Instr - Manual - GP 320-07.418.5-2 - GA7.412.5 - YZJ2007-820 - Crane 4

Instruction and Spare Parts Manual
NB: YZJ2007-820
IMO No.: L9506394
Crane type
GP320-07.418.5-2/GA7.412.5
Crane position
4
Project No.
2/07063.02DAL
INSTRUCTION MANUAL Project No. Page
Dept. C7250 Date: 2012-10-22 2/07063.02DAL 1(3)
TABLE OF CONTENTS
No. of manuals 3 pcs + 2 CD
Certificate for
crane issued by: GL
Certificate for
foundation issued by: -
IMO No. L9506394
Name of ship -
Newbuilding No. YZJ2007-820
Shipyard Yangzijiang
Owners T.Schulte
Project No. 2/07063.02DAL
Mfg. No. 62508171 - Crane 4
Type of crane GP 320-07.418.5-2/GA7.412.5
Order specification 490 6503 - 801 /B
Mechanical spec. 490 6962 - 801 /-
Hydraulic spec. 490 6766 - 801 /-
Electrical spec. 490 6767 - 801 /-
Slewing spec. -
SAFETY DOCUMENTS
Document names written with bold letters are documents with safety aspects.
INSTRUCTION NO. REV NAME OF INSTRUCTION
GENERAL 1 1.005 E e PREFACE

1.009 E a GENERAL INSTRUCTIONS, CLEANLINESS IN HYDRAULIC SYSTEMS
1.102 E c CONVERSION FACTORS
1.518.3 ED d HYDRAULIC AND ELECTRIC SYMBOLS
TECHN. DESCRIP. 2 2/07063.02DAL - TECHNICAL DATA

2.007.56 E c TECHNICAL DESCRIPTION
FUNCTION 3 3.110.70 E a HYDRAULIC FUNCTION

3.126.6 E - EMERGENCY POWER SUPPLY, FREE FALL LIFE BOAT HANDLING
3.142.10 E c CRANE CONTROL SYSTEM
3.157 E a WORKING AREA LIMITS FOR GP/HH CRANES
OPERATION 4 PM40 0815-E00 - OPERATING INSTRUCTION

PM40 1822-E00 e CREW CHECKLIST, BEFORE TAKING CRANE INTO OPERATION
PM40 7200-E00 - FREE FALL LIFE BOAT HANDLING/CARGO HANDLING
4.620.13 E b PARKING THE CRANE, SEA STOWING
MAINTENANCE 5 5.005.25 E i MAINTENANCE CHART

5.019 E a INSPECTION OF STRESSED COMPONENTS AND STRUCTURES
PM51 1217-E00 b LUBRICATING CHART, GP AND HH CRANES
5.302.29 E - CRANE HOUSING/HYDRAULIC OIL TANK
5.421.54 E - LUBRICANTS FOR DECK MACHINERY
SERVICE 6
INSTRUCTION MANUAL Project No. Page
Dept. C7250 Date: 2012-10-22 2/07063.02DAL 2(3)
TABLE OF CONTENTS
INSTRUCTION NO. REV NAME OF INSTRUCTION
6.0 6.000 E e HOW TO ORDER SPARE PARTS

6.000.1 E c STATEMENT REGARDING DELIVERY OF SPARE PARTS TO SWIVELS, LIFTING B
6.000.2 E e RETURN FORM
6.004.1 E bc WORLDWIDE SERVICE NETWORK
6.008.2 E a INTRODUCTION
6.1 6.100 E b MEASURES BEFORE STARTING, DURING AND AFTER COMPLETED SERVICE/M
6.120.21 E - SLEWING GEARSET
6.120.62 E f HYDRAULIC MOTORS, HOISTING AND SLEWING
6.120.96 E a WINCH
6.142.5 E a RECOMMENDATION FOR INSPECTION AND REPLACEMENT OF HYDRAULIC HO
6.2 6.214 E i TIGHTENING TORQUES STUDS/SCREWS AND BOLTS

6.216.69 E e ROPE REEVING DIAGRAM FOR CRANES TYPE GP AND HH
6.222.1 E a HANDLING, INSTALLATION AND MAINTENANCE OF STEEL WIRE ROPES
625/1473 E c INDENTATION AND WEAR ON WIRE SHEAVES
625/1560 E f LIFTING BLOCK/BEAM
625/1657 E b MEASURING PROCEDURE FOR WEAR IN SLEWING BEARINGS
625/1651 E a SLEWING BEARING GREASE SAMPLING PROCEDURE
6.3 6.305.11 E - ELECTRICAL EQUIPMENT, GENERAL MAINTENANCE

6.320.391 E - LIMIT SWITCHES FOR HOISTING WINCHES
6.990.58 E b EMERGENCY OPERATION IN CASE OF COMPLETE POWER FAILURE
EXTRA EQUIPMENT 7
APPENDICES 8
SPARE PARTS 9 SEE SEPARATE TABLE OF CONTENTS

PARTS MANUAL Project No. Page
Dept. C7250 Date: 2012-10-22 2/07063.02DAL 3(3)
TABLE OF CONTENTS
GROUP DESCRIPTION PART NUMBER FIG
9.0 HOW TO ORDER SPARE PARTS e 6.000 E
9.1 WINCH ASSEMBLY 289 3954-801 B/ 625-1440.090A

WINCH 289 3817-801 C/ 625-1450.087A
CAM LIMIT SWITCH, COMPLETE 875 13035-007 -/ 625-1451.100
GEAR, COMPLETE 875 13019-132 -/ 625-1451.176
FLANGE, COMPLETE 875 13021-034 -/ 625-1451.097
DRIVE IN, COMPLETE 875 13004-142 -/ 625-1451.175
OIL PIPE, COMPLETE 875 13009-082 -/ 625-1451.106
HYDRAULIC MOTOR 188 1769-801 A/ 625-2205.016
SLEWING GEAR 289 3823-801 C/ 625-3255.023A
DRIVE IN, COMPLETE 875 13004-129 -/ 625-3256.009
HYDRAULIC MOTOR 188 1250-801 A/ 625-2205.018
9.2 PUMP DRIVE 289 4178-801 B/ 625-4935.150

HYDRAULIC PUMP 188 1098-801 -/ 625-4945.010
9.3 JIB TOP MOUNTING 289 4575-801 -/ 625-6244.051

CYLINDER ASSEMBLY 289 3781-801 A/ 625-5882.034
LOAD WIRE ROPE W. THIMBLE 390 9790-828 N/ -
HOOK BLOCK 391 1683-801 -/ 625-7013.116
JIB BEARING ASSEMBLY 288 0348-801 B/ 625-6170.004A
GENERAL ARRANGEMENT 189 7274 A/ 189 7274
CRANE ASSEMBLY, RIGHT 1230868 -/- 1000021797
SLEWING ASSEMBLY 289 3963-801 -/ 289 3963
SLEWING BEARING 388 8844-801 C/ 388 8844
9.4 DIRECTION VALVE 188 1343-801 -/ 625-7322.018

MOTOR VALVE 388 6358-801 D/ 625-7331
BALANCE VALVE 388 6376-801 B/ 625-7330.001
BALANCE VALVE 289 0840-801 A/ 625-7330.005
LIMIT VALVE 388 6361-801 A/ 625-7334
FILTER - RETURN LINE 287 9463-801 B/ 625-7335
HYDRAULIC HOSES 625-7970G
HYDRAULIC CYLINDER 289 4177-801 -/ 625-7990.065A
HYDRAULIC SYSTEM SPECIFICATION 289 6762 -/ 289 6762
HYDR. INST. HOUSE JIB RIGHT 189 7719-801 A/ 189 7719
LIMIT ARRANGMENT, VALVES RIGHT 189 5295-801 A/ 189 5295
LIMIT ARRANGEMENT, CAMS RIGHT 190 0099-801 A/ 190 0099
9.5 EL. CENTRAL/STARTER 324 1326-801 A/ 625-8630.061A

REMOTE START/STOP BOX 324 0945-801 C/ 324 0945
POWER SWITCH BOX 324 1295-801 -/ 324 1295
ELECTRICAL SYSTEM SPEC. 324 1296 A/ 324 1296
9.7 HAND PUMP 289 5234-801 -/ 624-2499.001

GENERAL 1.005 E rev.: e 2003-09-09
Preface
This instruction manual covers the MacGREGOR Spare parts

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

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

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

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

Baugruppen
1. Hydraulic Symbols
Hydraulische Bildzeichen
Working oil line.

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

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

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

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

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

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

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

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

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

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

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

Filter mit Anzeiger.
Filter with by-pass valve.

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

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

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

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

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

Schnellkupplung oder Meßanschluß.
Gauge connection.
1
Meßanschluß.
Ventilation valve.
Entlüftungsventil.
Non-return valve with variable restriction.

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

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

Schieber, Grundzeichen.
Electrically controlled valve.

Schieber, elektromagnetisch gesteuert.
Pressure controlled valve.

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

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

Schieber, vorgesteuert, externer Steuerdruck.
Lever controlled valve.

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

Schieber, mechanisch gesteuert.
Valve with spring return.

Schieber mit Feder-Rückführung.
Valve with detent.

Schieber mit Lagehalter.
4/2 direction valve

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

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

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

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

Fluß Regulator mit Rückschlagventil.
Cartridge valve.
Patronenventil.
Pressure limiting valve, adjustable.

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

ing.
Druckbegrenzungsventil mit ferngesteuerter Öffnung
oder Schließung.
Pressure reducing valve.

Druckreduzierventil.
Pressure reducing valve with T-port.

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

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

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

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

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

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

Pumpe für Lastwinde.

