV I C E I N F O R M AT I O N
2 (2)
S E RV I C E I N F O R M AT I O N
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.
1 (2)
S E RV I C E I N F O R M AT I O N
Lubrication
Limitation of use
Table 1.
2 (2)
S E RV I C E I N F O R M AT I O N
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.
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)
S E RV I C E I N F O R M AT I O N
Measurement B
(back of crane) Empty hook
Measurement A
(front of crane)
Measurement C
(back of crane)
Jib direction
Min. outreach,
empty hook
2 (4)
S E RV I C E I N F O R M AT I O N
Jib
Reference point
Reference point
3 (4)
S E RV I C E I N F O R M AT I O N
Stb
Aft
Ps
Crane No.: 2
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.: 3
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.: 4
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
4 (4)
INSPECTION INSTRUCTION
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.
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)
INSPECTION INSTRUCTION
Grease sampling
area (inner seal) Grease sampling
area (inner seal)
Outer seal
Outer seal
2 (6)
INSPECTION INSTRUCTION
Inner seal
Grease sampling
Slewing bearing with balls. area (outer seal)
3 (6)
INSPECTION INSTRUCTION
4 (6)
INSPECTION INSTRUCTION
5 (6)
INSPECTION INSTRUCTION
6 (6)
SERVICE 6.303.49 E rev.: e 2010-05-31
Troubleshooting
Crane Control System CC3000
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
1.1 General
The following description refers to the
microcomputer based crane control system
CC3000 for MacGREGOR hydraulic deck cranes.
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SERVICE 6.303.49 E rev.: e 2010-05-31
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
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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)
8 (12)
SERVICE 6.303.49 E rev.: e 2010-05-31
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.
Both lamps One or both lamps are Check the error code in
are off. flashing or on. Control System cabinet
CT2.
9 (12)
SERVICE 6.303.49 E rev.: e 2010-05-31
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 driver’s 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
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.
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12 (12)
SERVICE 6.303.61 E rev.: c 2011-07-14
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
AI2 "Parameter" Parameter value
AI3 "Parameter" Parameter value
AI4 "Parameter" Parameter value
AI5 "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 Select/Info to enter menu tree.
• Push Down/Exit until the display shows
VER.
• Push Select/Info to select Version
Mode
3 (4)
SERVICE 6.303.61 E rev.: c 2011-07-14
4 (4)
SERVICE 6.303.68 E rev.: - 2011-01-18
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.
MV
(m
m)
MV distance
1 (4)
SERVICE 6.303.68 E rev.: - 2011-01-18
Preparation of hoisting
2 (4)
SERVICE 6.303.68 E rev.: - 2011-01-18
Preparation of slewing
0°
3 (4)
SERVICE 6.303.68 E rev.: - 2011-01-18
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.
Display
ENCODER
CALIBRATION
button
Select/Info
button
Up button
Down/Exit
button
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
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
No Revision
Crane Control System CC3000
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 driver’s 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
Note!
Before reporting to MacGREGOR (SWE) AB in Örnsköldsvik, 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 Örnsköldsvik • 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 Örnsköldsvik
Slewing Left movement. Check according to 30_01.
03 01-91 Safety processor errors
04 Joystick is not in zero position when system starts.
• Contact MacGREGOR(SWE) AB Örnsköldsvik
Check according to 30_01.
10 10 MEM card errors
31 01 Angle encoder communication error
• Replace the MEM card
• Check angle encode connection
• Contact MacGREGOR(SWE) AB Örnsköldsvik
• Replace the angle encoder
11 01-30 Parameter errors
• Contact MacGREGOR(SWE) AB Örnsköldsvik
Page Date
No Revision
Crane Control System CC3000 D
424 0739
37 Weight: Outreach, in EO
SERVICE 6.305.16 E rev.: - 2008-10-30
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.
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.
Oil thermostats
BT 2
The task of the oil thermostat is to protect the crane
against overheating.
BT 3 (Optional)
The task of the thermostat is to start the oil cooler
when the oil reaches +45oC when crane is set to winter
position.
2 (2)
SERVICE 6.307.14 E rev.: - 2003-02-19
Slip-Ring Unit
Connection crane
Slip-ring unit
Mounting screws
Connection box
Connection ship
power Guide pins
Driver
Rubber protection
Note! Must be
tightened.
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.
2 (2)
SERVICE 6.311.12 E rev.: - 2008-09-03
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.
1 (4)
SERVICE 6.311.12 E rev.: - 2008-09-03
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.
Note!
Operating crane when oil level is below MIN can cause
damage to crane equipment.
Fig. 5. Oil level MIN, continued operation.
2 (4)
SERVICE 6.311.12 E rev.: - 2008-09-03
Overheating protector
The crane stops automatically when the oil tempera-
ture exceeds 85°C. 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 85°C, see Fig. 8.
3 (4)
SERVICE 6.311.12 E rev.: - 2008-09-03
4 (4)
SERVICE 6.320.367 E rev.: b 2011-05-12
The movements and outreaches of the crane jib and This function prevents the jib from mechanical
hoisting block are controlled by limit switches in the touching of the hook block when luffing out, see
limit switch boxes. At large outreaches there is a risk page 6. If the crane is equipped with high hook,
that hook block and jib top will meet and that is taken values for outreaches for both luffing and hoisting
care of by crane's safety system, see page 7 and 8. winches can be found in tables in instruction
Some cranes are equipped with extra limit switches "Tecnical Data", section 2.
to prevent this, see paragraph "High Hook (optional)".
Limit switches
The limit switch boxes of the hoisting and luffing Limit switch box,
luffing winch
winches are similar except for the demultiplication
ratios of their driving gearboxes. Limit switch box,
hoisting winch
The cams in the luffing winch limit box are marked
BL1, BL2, BL3 etc.; those of the hoisting winch box,
BH1, BH2, BH3 etc.
1 (10)
SERVICE 6.320.367 E rev.: b 2011-05-12
K
Measure line Jib radius
5°
Adjustment screw
Fig. 4. Jib radius lifting height.
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.
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
3 (10)
SERVICE 6.320.367 E rev.: b 2011-05-12
BL1
4 (10)
SERVICE 6.320.367 E rev.: b 2011-05-12
MV
(m
m) First jib stay
Measure of
the distance MV
5 (10)
SERVICE 6.320.367 E rev.: b 2011-05-12
Raise the jib into the MIN Jib radius position, which is BH3
the correct jib position for setting the limit switches BH4
according to the below figures. Note that the switches
BH5
BH2 and BH3 actuate speed reduction of the crane
hook. BH6
BH3
BH 3
Speed reduce,
full drum H spr (m)
H (m)
Speed reduce,
empty drum K spr (m)
K (m)
BH 2
Speed reduce
= Stop position.
6 (10)
SERVICE 6.320.367 E rev.: b 2011-05-12
E spr (m)
This function prevents the jib from mechanical
E (m)
touching of the hook block when luffing out.
*) If high hook is applicable then BL7 and BL8 are used.
Limit switch BH5 (speed reduce switch, hoisting) takes NA = High hook is not applicable.
care of the area . See Technical Data, section 2.
Speed reduce.
Limit switch BH6 (detector switch) takes care of the
area and gives signal to BL8 (stop cam, luffing) Stop. To by-pass those positions correct operation
mode has to be selected by help of the key switch
if the hook block is in the wrong area. in cabin.
There is no stop function on the hoisting winch. Fig. 12. Extra luffing limit switches, high hook.
Detector switch BH6 prevents the jib from mechanical
touching of the lifting block.
BH4
F ds - Detector switch
ib E (m) BH(X)*)
c/c j Note! To be set
Stop limit at maximum
F spr (m)
outreach (BL3),
BH(X) *) luffing winch.
Speed reduce switch
towards jib top
7 (10)
SERVICE 6.320.367 E rev.: b 2011-05-12
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.
8 (10)
SERVICE 6.320.367 E rev.: b 2011-05-12
Lifting height
H (m)
Block touches
jib top
jib
c/c
Jib bearing
centre Outreach (m)
Hook stop
Hook stop
9 (10)
SERVICE 6.320.367 E rev.: b 2011-05-12
10 (10)
SERVICE 6.321.13 E rev.: a 1999-11-23
Functional test, hoisting The lifting block may lay flat on the ground/deck and
the slack wire device may still not be activated.
Lower the hook block on to the deck to slacken the
hoisting wire rope. Hoist the hook in order to check
This is most evident at minimum outreach. In these
that the switch returns properly.
cases there will probably never be a slack at the winch
and therefore never an automatic stop of the lowering
motion.
Switch
Arm
Slack wire safety switch. Normal condition. Slack wire safety switch. Slack wire condition.
1 (2)
SERVICE 6.321.13 E rev.: a 1999-11-23
2 (2)
SERVICE 6.324.1 E rev.: b 2010-11-02
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
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.