13 (30)

Pump for luffing winch.

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

Pumpe für Einziehwinde.
Pump for luffing or slewing.

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

Pumpe für Schwenkantrieb oder Einziehwinde.
Pump for slewing.

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

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

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

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

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

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

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

Ventileinheit für Stabilisierungswinde.
Unloading unit for feed pump.

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

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

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

Leitungsverbindung, fest.
Conductor junction, separable.

Leitungsverbindung, trennbar.
Crossed conductor, no connection.

Kreuzende Leitungen, ohne Verbindung.
Slip ring with brush.

Schleifring mit Bürste.
Fuse, supply side indicated.

Sicherung, Zuführungsseite markiert.
Magnetic relay, contactor.

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

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

Kontakt, von Hand betätigt, nicht selbstrückstellend.
Emergency stop.
Notschalter.
Contact with delayed opening.

Kontakt mit Ausschalt-Verzögerung.
Contact with delayed closing.

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

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

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

Temperaturwächter, Thermostat.
Touch free contact.

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

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

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

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

Dreipoliges thermisches Relais (Überstrom-Aus-
lösung).
Frequency converter.
Frequenzumformer.
25 (30)
Diode.
Diode.

Light emitting diode.
Leuchtdiode.
Pilot lamp.
Meldeleuchte.
Light.
Beleuchtung.
Flood light.
Scheinwerfer.
Alarm signal.
Alarmsignal.
Alarmsiren.
Alarmhupe.
Single-phase outlet.
Steckdose, einphasig.
26 (30)
Position encoder.
Drehfeldgeber.
Puls/speed encoder
Geschwindigkeitsgeber
Flexible lead connector.

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

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

Ölbehälterheizer.
28 (30)
Controller, hoisting.
Steuerknüppel, Lastwinde.
Controller, luffing and slewing.

Steuerknüppel, Einziehwinde und Schwenkantrieb.
29 (30)
30 (30)
TECHNICAL DATA Project No.: 2/07063.02DAL rev: - 2012-10-23
TECHNICAL DATA
GENERAL
Type of crane GP320-07.418.5-2/GA7.412.5
Work order 2/07063.02DAL
Serial number 62508171 - CRANE No. 4
Ambient temp range -25 to + 45° C
BASIC DATA
Lifting height Hook travel = H + K 40 m
Hoisting Hoisting Hoisting Luffing time Slewing Jib radius, Jib radius,
capacity, speed, speed, Max – min speed Minimum Maximum
SWL Low High radius
(ton) (m/min) (m/min) (sec) (rev/min) (m) (m)

7.4 - 16 120 0.7 3.7 18.5
1 (2)
TECHNICAL DATA Project No.: 2/07063.02DAL rev: - 2012-10-23
MAIN SUPPLY
Rated voltage 440 V
Type of frequency 3 Phase ~ 60 Hz
Control voltage 220 V
ELECTRIC MOTOR, pump drive
Rated power, continous 33 kW
Starting current 435 A
WIRE ROPE
Load wire rope Ø 18 mm × 103 m

No. 390 9790-828
OIL VOLUME / OIL FILLING (per unit)
Hydraulic oil tank (Crane house) 950 liters
Slewing gear 8 liters
Hoisting winch 2.5 liters
2 (2)
TECHNICAL DESCRIPTION 2.007.56 E rev.: c 2007-07-21
Technical Description
Hoisting wire rope
Hoisting winch
Limit switch box

Jib lights (Optional)
Hook block
Crane jib
Pennant
(only HH type)
Luffing cylinder
Slewing gear
Luffing limits
(optional)
Operator's Slewing limits

control panel (optional)
Oil tank
Heating fan
Pump
Cardan shaft
Main electric motor
Fig. 1. Crane types GP and HH.
1 (4)
The MacGREGOR Cranes hydraulic slewing The hydraulic oil circuit has a full flow return filter with
cranes type GP and HH are delivered as complete changeable filter insert.
units, installed on pedestals, tested electrically, hy-
draulically and mechanically. The tank is provided with an oil level indicator, a tem-
perature gauge and an air breather.
Crane control
The crane is controlled from an open platform above Electric pump motor
the slewing ring. Entrance to the platform is by lad- The electric pump motor is of a marine type, with class
der. "F" insulation (standardmotor) and provided with an
All motions have stepless speed control from 0 to anti-condensation heater for 220V.
max. Two motions can be operated at the same Motor enclosure IP54.
time with full capacity, but with reduced speed. Duty: S6-40% ID.
Remote control (optional) Electric starter

The remote control system allows the crane operator A.D.O.L. starter for location in the deck housing will
to drive the crane from a position on deck. be supplied as a separate item.
The starter includes as standard: ammeter,

Load limiting system
hourmeter, start/stop buttons, main switch and run-
Each hydraulic circuit is provided with equipment for
ning lamp in the front door.
limiting the hydraulic pressure to preset values
corresponding to the crane capacity.
Slewing machinery
The crane is provided with a slewing ring designed
Limit switches
for marine application. The gearing is internal.
Hook Travel Up: The crane is provided with an au-
tomatic hook stop at the top position.
Hoisting machinery
Luffing Up - Down: The luffing cylinder is designed The winch unit consists of:
for safe buffering in the extreme positions. - Drum with bearing and bracket.
- Winch gear with hydraulically operated fail-safe
Slewing Limits (optional): The crane is provided with brake.
limit switches for limiting of slewing angle. - Hydraulic motor with safety valve to "freeze"
movement in case of pressure drop.
Combined Slewing - Luffing Limits (optional):
The crane is equipped with an arrangement for re- Wire rope is of the non-rotating type and galvanized.
ducing allowable outreach through a certain angle. Minimum safety factor is according to classifica-
tion rules.
Electro-hydraulic power pack
The wire sheaves are provided with heavy duty roller
The crane is provided with a built-in power pack.
bearings on steel axles.
The electric pump motor is located in the centre of
the pedestal with output shaft pointing upwards and
All bearings have grease nipple lubrication.
driving the hydraulic pump through a cardan shaft.
The slewing column steel structure is utilized as

tank for the hydraulic oil.
2 (4)
Fig. 2. Crane system. Main components.
Jib cylinder Surface treatment

The jib cylinder is designed for marine use and has All surfaces of the crane are carefully prepared by
spherical bronze bearings on steel axles. sandblasting before being given a coat of primer.
As standard, the crane is painted with an
The front part of the piston rod is made of stainless anticorrosive system based on a two-component
steel to prevent rust formation when the crane is epoxy paint and an acrylic finishing coat.
parked.
Heating (valid for cranes working in an

Steel structure
ambient temperature below -20°C.)
The steel quality selected is in accordance with
classification society recommendations to obtain The crane is equipped with a heating fan located
necessary ductility for the lower temperature design in the foundation to warm up the hydraulic oil tank
limit. in case of low ambient temperatures.
All important welds are carried out in accordance

with welding pocedures.
After welding, a certain number of non-destructive

tests are carried out.
3 (4)
4 (4)
FUNCTION 3.110.70 E rev.: a 1999-01-07
Hydraulic Function
General
The following description refers to the Three hydraulic work circuits, ie, main hoisting
MacGREGOR service crane type GP/HH. circuit, luffing circuit and slewing circuit make up
the complete crane operating system.
Minor variations in the hydraulic system may occur
in individual cranes of the same type. All three hydraulic working circuits have a common
main pump. The main pump is located inside the
A complete hydraulic circuit diagram relating hydraulic reservoir which is integrated with the
specifically to your crane will be found in the cranehouse.
instruction manual, “Spare Parts”, Group 9.4.
Hoisting Luffing Slewing
Pump
Fig. 1. Identifying hydraulic circuits
1 (8)
FUNCTION 3.110.70 E rev.: a 1999-01-07
The system has also a common main directional Hoisting winch circuit
valve with three sections, one for each circuit, and
one common base shunt section with main pressure
Introduction
limitation.
Figure 2 shows a hoisting winch circuit diagram with
the following main components:
The main directional valve is a pressure
compensated valve, which gives load independant
Pump (common) 001
speed control. The speed is only depending on the
Hydraulic motor 102
control lever position. The load sensing function in
Brake unit 103
the valve (LS-signal) controls the system pressure
Main motor valve 104
to the level just above the highest required
Main directional valve (common) 002
momentary pressure.
The high-speed motor has a fixed displacement in

Identifying circuits in the hydraulic diagram
the hoisting circuit and is fitted to the winch via a
Figure 1 shows the arrangement of the three work flange.
circuits; main hoisting circuit, luffing circuit and
slewing circuit. The circuits appear in the same Transmission of torque to the winch drum is made
order in the hydraulic diagram. via planetary gearing.
Symbols The brake opens by the system pressure via

Every hydraulic component is represented by a sequence valve 104-2, see Fig. 2.
special symbol in the circuit diagram. The meaning
of the symbols is explained in Section 1, “Hydraulic
and Electric Symbols”. The symbol for the reservoir
is shown in several places in the diagram for greater
simplicity of drawing; but there is naturally only one
reservoir in actual fact.
Component identification
The main components are identified by three-digit
numbers in the diagram and on the actual
components in the crane. The first digit of each
number signifies the circuit to which the component
belongs, as follows:
1... Main hoisting circuit

2... Luffing circuit/Luffing cylinder
3... Slewing circuit
Legend
MMHO Hydraulic motor, main hoisting circuit
CLU Hydraulic cylinder, luffing circuit
MSL Hydraulic motor, slewing circuit
2 (8)
FUNCTION 3.110.70 E rev.: a 1999-01-07
Fig. 2. Hoisting winch circuit diagram
3 (8)
FUNCTION 3.110.70 E rev.: a 1999-01-07
Function Safety system