1 (2)
SERVICE 6.324.1 E rev.: b 2010-11-02
2 (2)
SERVICE 6.324.2 E rev.: - 2010-11-10
Procedure
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
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
1 (2)
SERVICE 6.324.3 E rev.: - 2010-10-28
2 (2)
SERVICE 6.990.56 E rev.: - 2008-10-16
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.
Plug *), to be
used when
emergency
slewing
Gauge 1D
T-coupling to Mp on pump,
hoisting or luffing
Valve 3B Valve 3A
1 (12)
SERVICE 6.990.56 E rev.: - 2008-10-16
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
Connection P
Oil tank
Hand pump 1A
Quick
coupling
4333
Quick
coupling1664
Directional
valve1226
Pilot hose, Wedge valve 4332
disconnect and plug **)
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
3 (12)
SERVICE 6.990.56 E rev.: - 2008-10-16
3B
3A
4 (12)
SERVICE 6.990.56 E rev.: - 2008-10-16
5 (12)
SERVICE 6.990.56 E rev.: - 2008-10-16
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
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.
Pilot hose
7 (12)
SERVICE 6.990.56 E rev.: - 2008-10-16
3B
3A
8 (12)
SERVICE 6.990.56 E rev.: - 2008-10-16
9 (12)
SERVICE 6.990.56 E rev.: - 2008-10-16
Connection Note!
- Install the hand pump 1A onto the base plate with The brake opens at approximately 1.2 MPa.
the screws provided. See Fig. 10.
- Connect the hoses from the hand pump as shown Warning!
in Fig. 10 and hydraulic diagram Fig. 11.
If the crane is tilted, the brake must be released with
- Close ball valve 3661 and open wedge valve 4332.
great caution. If the speed increases too much, the
See Fig. 10.
brake can be activated by ceasing to pump or opening
ball valve 3661.
Operation
- Release the brake by pumping oil from the hand After operation
pump.
After the slewing operation has been completed, reset
- The crane may now be slewed to a set position
the crane to NOT EMERGENCY COUPLED. Wedge
with the help of another crane. Use caution.
valve 4332 must be closed and ball valve 3661 must
be opened. See Fig. 10 and 12.
Quick-coupling 3664
Plug*)
Hand pump 1A
To be plugged at
emergency operation
T-coupling
10 (12)
SERVICE 6.990.56 E rev.: - 2008-10-16
11 (12)
SERVICE 6.990.56 E rev.: - 2008-10-16
12 (12)
CARGOHANDLING EQUIPMENT 7.003.2 E rev.: c 1996-05-22
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
1 (3)
CARGOHANDLING EQUIPMENT 7.003.2 E rev.: c 1996-05-22
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 direc- tion 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)
CARGOHANDLING EQUIPMENT 7.003.2 E rev.: c 1996-05-22
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).
3 (3)
THIS PAGE IS INTENTIONALLY LEFT BLANK
EXTRA EQUIPMENT 7.026.6 E rev.: - 2009-01-26
Stabilizing winch
Power swivel
1 (2)
EXTRA EQUIPMENT 7.026.6 E rev.: - 2009-01-26
2 (2)
7.075.11 E rev.: - 2010-11-10
General
1 (6)
7.075.11 E rev.: - 2010-11-10
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.
The current
Joystick, hoisting hoisting/lowering speed
2 (6)
7.075.11 E rev.: - 2010-11-10
Trim
ELCCL mode
Jack-knife
3 (6)
7.075.11 E rev.: - 2010-11-10
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
Fourth button:
Fifth button:
Sixth button:
Seventh button
5 (6)
7.075.11 E rev.: - 2010-11-10
6 (6)
7.076.2 E rev.: c 2009-06-29
USER MANUAL
DISPLAY
CC Pilot XS
1 COMPATIBILITY .............................................................................................................................................. 2
1 (4)
7.076.2 E rev.: c 2009-06-29
1 Compatibility
The display is compatible with Windows CE and Linux.
4 Code data
Device's code data is placed at the back of the unit.
Code data are important from the service point of view, and so beware from disposing those.
If the display would not work correct, please contact MacGREGOR, Service Department, Örnsköldsvik,
Sweden.
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
Sjögatan 4G
SE-891 85 ÖRNSKÖLDSVIK, Sweden
Telephone: 46 - 660 - 29 40 00
Telefax: 46 - 660 - 139 77
9.1 Machinery
www.cargotec.com
9.3 Mechanical
equipment
9.4 Hydraulic
components
9.5 Electric
components
9.6
Please send your inquiry or order to closest MacGregor global service station, see instruction "MacGregor Global
Services", 6.004.1 E.