Pressure limiting functions: Main pressure limiting
valves 002-6A and 002-7A.
Hoisting circuit
Neutral/idling
With the control lever in neutral and the pump
Luffing circuit
running, the hoisting winch performs no actual work.
The speed is controlled by the hand lever (direct Introduction

connected) integrated with the main directional Fig. 4 shows a luffing circuit diagram, i.e. the circuit
valve. that controls the movement of the jib and with the
following main components:
The control lever can be moved in two directions,
backwards or forwards, see Fig. 3. Cylinder 202
Balance valve 204
Hoisting and lowering Pump (common) 001 and main directional valve
(common) 002, see Fig. 2.
To hoist, move the control lever backwards from
neutral position. This will move the spool for hoisting
002-1A and connect the pump to the motor. The Luffing
system pressure increases up to the needed level To luff in, move the control lever backwards from
for the current load and the winch brake will open neutral position. This will move the spool for luffing
at a certain system pressure level and the winch 002-1B and connect the pump to the cylinder. The
starts to move in hoisting direction. system pressure increases up to the needed level
for the current load and the jib starts to move in
Increased movement of the lever increases the hoisting direction.
amount of flow from the pump through the spool
and to the winch motor and the speed increases in Increased movement of the lever increases the
the same manner. The speed is controlled by the amount of flow from the pump through the spool
control lever and increases continously in proportion and to the winch motor and the speed increases in
to the lever position. the same manner. The speed control is controlled
by the control lever and increases continously in
To lower the load the lever has to be moved proportion to the lever position.
forwards in similar way as for hoisting.
To luff out the jib the lever has to be moved forwards
in similar way as for luffing in.
Slewing Luffing Hoisting

Safety system
valves 002-6B and 002-7B.
Fig. 3. Control lever movements
4 (8)
FUNCTION 3.110.70 E rev.: a 1999-01-07
002
Fig. 4. Luffing circuit diagram
5 (8)
FUNCTION 3.110.70 E rev.: a 1999-01-07
Slewing circuit
Introduction
Fig. 5 shows a slewing circuit diagram with the
following main components:
Hydraulic motor 302

Brake 303
Balance valve 304
Pump (common) 001 and main directional valve

(common) 002, see Fig. 2.
Slewing
To slew left, move the control lever backwards from
neutral position. This will move the spool for slewing
002-1C and connect the pump to the motor. The
system pressure increases up to the needed level
for the current load and the slewing brake will open
at a certain system pressure level and the crane
starts to move in slewing left direction.
Increased movement of the lever increases the

amount of flow from the pump through the spool
and to the winch motor and the speed increases in
the same manner. The speed control is controlled
by the control lever and increases continously in
proportion to the lever position.
To slew right the lever has to be moved forwards in

similar way as for slewing left.
Safety system
valves 002-6C and 002-7C.
6 (8)
FUNCTION 3.110.70 E rev.: a 1999-01-07
002
Fig. 5. Slewing circuit diagram
7 (8)
FUNCTION 3.110.70 E rev.: a 1999-01-07
8 (8)
FUNCTION 3.126.6 E rev.: - 2006-04-05
Emergency Power Supply

Free Fall Life Boat Handling
General
The electric power to the crane is provided by the Ship Power 2

power switch box CT2 in two different ways, i.e.: In case of main power failure the ship’s emergency
power supply will provide power to the crane, see
- Ship Power 1 - main power supply. Fig. 1.
- Ship Power 2 - emergency power supply.
The crane is designed to run even if there is a brake Maintenance

down of the main power supply in the power switch
box CT2. The function of the emergency power supply should
be checked regularly. The intervals should be the
See electrical system, section 9.5. same as for the free fall life boat equipment.
Function - Visually inspect that contactors K11, K12 and K13

in the power switch box CT2 are not affected by
Ship Power 1 copper rust, see Fig. 2.
The main power supply provides the crane with - Make a function test.
electric power, see Fig. 1. - Start the crane and run all movements.
Example:
K11
K12
K13
Fig. 1. Electrical connection between ship and power

switch box CT2. Fig. 2. Power switch box CT2.
1 (2)
FUNCTION 3.126.6 E rev.: - 2006-04-05
2 (2)
FUNCTION 3.142.10 E rev.: c 2008-09-22
Crane Control System
The control system is based upon three control Hydraulic motors

levers (main direction valve) operated from the The hydraulic motors may be reversed by changing
outside crane housing/oil tank. The right lever the direction of the oil flow. They deliver constant
controls the hoisting winch, the middle controls the torque over their entire speed range.
luffing and the left lever controls the slewing
movement. All movements except for the luffing
Limit switch box, hoisting
movement are driven by hydraulic motors. The
Controls stop for full drum.
luffing movement is driven by a hydraulic cylinder.
The brake releases and closes in the correct

sequence when the hydraulic motor is started and
stopped.
Hydraulic pump
The pump is a fixed displacement pump.
The speed of the winch is depending on the lever

movement.
Fig. 1. Crane system. Main components.
1 (2)
FUNCTION 3.142.10 E rev.: c 2008-09-22
2 (2)
FUNCTION 3.157 E rev.: a 2011-10-12
Working Area Limits for GP/HH Cranes
General Slewing limits

The limit valves for slewing limit the slewing sector and
The working area of the crane is limited to prevent cause stops of the crane in each direction, see Fig. 1.
collision between the jib and objects standing close The limit valves and corresponding cams are placed
to the crane. Some cranes are prevented from turning inside the foundation. The limit valves are attached to
360° due to electrical wiring within the foundation. It the inner ceiling inside the foundation and the cams
is possible to limit both slewing and luffing move- are attached to the foundation wall, see Fig. 6.
ments with hydraulic limit valves that are operated by
mechanical cams. When a limit valve hits a cam the hydraulic pressure
is drained and the slewing motion stops.
Note!
For detailed information about the working area limi-
Combined luffing and slewing limits
tations for your crane, see drawings "General Arrang-
The combined luffing and slewing limit valves reduce
ement" in section 9.3 and "Limit Arrangement cams/
the maximum outreach through a certain sector of
valves" in section 9.4 in the parts manual.
the working area, see Fig. 2. The luffing limit valve
limits the outreach. The luffing limit valve operates in
For detailed information about the limit valves fun-
combination with a slewing limit valve.
ctions see hydraulic circuit diagram in section 9.4.
When a luffing limit valve and the related slewing limit
valve is hit, the hydraulic pressure is drained and the
Function slewing or luffing out movement stops.
A limit valve operates a cam that drains the hydraulic Note!

pressure which controls the slewing or luffing motion. If the slewing motion has been stopped in a slewing/
luffing limit you must luff in until the luffing limit valve
Note! is released or operate the slewing bypass valve, see
When no limit valve operates the minimum and maxi- Fig. 6.
mum outreach are limited by the luffing cylinder. It is
designed for a safe buffering at extreme positions. CAUTION!
Bypass slewing limit at your own risk.
Fig. 1. Slewing limits. Fig. 2. Combined luffing and slewing limits.
1 (4)
FUNCTION 3.157 E rev.: a 2011-10-12
Working area and non-working areas
The working area of the crane can be limited by sta-

tionary objects located near to the crane, see Fig. 4
and 5.
If it is not possible to pass an object, then the slewing

limit valves prevent the crane to slew into the non-
working area, see Fig. 3 and 4.
Objects in the outer range of the working area can be

avoided with the combined luffing and slewing limit
valves. It is possible to pass an object by luffing in the
jib before slewing, see Fig. 3 and 5.
1. Working area.
2. Non-working area limited by slewing limit valves.
3. Non-working area limited by combined luffing/ slewing limit valves.
Fig. 3. Crane working area and non-working areas.
2 (4)
FUNCTION 3.157 E rev.: a 2011-10-12
Fig. 4. Crane working area when slewing limit valves prevent crane from colliding with a stationary object.
Fig. 5. Crane working area when the combined luffing/slewing limit valves limit the outreach when passing a statio-
nary object.
3 (4)
FUNCTION 3.157 E rev.: a 2011-10-12
Limit valves and cams for luffing and slew-

ing
The limit valve (1) and cam (2) for luffing are installed at
the jib bearing. The cam moves with the jib. See Fig. 6.
The limit valves (3) and cams (4) for slewing are instal-
led inside the foundation. The limit valves move with
the crane. See Fig. 6.
2
1
1. Luffing limit valve.