Part description
Quantity required
When you order a wire rope or lifting block, please specify which certificate is needed.
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
SE-891 85 ÖRNSKÖLDSVIK, Sweden
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: ................................................
Confirmation of
phone call/conv.
6. See enclosure
............................................................................................................
............................................................................................................
...................................................................................................................
Name/ Title/
PARTS MANUAL Date Group Fig. Page
330 Nm
16
20
189 6696-801
625-1440.147
PARTS MANUAL Date Group Fig. Page
004 1 388 3580-801 . FLUSH AND UNLOADING UNIT SEE FIG. 625-7449
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
PARTS MANUAL Date Group Fig. Page
HOISTING WINCH
Item Qty Article no Description Supplementary data
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
PARTS MANUAL Date Group Fig. Page
HOISTING WINCH
Item Qty Article no Description Supplementary data
GEAR, COMPLETE
41 42 43
520 521
462
463
454 491
192003009
875 13019-122
625-1451.155
Weight 491 kg
PARTS MANUAL Date Group Fig. Page
GEAR, COMPLETE
Item Qty Article no Description Supplementary data
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
PARTS MANUAL Date Group Fig. Page
022 12 2121 2532-556 . SCREW MC6S 12x120 -8.8 FZB; DIN 912
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.
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.
PARTS MANUAL Date Group Fig. Page
9 10 13 14 12 11 8
195 Nm
4 7
875 13030-006
625-1451.010
Weight 40 kg
5 6 4 3
195 Nm
PARTS MANUAL Date Group Fig. Page
004 12 2121 2532-564 . SCREW MC6S 12x190 -8.8 FZB; DIN 912
ALT 1 ALT 2
HOLDING/CLOSING HOISTING WINCH
HOISTING WINCH
PARTS MANUAL Date Group Fig. Page
HYDRAULIC MOTOR
391 0458-801
625-2205.037
PARTS MANUAL Date Group Fig. Page
HYDRAULIC MOTOR
Item Qty Article no Description Supplementary data
LUFFING WINCH, C
19
15
1
20 19
17 16
163 Nm
189 1625-801
625-1440.046
PARTS MANUAL Date Group Fig. Page
LUFFING WINCH, C
Item Qty Article no Description Supplementary data
LUFFING WINCH
PARTS MANUAL Date Group Fig. Page
LUFFING WINCH
Item Qty Article no Description Supplementary data
LUFFING WINCH
PARTS MANUAL Date Group Fig. Page
LUFFING WINCH
Item Qty Article no Description Supplementary data
052 8 875 13001-003 .. MULTIPLE DISC, OUTER Change all 15 discs at the same time.
053 7 875 13001-004 .. MULTIPLE DISC, INNER Change all 15 discs at the same time.
054 14 875 13002-003 .. SPRING Change all 28 springs at the same time.
055 14 875 13002-004 .. SPRING Change all 28 springs at the same time.
071 6 2121 2532-562 .. SCREW MC6S 12x170 -8.8 FZB; DIN 912
HYDRAULIC MOTOR
PARTS MANUAL Date Group Fig. Page
HYDRAULIC MOTOR
Item Qty Article no Description Supplementary data
9 800 Nm
10 4
4
3
800 Nm 9
10
9 800 Nm
289 5365-801
625-2250.022
PARTS MANUAL Date Group Fig. Page
007 2 489 6415-801 . LIMIT SWITCHES BOX, MOUNT. SEE FIG. 625-6248.001
5 6
2 540 Nm
1
3
391 0247-801
625-3254.024
PARTS MANUAL Date Group Fig. Page
3 dl
135 Nm 6
1 dl
391 0279-801
625-3254.022
PARTS MANUAL Date Group Fig. Page
SLEWING GEAR
40
289 1855-801
625-3255.034 /0
Weight 360 kg
PARTS MANUAL Date Group Fig. Page
SLEWING GEAR
Item Qty Article no Description Supplementary data
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
PARTS MANUAL Date Group Fig. Page
020 17 2121 2532-554 . SCREW MC6S 12x110 -8.8 FZB; DIN 912
022 12 2121 2532-515 . SCREW MC6S 10x120 -8.8 FZB; DIN 912
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
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
HYDRAULIC MOTOR
PARTS MANUAL Date Group Fig. Page
HYDRAULIC MOTOR
Item Qty Article no Description Supplementary data
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
PARTS MANUAL Date Group Fig. Page
PUMP UNIT
Item Qty Article no Description Supplementary data
010 1 388 3580-801 . FLUSH AND UNLOADING UNIT SEE FIG. 625-7449
GEAR BOX
391 0431-801
625-4940.033 /0
Weight 143 kg
PARTS MANUAL Date Group Fig. Page
GEAR BOX
Item Qty Article no Description Supplementary data
TANDEM PUMP
275 Nm
391 0807-801
625-4944.001
PARTS MANUAL Date Group Fig. Page
TANDEM PUMP
Item Qty Article no Description Supplementary data
TANDEM PUMP
275 Nm
391 0808-801
625-4944.002
PARTS MANUAL Date Group Fig. Page
TANDEM PUMP
Item Qty Article no Description Supplementary data
PUMP
PARTS MANUAL Date Group Fig. Page
PUMP
Item Qty Article no Description Supplementary data
009 2 .. SEALING
PARTS MANUAL Date Group Fig. Page
SERVO VALVE
PARTS MANUAL Date Group Fig. Page
SERVO VALVE
Item Qty Article no Description Supplementary data
PUMP
PARTS MANUAL Date Group Fig. Page
PUMP
Item Qty Article no Description Supplementary data
009 2 .. SEALING
PARTS MANUAL Date Group Fig. Page
PUMP
PARTS MANUAL Date Group Fig. Page
PUMP
Item Qty Article no Description Supplementary data
009 2 .. SEALING
PARTS MANUAL Date Group Fig. Page
VANE PUMP
391 0571-801
625-4945.058
PARTS MANUAL Date Group Fig. Page
VANE PUMP
Item Qty Article no Description Supplementary data
DISTANCE PIECE
391 0469-801
625-4963.014
PARTS MANUAL Date Group Fig. Page
DISTANCE PIECE
Item Qty Article no Description Supplementary data
DISTANCE PIECE
4
391 0470-801
625-4963.015
PARTS MANUAL Date Group Fig. Page
DISTANCE PIECE
Item Qty Article no Description Supplementary data
OIL COOLER
1
2
289 6815-801
625-5740.031 /0
Weight 81 kg
PARTS MANUAL Date Group Fig. Page
OIL COOLER
Item Qty Article no Description Supplementary data
007 1 490 0197-801 . MOUNTING SET Incl. screws, nuts and washers
6
5 8
10
10
12
13
4
9
7
1
11
391 0300-801
625-5740.022
PARTS MANUAL Date Group Fig. Page
391 2766-801
625-5740.032
PARTS MANUAL Date Group Fig. Page
21
17
16 15
20
18 19
14
13
9
5 6
8
4
10 11
2
7
12
1190634 22
625-6102.520
PARTS MANUAL Date Group Fig. Page
011 2 391 0247-801 . SLEWING GEAR ASSEMBLY SET SEE FIG. 625-3254.024
016 1 391 0300-801 . OIL COOLER ASSEMBLY SET SEE FIG. 625-5740.022
019 1 289 4601-801 . VENTILATION FAN ASSEMBLY SET SEE FIG. 625-6625.022
SLEWING SPECIFICATION
le”
cip
rin
“P
CRANE
FOUNDATION
490 6433-801
625-6122.030
PARTS MANUAL Date Group Fig. Page
SLEWING SPECIFICATION
Item Qty Article no Description Supplementary data
391 1210-801
625-6125.001
PARTS MANUAL Date Group Fig. Page
COVER MOUNTING
PARTS MANUAL Date Group Fig. Page
COVER MOUNTING
Item Qty Article no Description Supplementary data
COVER ASSEMBLY
PARTS MANUAL Date Group Fig. Page
COVER ASSEMBLY
Item Qty Article no Description Supplementary data
8
6
4
3
2
5
391 0467-801
625-6170.068
PARTS MANUAL Date Group Fig. Page
10
4
5
3
1
12 5
4
11 9
6
11
12
2
391 0468-801
625-6170.069
PARTS MANUAL Date Group Fig. Page
12
10
22
62 10
10
18
62
9
23
8
23
23
23
9
18
22
1195437
625-6244.073
PARTS MANUAL Date Group Fig. Page
22
23 24
31
14 15
16 17
32
18 19 20 21
25
289 5323-801
625-6245.635 /A
PARTS MANUAL Date Group Fig. Page
001 1 875 15017-012 . CAM DISC WITH ARM, COMPLETE 30° - 55°
002 1 875 15017-012 . CAM DISC WITH ARM, COMPLETE 30° - 55°
003 1 875 15017-012 . CAM DISC WITH ARM, COMPLETE 30° - 55°
004 1 875 15017-012 . CAM DISC WITH ARM, COMPLETE 30° - 55°
005 1 875 15017-013 . CAM DISC WITH ARM, COMPLETE 55° - 100°
006 1 875 15017-013 . CAM DISC WITH ARM, COMPLETE 55° - 100°
015 2 875 15001-002 . THREADED STUD WITH NUTS M3. Cut to right length.