2. Luffing limit cam.
3. Slewing limit valves.
4. Slewing limit cams.
5. Bypass valve for slewing limit.
Fig. 6. Arrangement of limit valves and cams.
4 (4)
OPERATION PM40 0815-E00 rev.: - 2008-02-18
OPERATING INSTRUCTION
Notify responsible officer onboard before taking crane into operation.
Make sure that there is nobody in the crane working area who might be injured.
START - STOP
BEFORE STARTING START REMOTE START/STOP
Set main switch, placed on starter Press the green "I" button on starter Press green "Start" button or red
box, in position "1". box. "Stop" button on remote start/stop
The white indicator lamp for main The green indicator lamp for crane box, placed on the crane foundation.
supply illuminates. running illuminates.
The yellow lamp for anti-condensation The yellow indicator lamp for anti-
heater illuminates. condensation heater goes out.
START
START STOP
Main switch should be switched
on approx. 10 hours before the STOP STOP
crane is taken in operation. Press the red "0" button on Starter

box.
The green indicator lamp for crane
AFTER STOPPING running goes out.
Set main switch in position "0". The yellow lamp for anti-
condensation heater illuminates.
Emergency stop
STARTER BOX
A. Main switch
B. Stop button
A 200
150
100
50
0
00000250 h
C. Start button
D. Crane running lamp

B C D E F
E. Main supply lamp
A F. Anti-condensation heater lamp
1 (2)
CRANE OPERATION
If more than one crane movement are activated at the same time the speed of the crane will be reduced.
Notice! The movements of the crane are activated directly by the movements of the control levers.
Notice! Always check that the wire runs correctly on the drum.
1. Control lever Slewing 2. Control lever Luffing 3. Control lever Hoisting

Moving the control lever forwards or Moving the control lever forwards or Moving the control lever forwards or
backwards will operate the slewing backwards will operate the luffing backwards will operate the hoisting
movements. movements. movements.
1 2 3 4
EMERGENCY STOP
Turn Emergency stop lever (4) to
stop crane movements.
Fig. 1. Operator's control panel.
1. Slewing 2. Luffing 3. Hoisting
Fig. 2. Sign on operator's control panel.
2 (2)
OPERATION PM40 1822-E00 rev.: e 2009-04-01
Crew Checklist before Taking Crane into Operation
List Wires and sheaves

Verify that the ship does not list more than 5 degrees. Verify that wires run
correctly in the sheaves
and that the wire ends
Max 5
are securely clamped.
Oil level
Verify that hydraulic oil level is between min. and max.
on oil level dipstick.
Trim
Verify that the ship does not trim more than 2 degrees.
MAX
Max. 2
MIN
Jib and hook release

Loosen hook and jib from its parking position manually
before raising jib from its parking support.
1 (2)
OPERATION PM40 1822-E00 rev.: e 2009-04-01
2 (2)
Free Fall Life Boat Handling
General
The crane is designed/certified for provision hand- Warning! The ball valve must be set in "Life Boat"
ling and launching/recovery of fully boarded free fall position before launching or recovery of the life boat,
life boats. see Fig. 2.
Function Power switch box CT2 (optional)
Maximum outreach for handling the free fall life boat In case of main power failure the control system in
is limited by switches. The crane is equipped with a CT2 will automatically be switched over to ship
two-position ball valve and a limit switch that power 2 mode, see separate instruction in section 3
maximizes the outreach in free fall boat handling of the instruction manual.
mode, see Fig. 2.
Free fall life boat
Aft
Bridge
Max. outreach, provision handling
Max. outreach, free fall life boat handling
Fig. 1. Maximum outreaches for free fall life boat and provision handling.
1 (2)
Operation
"PROVISION" position - max outreach, provision

handling.
"LIFE BOAT" position - max outreach, free fall life

boat handling.
PROVISION
LIFE BOAT
Fig. 2. Crane operator's position, view from above.
2 (2)
OPERATION 4.620.13 E rev.: b 2008-09-24
Parking the Crane, Sea Stowing
Sea stowing
Prior to sea voyage, the crane jib should be put on Caution!

its parking support, see Fig. 1. If the hook is to be The wire ropes must not be tightened by the winch.
stowed to deck, fibre strops with low ultimate load or The wire ropes, sheaves, and winches are subject to
manual "stretching screw" are to be used, see Fig. 3. heavy stress during sea voyage.
Tighten hook attachment manually to make sure that Note! Before operation release hook from sea
the wire rope does not slack between the winch and stowing position manually. Make sure that hook and
the jib top. Maximum tightening force between hook crane jib are loose before raising the jib from its
and deck is dependent on work load and reeving, parking support.
see Table 1.
Fig. 1. Crane in sea stowing position.
Fig. 2. Wire rope must not slack between winch and jib top.
1 (2)
OPERATION 4.620.13 E rev.: b 2008-09-24
Recommendation for parking the hook
Hand-tighten only to the extent that the wire rope is

not slack.
Maximum tightening force (kN) between hook and

deck, see Table 1.
Reeving
1-part 2-part 3-part 4-part
0≤5 5 5 - -
SWL (T)
5≤8 5 10 - -
8 ≤ 20 5 10 15 15
20 ≤ 25 - - - 15
Rope connection
Stretching screw turnbuckle
Deck
Fig. 3. Recommendation for parking the hook. Table 1. Maximum tightening force (kN).
Cranes equipped with stainless steel wire

ropes (optional)
Caution!
Stainless steel wire ropes must be strapped to the
metal bars on jib during sea voyage. See Fig. 4.
Stainless steel wire ropes have lower tolerance for

impacts than galvanized wire ropes and can be
damaged if not tightened and strapped according to
instruction.
Fig. 4. Stainless steel wire rope attachment.
2 (2)
MAINTENANCE 5.005.25 E rev.: i 2009-10-21
Maintenance Chart
Lubricate crane according to LUBRICATING to slacken, tighten all studs/screws. Tightening

CHART. torque, see drawing "Slewing assembly", section
9.3.
Every time before taking crane into After 200 operating hours (running in
operation period)
Crane housing/Hydraulic oil tank
- Check oil level. Slewing gear case
- The first oil change.
Oil filter
- Check oil pressure. See "Lubricating Chart", Winch
section 5. - The first oil change.
Slewing gear case

- Check oil level. See instruction "Slewing
Gearset", section 6.1. The oil quantity is marked Every six months or every 500 working
on the name plate and in "Technical Data", hours
section 2.
- Check visually all sides. Check for leaks, Wire ropes, wire rope clamps
particularly on the bottom shaft seal ring. - Inspect for wear. See instruction "Handling,
Installation, and Maintenance of Steel Wire
Winch Ropes" in section 6.2.
- Check oil level. See instruction "Winch", section - Wire ropes are inspected according to
6.1. The oil quantity is marked on the name plate stipulations issued by Classification Associations
and in "Technical Data", section 2. and National Bodies.
Loose gear Bottom plate
- Check that block, beam, hook, swivel, and - Check for leaks.
shackle are intact.
Check according to instruction "Lifting Block/Beam", Wire sheaves
section 6.2. - Inspect for wear
Loose gear
Every two months or every 200 - Check that hook and swivel are intact.
operating hours
Electrical equipment
Slewing bearing studs/screws - Inspect according to “Electrical Equipment,
General Maintenance” in section 6.3, Service.
- Inspect visually the slewing bearing studs/screws
from deck If any stud/screw shows a tendency
1 (4)
Crane house, foundation, and jib welding joints Air filter

- Inspect for any sign of crack. See "Inspection of - Check and change air filter.
Stressed Components and Structures", section 5.
Slewing bearing studs/screws/nuts

Hydraulic system - Inspect visually and by hammer test.
- Measure the pressures according to the hydraulic
circuit diagram’s adjoining list, section 9.4.
- Reset as required.
Oil analysis Every two years or every 2000 hours of

- Sample oil and analyse every six months. operation
- If no oil analysis is done the oil must be changed
every two years or every 2000 hours of operation. Crane housing/Hydraulic oil tank; oil change
and cleaning
See separate instruction section 5.
- Drain oil and clean the reservoir. (See “Hydraulic
Slewing bearing Oil Tank”, section 5.)
- Measurement to be taken according to instruction - Top up with fresh oil according to “Lubricants for
"Measuring Procedure for Wear in Slewing Deck Machinery”, section 5
Bearings for Crane Types GP and HH" in section - Change oil filter cartridge
6.2. - Change air filter.
- Check seals.
Multiple disc brake, winch
Slewing gear, pinion - Check for leaks
- Check backlash. - Check discs.
Check according to instruction "Hoisting Winch" in
section 6.1.
Multiple disc brake, slewing gearset

Every 1000 operating hours or at least - Check for leaks
every year - Check discs.
Slewing gear case Check according to instruction "Slewing Gearset"
under section 6.1.
- Change oil. Gear box
- Change oil. Disc-room
Hydraulic hoses and couplings outside crane
- Check motor spline shaft for deformations or
house
wear.
See instruction "Slewing Gearset", section 6.1. - Inspect for damage and leaks.
Winch
- Oil analysis
- Change oil. Gear box
- Change oil. Room between motor and gear.
See instruction "Hoisting Winch", section 6.1.
2 (4)
At dry docking or at maximum 5 years

interval
Slewing bearing studs/screws

- Tighten all studs or screws. Tightening torque, see
separate drawing, "Slewing assembly", section
9.3
- Consult MacGREGOR, Service Division before
replacing studs/screws with any other
specifications than recommended.
Every five years
Hydraulic hoses and couplings inside crane

house
- Check according to instruction under section 6.1.
Hydraulic hoses outside crane house
- Replace all hydraulic hoses.
Every ten years
Hydraulic hoses inside crane house

- Replace all hydraulic hoses.
3 (4)
4 (4)
MAINTENANCE 5.019 E rev.: a 2007-01-12
Inspection of Stressed Components and Structures
Introduction
Stressed parts of the crane structure subjected to This inspection should be performed at intervals ac-
high loads require inspection for signs of cracks and cording to the Maintenance Chart.
other damage at regular intervals.
Note!
Cracks detected at an early stage do not generally Rust on a painted surface does not necessarily
impair the handling safety of the crane unless they mean that there is a crack in the underlying mate-
are not repaired. rial.
For safety reasons, service routines should include Remedy

a regular inspection of the entire crane, with par-
When rust is found on top of or near a weld, grind
ticular attention paid to stressed parts.
the topmost surface layer away to expose the crack
clearly. When in doubt, use a liquid penetrant to
Inspection identify the crack.
A thorough visual inspection is fairly easy to carry
out as cracks will generally show by cracking or Before repairing of a crack in a stressed part, always
flaking of the paint followed by a brownish discol- contact MacGREGOR (SWE) AB, Service Division
oration by rust. for advice.
(Inspect welds and surrounding material.)
Fig. 1. Crane Structure.
1 (2)
MAINTENANCE 5.019 E rev.: a 2007-01-12
2 (2)
LUBRICATING CHART PM51 1217-E00 rev.: b 2007-02-06
GP- and HH-cranes