022 1 875 15012-013 . WORM GEAR, COMPLETE Incl. screws. Ratio 50:1.
22 33
23 24
32
1
14 15
2
16 17 5
8
18 19 20 21
9
289 5449-801 25 31 10
625-6245.643 /0
PARTS MANUAL Date Group Fig. Page
001 1 875 15017-008 . CAM DISC WITH ARM, COMPLETE 30° - 55°
002 1 875 15017-009 . CAM DISC WITH ARM, COMPLETE 55° - 100°
003 1 875 15017-009 . CAM DISC WITH ARM, COMPLETE 55° - 100°
004 1 875 15017-008 . CAM DISC WITH ARM, COMPLETE 30° - 55°
005 1 875 15017-008 . CAM DISC WITH ARM, COMPLETE 30° - 55°
006 1 875 15017-010 . CAM DISC WITH ARM, COMPLETE 100° - 175°
007 1 875 15017-010 . CAM DISC WITH ARM, COMPLETE 100° - 175°
008 1 875 15017-010 . CAM DISC WITH ARM, COMPLETE 100° - 175°
009 1 875 15017-011 . CAM DISC WITH ARM, COMPLETE 175° - 290°
010 1 875 15017-011 . CAM DISC WITH ARM, COMPLETE 175° - 290°
015 2 875 15001-002 . THREADED STUD WITH NUTS M3. Cut to right length.
022 1 875 15012-005 . WORM GEAR, COMPLETE Incl. screws. Ratio 50:1.
1195436
625-6408.115
PARTS MANUAL Date Group Fig. Page
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
PARTS MANUAL Date Group Fig. Page
4 3 2
390 7581-801
625-6459.051
PARTS MANUAL Date Group Fig. Page
INCLINOMETER, C
PARTS MANUAL Date Group Fig. Page
INCLINOMETER, C
Item Qty Article no Description Supplementary data
CAB INSTALLATION
5
1
3 7 8
289 6809-801
625-6540.040
PARTS MANUAL Date Group Fig. Page
CAB INSTALLATION
Item Qty Article no Description Supplementary data
CAB ASSEMBLY
190 0115-801
625-6545.068
PARTS MANUAL Date Group Fig. Page
CAB ASSEMBLY
Item Qty Article no Description Supplementary data
WINDSCREEN CLEANER
PARTS MANUAL Date Group Fig. Page
WINDSCREEN CLEANER
Item Qty Article no Description Supplementary data
3 4 5 6
2 4 5 6
289 4601-801
625-6625.022
PARTS MANUAL Date Group Fig. Page
VENTILATION FAN
388 9464-801
625-6625.015
PARTS MANUAL Date Group Fig. Page
VENTILATION FAN
Item Qty Article no Description Supplementary data
LIFTING BLOCK
PARTS MANUAL Date Group Fig. Page
LIFTING BLOCK
Item Qty Article no Description Supplementary data
001 1 875 12401-022 . SHEAVE, COMPLETE Incl. bearing and lock rings.
011 1 875 12064-016 .. SAFETY LATCH KIT Incl. spring, screw, nut.
013 2 875 12406-022 . SPACER, COMPLETE Incl. spacer tube, screw, nut.
015 4 875 12406-023 . SPACER, COMPLETE Incl. spacer tube, screw, nut.