Key to symbols PART OF CRANE a b c d e f g
a Daily or before taking crane into operation. 1 WIRE SHEAVES AND THIMBLE, JIB TOP, 3-4 NIPPLES
b Every 50 working hours (item 7 and 14*). 2 WIRE ROPE
After more than 48 hours off duty (item 14*). 3 LIFTING EQUIPMENT, 1-3 NIPPLE(S)
c Every 100 working hours. 4 HOISTING WINCH BEARING, 1 NIPPLE
d Every two months or every 200 working hours. 5 AIR BREATHER
e Every six months or every 500 working hours.
6 OIL DRAIN PLUG (IN PUMP BRACKET) 1)
f Every year or every 1000 working hours.
BEARING, SLEWING RIM, 3-8 NIPPLES,
g Every two years or every 2000 working hour. 7 2)
SEE DRWG. PARTS MANUAL SEC. 9.3
8 SLEWING RIM TEETH
Key to symbols 9 JIB BEARINGS, 2 OR 4 NIPPLES
Grease for ball and roller bearings 10 OIL LEVEL TEMPERATURE GAUGE
Grease for wire ropes 11 SLEWING GEAR CASE, OIL CHANGE
Grease for open spur gears 12 WINCH GEAR BOX, OIL CHANGE.
Check oil level 13 WINCH + SLEWING GEAR
Cylinders 14 LUFFING CYLINDER BEARINGS, 4 NIPPLES (INNER)
Oil filter, check/change 15

LUFFING CYLINDER BEARINGS, 3)
4 NIPPLES (OUTER)
Check air breather
Hydraulic oil tank, oil change 16 PISTON SEALING, 1-3 NIPPLE(S)
Sample oil and analyse every six months. If 17 OIL FILTER 4)

necessary change oil and clean tank 18 CARDAN SHAFT, 2 NIPPLES
Slewing gear case, oil change 19 OPEN GEAR
The first oil change after 200 working hours. 20 DRAIN COCK, HYDRAULIC OIL DRAIN
Winch, oil change
ELECTRIC MOTOR, UPPER AND LOWER BEARING,
The first oil change after 200 working hours. 21
NIPPLES
Winch + slewing gear 22 OIL FILLING
Motor flange/shaft coupling; oil change.
1) Open oil drain plug after oil tank is drained through drain cock.
2) Relubrication should be performed under slewing motion. If that
Maintenance intervals: See "Maintenance Chart", is not possible relubricate bearing through all grease fittings,
section 5. than turn bearing approx. 200 mm and relubricate again. Repeat
Lubricants: See "Lubricants for Deck Machinery", this procedure until overlap of greasing is achieved and the
section 5. whole bearing circumference is filled with new grease at the
gaps and seals. (Five rotations/greasings should be sufficient.)
Oil volumes: See tables page 2. 3) Cylinder to be lubricated only at assembly/replacement.
* Four times a year if the crane is off duty for a longer 4) Check pressure on the manometer every time before taking
period (item 14). crane into operation. The pressure must not exceed 1.5 bar
(0.15 MPa). If necessary, change filter.
14 12 13 4
2 (1. Alternative to
central lubrication.)
9
5
1
22 17 (14. Alternative to
Jib support
10 14
15
11 16 3
15
8 1 19
20 7
6 18 3
21 (1. Alternative to
CAUTION! Filling of oil and checking oil level in oil tank and winch
to be made at horizontal jib and/or cylinder in bottom position.
1 (2)
MAINTENANCE PM51 1217-E00 rev.: b 2007-02-06
Oil volumes
Crane size Oil volume Oil volume Oil volume

(litres) (litres) (litres)
Total hydraulic Oil tank Slewing gear
system
63 250 200 2.2
100 500 450 NA
160 600 550 6.5
250 750 700 8.0
320 1050 950 8.0
400 1100 950 16.0
500 1250 1100 16.0
630 1250 1100 2 x 8.0
800 2050 1800 2 x 8.0
Table 1.
SWL Winch*
(tonnes) (litres)
>0 to 3 1.5
>3 to 5 1.5
>5 to 8 2.0
>8 to10 NA
>10 to15 2.5
>15 to 20 NA
>20 to 25 NA
* For exact volume, oil filling, see
Technical Data in section 2.
Table 2.
NA = Not applicable.
2 (2)
MAINTENANCE 5.302.29 E rev.: - 2008-07-02
Crane Housing / Hydraulic Oil Tank
General Cleaning the crane housing/oil tank

The crane housing, with the pump placed inside, Before cleaning the crane housing/oil tank, immobilise
functions as an oil tank. the crane jib in a suitable manner and stop the electric
motor. Open the drain cock and drain off the oil into
Checking oil level clean empty barrels or drums then open the oil drain
plug on pump bracket and drain off oil left.
The crane housing/oil tank has an oil level dipstick.
Check that oil level is between min. and max. See
Remove the tank cover. Scrape off sediment, if any,
Fig. 1.
from the tank bottom and sides using a rubber scraper.
Filling oil Flush the tank with white spirit.

Oil is filled into the crane housing/oil tank. When filling
oil the hydraulic machinery must be at rest, crane jib Wipe the tank dry with clean rags. DO NOT USE
in parking position (cylinder not projected) and the COTTON WASTE, or other linting material. Apply new
electric main switch open. Fill oil to just under the MAX sealing compound and reinstall the tank cover.
mark, see Fig. 1. Use oil according to instruction
”Lubricants for Deck Machinery". If the drained oil is in good condition and can be used
anew, it should be filtered before refilling.
Caution! Oil filled in the tank must be filtered to ISO
16/13 or better. Filling of oil to be made at horizontal Pump and hoses used for filling must be perfectly
jib and/or cylinder in bottom position. clean.
Oil temperature Fill oil to just under the MAX mark. Use oil according
to instruction ”Lubricants for Deck Machinery".
The oil tank is equipped with a thermometer that shows
the actual temperature of the oil.
Inspection cover
Oil level dipstick
Oil filling
Drain plug on pump bracket

o
MAX Drain cock
MIN
Foundation
Thermometer
Fig. 1. Crane housing / Hydraulic oil tank.
1 (2)
2 (2)
Lubricants for Deck Machinery
A. OILS B. GREASES
The oil shall be refined oil containing additives against Roller bearings. Crane jib bearing
oxidation, rust and foaming, as well as wear inhibitor Grease with EP additives.
and/or EP additives.
NOTE!
Hoisting winch gear box, slewing gear case MUST NOT contain molybdenum disulphide.
Must withstand wet conditions.
Oils with oil film reinforcing additives.
Example: SHELL Alvania EP (LF) 2 (-20 to +130 °C)
Viscosity approx. 150 cSt/40o C.
Arctic climate: SHELL Albida PPS2.
Solidification point -30o C or better.
Description according to DIN: DIN51517 CLP PAO 150
Example: SHELL OMALA HD 150. Ropes
Grease resistant to salt water and with antirust properties
Hoisting winch; motor flange (very thin.)
Temperature range -30 to +100°C.
Slewing gear; motor flange
Half the motor flange should be filled with hydraulic oil Viscosity 9.8 cSt/40°C
to prevent wear/rust on motor shaft/coupling. Example: FUCHS CEDRACON
Arctic climate: FUCHS Ceplattyn
NOTE!
Open spur gear units
When replacing brake discs the new discs should be
slightly wet with ATF-oil. Grease with good adhesion properties.
Example: SHELL MALLEUS GL95 (-15 to +150 °C)
SHELL MALLEUS GL65 (-30 to +150 °C)
Crane hydraulic system
Viscosity approx. 46 cSt/40o C (ISO VG 46 HV).
Cylinder
Viscosity index (VI) approx. 150.
Solidification point -45o C or better. A lithium/calcium-based grease with base oil viscosity
Example: SHELL TELLUS T46. 150 - 200 cSt/40°C.
NOTE!
MUST NOT contain molybdenum disulphide.
Please contact Cargotec Sweden AB, MacGregor Example: SHELL CALITHA EP T2
Cranes, Service Division, when choosing lubricants for
extreme temperatures.
1 (2)
2 (2)
Cargotec Sweden AB How to order
MacGregor Cranes 6.0
Sjögatan 4G
spare parts
SE-891 85 ÖRNSKÖLDSVIK, Sweden
Telephone: 46 - 660 - 29 40 00
Telefax: 46 - 660 - 139 77
www.cargotec.com
SERVICE
Hydraulic system 6.1
Mechanical
6.2
equipment
Electrical
6.3
equipment
SERVICE 6.000 E rev.: e 2010-09-08
How to Order Spare Parts
Important details when enquiring or ordering spare parts
Please send your inquiry or order to closest MacGregor global service station, see instruction "MacGregor Global
Services", 6.004.1 E.
To speed up the process we request you to provide us with below information:
State name of company as well as your name
Vessel's name and IMO number (and/or Lloyd's number)
Crane type (see manual or name plate in operator's cabin)
Crane place on the vessel. No. 1 counted from the fore
Crane serial number (see manual or name plate in operator's cabin)
Spare part figure or drawing number. To be found in section 9 in the manual
Part description
Item number from spare part figure or drawing respectively
Part number, if available, from spare part figure or drawing respectively
Quantity required
When you order a wire rope or lifting block, please specify which certificate is needed.
Deadline - when or where in the world do you need the parts?
Delivery details such as: consignee as well as phone and fax numbers
Terms of delivery: by DHL, air freight direct or consignment, by truck or shipping freight
The more you can provide us with above details the faster and more reliable replies and deliveries will be made.
Address:
Cargotec Sweden AB
MacGregor Cranes
Phone: 46 - 660 - 29 40 00
Telefax: 46 - 660 - 139 77
www.macgregor-group.com
1 (2)
6.000 E rev.: e 2010-09-08 page 2 (2)
Tel: 46 - 660 - 29 40 00
Direct: Fax: 46 - 660 - 139 77
Date: ................................................
Spare parts/Service specification

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

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

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

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

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

(b) after any renewal or repair of a stress-bearing
part.
1 (2)
SERVICE 6.000.1 E rev.: c 2007-01-08
2 (2)
SERVICE 6.000.2 E rev.: e 2012-05-21
RETURN FORM
How to return parts from deck crane manufacturing,
installation or guarantee exchange
Delivery address: MacGregor Cranes

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

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

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

have to be enclosed.
The above refers only to the return shipment as such.
1 (2)
SERVICE 6.000.2 E rev.: e 2012-05-21
RETURN FORM
To be packed inside return box or parcel
Date:
Sent by:
Newbuilding no.:
Ship’s name:
IMO no.:
Crane place on board:

Crane serial no.:
Returned part’s
drawing or article
no, serial no.:
Part description:
Serial no. of unit

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

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

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

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

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

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

Cargotec Sweden AB SE-891 85 ÖRNSKÖLDSVIK (+46) 660-29 40 00 (+46) 660-139 77
www.macgregor-group.com/cranes Sweden
2 (2)
SERVICE 6.008.2 E rev.: a 2007-01-12
Introduction
Before proceeding to trouble-shooting, the crane

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

used in the circuit diagrams to facilitate tracing the
probable fault in the circuit diagrams, checking the
findings afterwards in the crane proper.
Take care always to have correct circuit diagrams

available on board. If a diagram has gone astray, a
new one can be had from MacGREGOR (SWE) AB,
Service Division. Proper measuring instruments must
always be available, e.g. pressure gauges and
voltmeters.
The trouble-shooting method described here is only

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

generally does so in actual operation. This means
that the crane operator will often be able to give
valuable suggestions, e.g.:
- Did the crane function fail without warning? Electric circuit diagram
- Was the operating speed first reduced, or did
Electric circuit diagram
the movement run irregularly?
- What manoeuvre immediately preceded the Electric circuit diagram
failure?
Begin checking if there are any visible defects.
1 (2)
SERVICE 6.008.2 E rev.: a 2007-01-12
When consulting MacGREGOR (SWE) AB, Service Analysis of information collected

Division for service or advice, always give the By methodical trouble-shooting, it is often possible to
following information at once: find, at an early stage, the defect producing the faulty
operation, thereby avoiding unnecessary waste of
1. Which crane function has ceased to function? time.
2. Has it failed completely, or in part?
A first check of the crane may be made thus:

- Are there any leakages (jog crane)
- Does the pump follow the control lever
movements?
To summarise, trouble-shooting operations should

prefarably be carried out in the following manner:
By studing the symptoms of the crane and its

equipment, it is possible to deduce:
1. Is the fault electrical, hydraulic, or mechanical in

nature?
2. In which function does the fault appear:

- Hoisting circuit
- Luffing circuit
- Slewing circuit
3. Is the trouble limited to:

- Raising or lowering of the load
- Raising or lowering of the jib
- Slewing right or left
4. Special observations:
- Is the hoisting, luffing, or slewing capacity
restricted?
- Do disturbances occur only at certain speeds?
- In the event of abnormal noise:
- To which of the main functions does the noise
pertain?
- Is the frequency of the noise high or low?
- Try to describe the noise (hissing, blowing,
humming, rasping etc.)
These questions are always to be answered when

consulting MacGREGOR (SWE) AB, Service Division.
2 (2)
SERVICE 6.100 E rev.: b 1998-10-22
Measures Before Starting, During and After Completed

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

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

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

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

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

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

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

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

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

after completed work.
1 (2)
SERVICE 6.100 E rev.: b 1998-10-22
2 (2)
SERVICE 6.120.21 E rev.: - 2011-02-21
Slewing Gearset
General
The slewing gearset comprises the following com- The brake housing is mounted on top of the gearcase,
ponents: with long assembly screws through the motor adapter
- Motor housing and both parts of the brake housing.
- Brake
- Gearbox The sleeve disc carrier, with the internal discs, is fixed
on the driven shaft with a shaft key or by splines.
The disc assemblies are pressed together by a set

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

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

C-00115
short period, a few seconds.
Fig. 1. Slewing gearset. - Inspect brake discs and replace if excessively worn.
Motor - If discs are coloured dark yellow to blue, the discs
See separate instruction. have been overheated. Replace discs and springs.
- Inspect sealings for wear. If sealings are defect
Multiple-disc brake replace complete pressure unit.
b. Brake heats
Technical description Check the hydraulic pressure to make sure that it is
The brake comprises the following major components, sufficient in order to disengage the brake completely.
see Fig. 2: See hydraulic drawing, section 9.4, setting for control
- Brake piston pressure gauge outlet 2.
- Pressure unit
- Disc carrier
- Internal discs
- External discs
- Sealings
- Pressure springs
1 (4)
SERVICE 6.120.21 E rev.: - 2011-02-21
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
3
4
The gearbox is a three planetary stage type.
2
5
Maintenance
Lubrication 1
6
The slewing gear is splash lubricated. The output shaft
roller bearing is ”for-life” lubricated with ball bearing
grease.
Oil level check Check oil level. The oil must be fil-
led up to the middle of the sight glass. 7
Inspect oil level when the gear is at rest with the brake
engaged.
Caution!
C-00117
As oil expands during operation, this expansion can

falsify the oil level. Examine the oil level only when the
slewing gear is cold! 1. Sight glass
2. Oil filling plug
3. Ventilation filter
4. Brake connection
5. Position "a"
6. Air ventilation valve
7. Oil outlet (x4)
Fig. 3. Slewing gearset.
2 (4)
SERVICE 6.120.21 E rev.: - 2011-02-21
Oil changes for slewing gears Checking and setting slewing bearing
backlash
- For oil change open the oil filling plug.
- Remove the air ventilation valve, at position "a", for An oversize backlash between the pinion and the
better ventilation. See Fig. 3. slewing bearing will cause irregularities in the slewing
- Remove the oil drain plug to allow the oil to drain. movement of the crane. Read this instruction carefully
- Clean the oil plug thoroughly. If necessary, replace prior to checking or resetting!
the seal ring.
- Install the oil drain plug.
- Top up with oil up to the middle of the sight glass. Checking backlash
- Install the air ventilation valve. The backlash should be checked by a dial gauge or a
At low ambient temperatures, flush out the gear case feeler. When slewing the crane, the backlash may vary
with a quantity of fresh oil to remove abraded matter from one position to another due to some slight play
and contamination particles. of the slewing bearing. It is therefore recommended
to check the backlash at four positions of the slew-
Oil inspection ing bearing.
Proceed as follows:
Sampling oil - Check the backlash at one spot.
Withdraw a sample of gearcase oil for inspection from - Put the dial gauge on the tooth of the pinion. By
the oil drained off at intervals as described in the manual turning at the input, the pinion can be
Maintenance Chart. To obtain a representative sample, moved in both directions up to contact with the
drain the gearcase during operation and with the oil teeth. Now, the tooth flank clearance can be exactly
at operating temperature. measured on the dial gauge.
- Proceed to check the backlash at four 90-degree
Oil discoloration position in the bearing.
A darkish or black colour of the used oil suggests that - Compare the four backlash values.
temperatures in excess of 100o C did occur in opera-
tion, causing accelerated aging of the oil and impaired The backlash shall be set at the position of the slewing
lubricating properties. In this case the oil should be bearing with the lowest backlash value.
changed at shorter intervals.
Contact MacGregor Cranes for advice.
If the oil sample displays a cloudy aspect, it may be Setting backlash
that water has managed to seep into the oil. The oil The backlash may be set by turning the entire gearset
must then be changed a t o n c e, and the gearcase one or more screw hole divisions.
flushed out very thoroughly several times with fresh oil.
Proceed as follows:
Overall assessment - Slew the crane into the position with the
The maximum permissible amount of foreign matter lowest backlash value.
carried by the oil is some 0.15 per cent of the total - Remove all screws holding the gearset to crane
mass of the oil in the gearcase. These impurities must house floor.
be, exclusively, very fine abraded matter (max. 25 µ). If - Release the disc brake hydraulically by means of
the contamination keeps within these limits, continued a manual pump.
operation of the gearset is permitted after the oil has - Turn the entire gearset one or more screw
been changed. hole to achieve the desired backlash.
If larger particles (above 25 µ) or flake off material is To turn the gearset, remove the hydraulic motor
found, the gearset must be repaired, irrespective of and turn the spline sleeve on top of the gear.
the actual amount of foreign matter present. - Install the screws holding the gearset to the crane
house floor.
3 (4)
SERVICE 6.120.21 E rev.: - 2011-02-21
This page is intentionally left blank
4 (4)
SERVICE 6.120.62 E rev.: f 2003-03-19
Hydraulic Motors, Hoisting and Slewing

Cranes type GP and HH
Hydraulic Motor 187 8383-801 Oil filling/Drain connection
Before the first operation the hydraulic motor housing

should be pre-filled with hydraulic oil.
The type of hydraulic oil must agree with the "Lubricating

Chart", Section 5.
Displacement: 30.0 cm3/rev.