VALVE UNIT
PARTS MANUAL Date Group Fig. Page
VALVE UNIT
Item Qty Article no Description Supplementary data
VALVE UNIT
PARTS MANUAL Date Group Fig. Page
VALVE UNIT
Item Qty Article no Description Supplementary data
FLUSHING VALVE
PARTS MANUAL Date Group Fig. Page
FLUSHING VALVE
Item Qty Article no Description Supplementary data
UNLOADING UNIT
PARTS MANUAL Date Group Fig. Page
UNLOADING UNIT
Item Qty Article no Description Supplementary data
001 1 . FILTER
003 1 . COVER
006 1 . WASHER
007 2 . O-RING
001 1 . FILTER
005 2 . COVER
010 1 . DIN-CARTRIDGE
014 4 . O-RING
015 1 . SEAL
DIRECTION VALVE
PARTS MANUAL Date Group Fig. Page
DIRECTION VALVE
Item Qty Article no Description Supplementary data
DIRECTION VALVE
PARTS MANUAL Date Group Fig. Page
DIRECTION VALVE
Item Qty Article no Description Supplementary data
UNLOADING UNIT
PARTS MANUAL Date Group Fig. Page
UNLOADING UNIT
Item Qty Article no Description Supplementary data
ACCUMULATOR
Old design
New design
1 2
388 0362-803
625-7951.005
PARTS MANUAL Date Group Fig. Page
ACCUMULATOR
Item Qty Article no Description Supplementary data
000 1 388 0362-803 ACCUMULATOR Charge Press. 2.0 MPa (20 bar)
HYDRAULIC HOSES
HYDRAULIC HOSES
MacGREGOR Cranes
Quality and Manufacturing Demands - Hydraulic Hoses
MacGREGOR Cranes are certified holders according to ISO 9001, and therefore the
hydraulic hoses with couplings supplied by us must have type approval on all ma-
terial.
Standard rubber hose for our 1" high pressure hoses are made for a working
pressure of 380 bar.
100% of the high pressure hoses are proof tested and leakage tested at 450 bar
during minimum 30 seconds and maximum 60 seconds. This pressure corresponds
to 1.3 times the working pressure.
100% of the hoses are marked with MacGREGOR Cranes part numbers, for quick
and correct identification.
100% of all high pressure hoses are, furthermore, marked with manufacturing date.
100% of all hoses are carefully cleaned after testing. They are cleaned by means of
cavitation with a mixture of water and an anti-corrosive agent.
The cleanliness after washing is equal to, or better than, class 9 according to NAS
norm 1638.
288 1436-801
625-7994.001
PARTS MANUAL Date Group Fig. Page
DRIVER’S DESK
7 8
14 72 73 9 10
15 74
11 12
13
124 0827-801
625-8563.059
PARTS MANUAL Date Group Fig. Page
DRIVER’S DESK
Item Qty Article no Description Supplementary data
124 0760-801
625-8567.049
PARTS MANUAL Date Group Fig. Page
25 26
124 0761-801 2 14 13 12
625-8567.050
PARTS MANUAL Date Group Fig. Page
CONTROLLER, HOISTING
PARTS MANUAL Date Group Fig. Page
CONTROLLER, HOISTING
Item Qty Article no Description Supplementary data
002 1 414 2081-801 BELLOWS WITH BRACE SPARE PART NO: 662 0034-000
PARTS MANUAL Date Group Fig. Page
CONTROLLER, LUFFING/SLEWING
PARTS MANUAL Date Group Fig. Page
CONTROLLER, LUFFING/SLEWING
Item Qty Article no Description Supplementary data
002 1 414 2081-801 BELLOWS WITH BRACE SPARE PART NO: 662 0034-000
PARTS MANUAL Date Group Fig. Page
CONTROLLER
PARTS MANUAL Date Group Fig. Page
CONTROLLER
Item Qty Article no Description Supplementary data
224 0483-801
625-8597.041
PARTS MANUAL Date Group Fig. Page
224 0483-801
625-8597.041
PARTS MANUAL Date Group Fig. Page
324 2043-801
625-8597.061
PARTS MANUAL Date Group Fig. Page
324 1724-801
625-8597.063
PARTS MANUAL Date Group Fig. Page
324 1723-801
625-8597.064
PARTS MANUAL Date Group Fig. Page
2 3
14 15
324 1777-801
625-8597.070
PARTS MANUAL Date Group Fig. Page
1 3
324 1819-801
625-8597.071
PARTS MANUAL Date Group Fig. Page
1, 2
1202310-801
625-8597.072
PARTS MANUAL Date Group Fig. Page
1205863