Pre-filling volume: 1.0 litre (Approx.)
T1 alternatively T2 can be used as oil filling and drain

connections.
Oil filling/Drain connection


Chart", Section 5.

T1 alternatively T2 can be used as oil filling and drain

connections.
1 (4)
SERVICE 6.120.62 E rev.: f 2003-02-19

The type of hydraulic oil must agree with the

"Lubricating Chart", Section 5.

Oil filling/Drain
connection
Hydraulic Motor 188 1250-801 Oil filling/

Drain connection


Chart", Section 5.
Oil filling/
Drain connection
Pre-filling volume: 1.0 litre. (Approx.)

Drain connection

Chart", Section 5.

Oil filling/
Drain connection
2 (4)
SERVICE 6.120.62 E rev.: f 2003-03-19

Drain connection


Chart", Section 5.
Displacement: 63.0 cm3/rev. Oil filling/

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

Drain connection
288 2158-801


Displacement Vg: 54.8 - 0 cm3/rev.

Oil filling/
Drain connection

Drain connection


3 (4)
SERVICE 6.120.62 E rev.: f 2003-02-19
4 (4)
SERVICE 6.120.96 E rev.: a 2007-01-12
Winch
Winch and gearbox
General
The hoisting winch is driven by a high speed hydrau- - Connect brake line and release the disc brake
lic motor via a planetary gearbox. hydraulically. The drive sleeve in the drive unit
must turn easy.
The planetary gearbox has splash lubrication and is - Remove plug from the drive sleeve of the drive
normally filled with gear oil. unit. For protection against corrosion, the drive
sleeve is provided with gear oil from the gear. The
If the winch is supplied without oil, this is indicated plug prevents the motor flange filling with oil before
on a corresponding label. mounting the motor.
- Centre motor on the motor flange. Seal connection
A brake is integrated in each winch gear set. When surface with Loctite 572 or similar. Fix motor with
the winch is running, the brake is automatically screws. Motor shaft must be grease-free.
released by hydraulic pressure. - Before test-running, fill the motor flange completely
with gear oil.
- Check oil level with oil dipstick. Refill oil if
Assembly of winches
necessary.
- Mount the winch together with winch support. The - Be sure that jib is in horizontal position, see Fig. 2,
clamping screws of the winch support must be when checking oil level.
easily connectable.
- Oil volume: See nameplate on winch or instruction
- Tighten the screws according to torque "Technical Data", section 2.
recommended. Secure with Loctite 242 or a sim-
- Oil type: See instruction "Lubricants for Deck
ilar compound. Machinery", section 5.
- Remove the motor flange transport cover.
- Check rope winch with running motor as to function.
Check above all the control and function of the
holding brake and the drive motor.
Journal - After test-running, check oil level once more with
bearing oil dipstick. During the test-running, the oil level in
Oil filler inlet the gear and motor flange adjusts itself and fills
Oil dipstick
the space around the motor shaft slowly with gear
oil. The oil level may therefore be reduced.
- If necessary, refill oil.
- The journal bearing is filled with grease. Before
bringing into operation, grease again until grease
emerges at the sealing profile.
- Insert rope and fix it. Secure screws accordingly.
Oil filler inlet for wet

running motor and shaft.
Oil outlet
Fig. 1. Winch with oil filler inlet, dipstick and outlet. Fig. 2. Jib in horizontal position.
1 (4)
SERVICE 6.120.96 E rev.: a 2007-01-12
Oil changes Oil discoloration

Whenever practicable, let the oil drain off while still A darkish or black colour of the used oil suggests
hot. Remove the inlet plug (air filter). At low ambient that temperatures in excess of 100°C have occurred
temperature, flush out the gearbox with a quantity of in operation, causing accelerated ageing of the oil
fresh pre-heated oil to remove particles and sedi- and impaired lubricating properties. In this case the
ment. oil should be changed at shorter intervals.
If the oil sample displays a cloudy aspect, it may be
Maintenance that water has managed to seep into the oil. The oil
- Change gearbox oil, see Fig 1. must then be changed at once, and the gearbox
flushed out very thoroughly several times with fresh
- Grease journal bearing, see Fig 1.
oil.
- Check oil level, see Fig 1.
The gearbox should preferably be dismantled for
Note! inspection beginning at the input side, and the
Oil level can only be inspected with non-running gears components examined for signs of corrosion.
and with jib in horizontal position, see Fig. 2.
Maintenace interval and number of grease nipples: Foreign solid matter

See "Lubricating Chart", section 5. As a first simple test, drop some of the used oil onto
the filter fleece specified. Coarse foreign matter, if
Types of oil and grease:
present, will then show up on inspection through
See "Lubricants for Deck Machinery", section 5.
(preferably) a magnifying glass.
Oil volume:
A better test can be made by diluting an oil sample
See "Technical Data", section 2.
with n-heptane, passing it through a diaphragm
filter, washing and drying it, and weighing it to
Sampling oil determine the mass difference.
Take a sample of gearbox oil for analysis at intervals
as described in the "Maintenance Chart". Overall assessment
The maximum permissible amount of foreign matter
Procedure for oil sampling: carried by the oil is some 0.15 per cent of the total
- The oil temperature in the gearbox should be mass of the oil in the gearbox. These impurities may
above +40 0C. only consist of very finely abraded matter (max. 25
- Special oil sampling bottles should be used that µm). If the contamination keeps within these limits,
can be obtained from oil companies. continued operation of the gear set is permitted after
- The oil sample should be taken from the oil drain the oil has been changed.
on the winch, see Fig. 1.
If coarser abraded matter (above 25 µm) or flake-off
- Drain 1-2 litres of oil into a bucket. This oil should
material from the gear teeth is found, the gear set
be disposed of.
must be dismantled, irrespective of the actual amount
- Fill the oil sample bottle.
of foreign matter present, beginning at the input end
- Send the oil sample to an oil company for analysis.
of the gear set.
The oil company will be able to recommend if the
oil can be further used.
Feedback on the oil analysis can also be obtained
from MacGREGOR (SWE) AB, Service Division.
2 (4)
SERVICE 6.120.96 E rev.: a 2007-01-12
Hydraulic-Release Multiple-Disc Brake
Technical description Trouble-shooting

The brake comprises the following major Braking torque insufficient
components. See also Fig. 3.
Test of brake may be performed as follows:
- Brake piston
- Brake cylinder - Drive winch hydraulic motors against closed brake.
The motor shall not be able to rotate.
- Disc carrier
Note! Test procedure shall be performed only for
- Inner discs
a short period; a few seconds.
- Outer discs
- Inspect brake discs and replace if excessively
- Hydr. part for disc brake
worn. If brake discs are coloured dark yellow to
- Compression spring
blue, the discs have been overheated. Replace
The brake housing is mounted on the input side of discs and springs.
the gearbox, with long assembly screws through the - Inspect brake for leakage. If leakage appears in oil
motor adapter housing and both parts of the brake pressure unit, the complete unit must be replaced.
housing. Note! Sealings are not available as spare parts.
The disc assemblies are pressed together by a set
of compression springs and the brake is disengaged
Brake heats
by hydraulic power.
Check the hydraulic pressure to make sure that it is
sufficient in order to disengage the brake completely.
Maintenance
The brake is self-adjusting.
Motor side
Hydr. part for disc brake Compression spring
Connect pressure oil
Leakage oil
Outer disc Arrangement of Inner discs Disc carrier

the brake discs
Gear side
Fig. 3. Disc brake.
3 (4)
SERVICE 6.120.96 E rev.: a 2007-01-12
4 (4)
SERVICE 6.142.5 E rev.: a 2002-01-09
Recommendation for Inspection and

Replacement of Hydraulic Hoses
Hydraulic hoses and couplings assembled

inside crane house
Hydraulic hoses assembled inside crane house If the rubber in the hose is damaged so that the steel
should be inspected for damage every five (5) years, core can be exposed to corrosion the hose should be
see Maintenance Chart in section 5. replaced.
If the rubber in the hose is damaged so that the steel The hose couplings should also be inspected for
core can be exposed to corrosion the hose should leakage and damage of the corrosion protective Den-
be replaced. syl tape. If the corrosion protection is damaged so
The hose couplings should also be inspected for that the coupling can be exposed to corrosion the
damage and leakage. If the coupling is damaged or corrosion protection should be removed and the
severely corroded the hose should be changed. coupling inspected for damage and severe corrosion.
If the coupling is leaking the coupling should be tighte- If the coupling is damaged or severely corroded the
ned at first. If tightening does not help, the hose and hose should be changed.
the mating couplings should be changed, see Fig. 1. If the coupling is leaking the coupling should be tighte-
If the coupling is of flange type the O-ring and screws ned at first. If tightening does not help, the hose and
should be changed, see Fig. 2. the mating couplings should be changed, see Fig. 1.
If the coupling is of flange type the O-ring and screws
Hydraulic hoses and couplings should be changed, see Fig. 2.
assembled on outside of crane house
Replacement of hydraulic hoses
Hydraulic hoses assembled on outside of crane house
should be inspected for damage every two (2) years, All hydraulic hoses assembled inside crane house
see Maintenance Chart in section 5. should be replaced after ten (10) years due to safety
reasons.
All hydraulic hoses assembled on outside of crane
house should be replaced after five (5) years due to
safety reasons.
Hose coupling
Mating coupling O-ring
Screw
Fig. 1. Hose coupling with O-ring. Fig. 2. Flange coupling with O-ring.
1 (2)
SERVICE 6.142.5 E rev.: a 2002-01-09
2 (2)
SERVICE 6.214 E rev.: i 2007-03-02
Tightening Torques
Studs/Screws and Bolts
Introduction
This instruction applies to studs, screws and bolts Note!