625-8597.073
PARTS MANUAL Date Group Fig. Page
1 12
324 1848-801
625-8597.074
PARTS MANUAL Date Group Fig. Page
S
P
3 1
3
3
3
2 P
S
4
324 1236-801
625-8597.075
PARTS MANUAL Date Group Fig. Page
003 4 5217 4839-116 . CODING SET Includes 1 pcs (S) + 1 pcs (P)
2 3
324 1864-801
625-8597.076
PARTS MANUAL Date Group Fig. Page
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
PARTS MANUAL Date Group Fig. Page
023 1 5217 4839-116 . CODING SET Includes 1 pcs (S) + 1 pcs (P)
1198703
625-8598.121
PARTS MANUAL Date Group Fig. Page
1198703
625-8598.121
PARTS MANUAL Date Group Fig. Page
1215193
625-8598.132
PARTS MANUAL Date Group Fig. Page
1215193
625-8598.132
PARTS MANUAL Date Group Fig. Page
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
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
PARTS MANUAL Date Group Fig. Page
224 0116-801
625-8650.001
PARTS MANUAL Date Group Fig. Page
2 6
224 0119-801
625-8650.003
PARTS MANUAL Date Group Fig. Page
15
3
14
2 15
224 0474-801
625-8650.004
PARTS MANUAL Date Group Fig. Page
1, 2
4
224 0547-801
625-8650.005
PARTS MANUAL Date Group Fig. Page
1, 2
224 0506-801
625-8650.010
PARTS MANUAL Date Group Fig. Page
224 0154-801
625-8650.011
PARTS MANUAL Date Group Fig. Page
001 2 324 0089-801 . RELAY CARD WITH LED’S SEE FIG. 625-8599.020
PARTS MANUAL Date Group Fig. Page
224 0249-801
625-8650.012
PARTS MANUAL Date Group Fig. Page
EL.INST.CONT.SWITCHES CT1/CT2
224 0429-801
625-8650.013
PARTS MANUAL Date Group Fig. Page
EL.INST.CONT.SWITCHES CT1/CT2
Item Qty Article no Description Supplementary data
005 1 324 0089-801 . RELAY CARD WITH LED’S SEE FIG. 625-8599.020
PARTS MANUAL Date Group Fig. Page
224 0505-801
625-8650.014
PARTS MANUAL Date Group Fig. Page
224 0548-801
625-8650.015
PARTS MANUAL Date Group Fig. Page
3
5 6
S
P
1
1
1
1
P
S
124 0524-801
625-8650.016
PARTS MANUAL Date Group Fig. Page
001 4 5217 4839-116 . CODING SET Includes 1 pcs (S) + 1 pcs (P)
CABIN DISPLAY
424 0715.801
625-8655.001
PARTS MANUAL Date Group Fig. Page
CABIN DISPLAY
Item Qty Article no Description Supplementary data
SLIPRING UNIT
PARTS MANUAL Date Group Fig. Page
SLIPRING UNIT
Item Qty Article no Description Supplementary data
1182879
625-9597.081
PARTS MANUAL Date Group Fig. Page
324 1956-801
624-2145.009
PARTS MANUAL Date Group Fig. Page
CABLE WINCH
PARTS MANUAL Date Group Fig. Page
CABLE WINCH
Item Qty Article no Description Supplementary data
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
PARTS MANUAL Date Group Fig. Page
STABILIZATION WINCH
Item Qty Article no Description Supplementary data
3
1 2
18 17
9, 13, 14, 15 6
4
5
189 7669-801
624-2435.010
PARTS MANUAL Date Group Fig. Page
003 1 189 7420-801 . STAB WIRE SHEAVE ASSY SEE FIG 624-2162.011
HAND PUMP
50
22 13
9
49
8
6
19
27
2
28
21
52
7
3 10
20
36
189 1952-801
624-2492
PARTS MANUAL Date Group Fig. Page
HAND PUMP
Item Qty Article no Description Supplementary data
490 4074-801
624-2524
PARTS MANUAL Date Group Fig. Page
10 5 6
9
11
7
4
10
189 7420-801
624-2162.011
PARTS MANUAL Date Group Fig. Page
324 2274-801
624-2147.002
PARTS MANUAL Date Group Fig. Page
MOUNTING ENCODER
390 9851-801
624-2180.014
PARTS MANUAL Date Group Fig. Page
MOUNTING ENCODER
Item Qty Article no Description Supplementary data
MOUNTING ENCODER
390 9852-801
624-2180.015
PARTS MANUAL Date Group Fig. Page
MOUNTING ENCODER
Item Qty Article no Description Supplementary data
SENSOR ASSEMBLY
1
4
7
17
5
2
7
17
1196357
624-2195.013
PARTS MANUAL Date Group Fig. Page
SENSOR ASSEMBLY
Item Qty Article no Description Supplementary data
124 0335-801
624-2196.006
PARTS MANUAL Date Group Fig. Page