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

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

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

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

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

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

assembling.
Type of Thread Tightening Type of Thread Tiightening

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

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

Grease
O-ring sealed Sealing
4 (4)
SERVICE 6.216.69 E rev.: e 2011-11-08
Rope Reeving Diagrams for Cranes Type GP and HH

1-, 2-, 3- and 4-Parts Rigging
IMPORTANT!
The hoisting wire must have at least three locking turns around the winch drum.
C-00234
Example of hoisting winch
1 (6)
SERVICE 6.216.69 E rev.: e 2011-11-08
Rope Reeving Diagram for Cranes Type GP and HH

1-Part Rigging
Hoisting wire rope
2 (6)
SERVICE 6.216.69 E rev.: e 2011-11-08

2-Parts Rigging
Hoisting wire rope
Locking plate
Lock washer
Screw
Spacer
Wire thimble
Note! The wire rope thimble should be safely secured.
3 (6)
SERVICE 6.216.69 E rev.: e 2011-11-08

3-Parts Rigging
Hoisting wire rope
Spacer
Bolt
Nut
Split pin
4 (6)
SERVICE 6.216.69 E rev.: e 2011-11-08

4-Parts Rigging
Hoisting wire rope
Locking plate
Lock washer
Screw
Spacer
Wire thimble
5 (6)
SERVICE 6.216.69 E rev.: e 2011-11-08
6 (6)
SERVICE 6.222.1 E rev.: a 1998-04-17
Handling, Installation and Maintenance

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

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

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

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

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

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

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

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

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

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

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

shown below.
The aluminum ferrule with mechanical splice.

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

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

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

cessary as to whether the wire rope should be pulled
through the whole reeving system or whether it
should first be wound from the coil or reel onto the
drum and afterwards be reeved into the system.
4 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
Here, special attention must be paid to the hook tional wire ropes one must at least make sure that
block. It must be secured in an upright position so they have the same direction of lay as rope to be
that the rope can be spooled without any fleet an- installed.
gles occuring between the rope and the 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.
If that connection is applied, its safety should be

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

size sheaves are used. Vibrations and torsional
stress loads in the rope accelerate fatigue rupture.
11 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
12 (12)
S E RV I C E I N F O R M AT I O N
625/1473 E rev.: c 2010-06-23
Indentation and Wear on Wire Sheaves
General
To ensure safe working conditions and long lifetime The wear, see Table 1, can certainly occur on every
of the wire rope it is important to inspect the condition spot where the wire rope is in contact with the wire
of the wire sheaves. sheave, not only on places shown in Fig. 1.
Wear criterias Indentation

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Class Working load limit Proof load
ABS PL = 2 x WLL
BV WLL < 25 T PL = 2 x WLL
25 T < WLL < 160 T PL = (0.933 x WLL) + 27
WLL > 160 T PL = 1.1 x WLL
DNV PL = 2 x WLL
GL WLL < 25 T PL = 2 x WLL
WLL > 25 T PL = (1.22 x WLL) + 20
LRS WLL < 25 T PL = 2 x WLL
WLL > 25 T PL = (1.22 x WLL) + 20
WLL = Working Load Limit (SWL)
T = 1 metric ton = 1000 kg
PL = Proof Load
2 (2)
625/1657 E rev.: b 2011-12-29
Measuring Procedure for Wear in Slewing Bearings
General
Below measuring procedure is valid for cranes type It is important that the same position are used for
GP and HH. all further measurements to be able to compare the
measurements.
The slewing bearing is an essential part of the crane
and must be well maintained. Over the years the slew- For maximum allowed wear, see table on page 3.
ing bearing will have some wear, and to be able to
know if there is a need for changing the slewing bear- The table on page 4 can be used to record the meas-
ing it is needed to keep a record of the wear. urements.
The initial measurements should be taken when WARNING!

the crane is installed at yard or within 2 months Do not enter the crane foundation during crane op-
from crane installation. eration.
Moving crane house and machine parts may suddenly
If the wear measurement shows wear, grease samples cause bodily injury or death.
can be taken for analysis.
Slewing bearing grease sampling proce-

dure
See Inspection Instruction 625/1651 E.
Measuring
Measurements should be taken regularly, every 6

months. When measurements are to be taken the ship
shall have as little list/trim as possible.
Procedure
Two measurements shall be taken on four positions
of the slewing bearing, see Fig. 1, if possible, with the
jib pointing:
- forward to the ship
- starboard
- aft
- port side
1 (4)
625/1657 E rev.: b 2011-12-29
Measurement B
(back of crane)
Clean these surfaces thoroughly
Jib at maximum outreach

Empty hook
Measurement A
(front of crane)
Clean these surfaces thoroughly
Fig. 1. Measuring the wear on slewing bearing.
2 (4)
625/1657 E rev.: b 2011-12-29
Maximum allowed wear on slewing bearing
Crane size Allowed wear (mm)*

63 1.4
100 1.5
160 1.6
250 2.0
320 1.8
400 2.1
500 2.2
630 2.8
800 2.9
For crane size, see Technical Data in section 2 of the

instruction manual:
Type of crane : GP 100-xxxx

HH 400-xxxx
If the measured wear is bigger than the allowed

wear contact Cargotec Service Organisation.
3 (4)
625/1657 E rev.: b 2011-12-29
Vessel name: ........................................................... Fore Note!

- If B - A = 0 or negative the
IMO No.: ................................................................... measurement is wrong.
Ps Stb
Date: .........................................................................
Aft
Actual measurement (accuracy 0.1 mm) Measured wear
Date Jib direction A (front of crane) B (back of crane) B-A
Fore mm mm mm
Stb mm mm mm
Aft mm mm mm
Ps mm mm mm
Fore mm mm mm
Stb mm mm mm
Aft mm mm mm
Ps mm mm mm
Fore mm mm mm
Stb mm mm mm
Aft mm mm mm
Ps mm mm mm
4 (4)
INSPECTION INSTRUCTION
625/1651 E rev.: a 2012-01-04
Slewing Bearing Grease Sampling Procedure
General
One of the criteria's to evaluate a slewing bearing's - Clean up the seal and the surrounding areas where
condition is to analyse the grease samples. The other the sample will be taken. When cleaning the area
is to make play measurements. The grease analysis of the seal, prevent the cleaner from contacting the
can be done in two steps, simplified or in a laboratory. seals or from entering the raceway's system.
What method to be used must be decided after the - Push new grease into the grease nipples / bearing
play measurement is taken. It must be noted that a without rotation and collect the first used grease
single laboratory test of a grease sample gives very which will come out at the seal.
little information. Laboratory tests must be done on
regular basis to see trends. Attention: Do not take fresh grease for analysing!
The required quantity of grease for analysing is ap-
The play measuring normally tells more about the proximately 3 cm3.
bearing condition than a grease sample. Both methods
provide together the best basis for evaluation of the The normal interval for grease sampling is 6 months.
bearing condition.
If steel particles are seen when the simplified grease
analysis is done or if the laboratory grease analysis
Procedure of grease sampling shows a too high value the grease sampling period
should be increased to each 50 crane operating hours
Following information is necessary in order to give a or every two months.
correct statement and allow further advice:
1. Type of grease used at lubrication (manufacturer

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

important, below procedure should be done.
Procedure
- Slew the crane until the jib is in the main working
area.
- The grease sample should be taken at the inner or
outer seal of the bearing, see Fig. 1 and 2.
- One sample should be taken from the front part of
the crane and one sample from the back part of the
crane.
1 (6)
625/1651 E rev.: a 2012-01-04
Grease sampling area Grease sampling area

(see below figures) (see below figures)
Grease sampling
area (inner seal) Grease sampling
area (inner seal)
Outer seal
Slewing bearing with rollers.
Outer seal
Slewing bearing with balls.
Fig. 1. Grease sampling areas.
2 (6)
625/1651 E rev.: a 2012-01-04
Grease sampling area Grease sampling area

(see below figure) (see below figure)
Inner seal
Grease sampling
Slewing bearing with balls. area (outer seal)
Fig. 2. Grease sampling area.
3 (6)
625/1651 E rev.: a 2012-01-04
Simplified grease analysis
1. Take a grease sample.
2. Spread the grease on a white paper.
3. Spread it out in a very thin layer.
4. Place the sample under a lamp and look for steel

particles.
4 (6)
625/1651 E rev.: a 2012-01-04
Laboratory grease analysis
Normally a grease laboratory analysis should give

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

analysis of fresh grease should be available to recog-
nize the deviations of the used grease.
Recommended analyze limits
Ok Attention Risk
Fe ≤ 1500 ≤ 5000 > 5000
PQ Index = Fe >5μ ** ≤ 500 ≤ 1500 > 1500
Si ≤ 100 ≤ 200 > 200
Water * ≤ 1000 ≤ 2000 > 2000
All values in ppm = mg/kg
* Depend on the fresh grease / max. allowable water content of the manufacturer
** Thus a high PQ - index always indicates wear.
5 (6)
625/1651 E rev.: a 2012-01-04
6 (6)
SERVICE 6.305.11 E rev.: - 1999-06-08
Electrical Equipment, General Maintenance
Introduction Portable control boxes

General maintenance of the electric equipment of Control panels and remote control boxes may be sub-
the crane is important in order to prevent unexpected jected to abuse an abnormal wear, and should be
breakdowns. The following general advice may be inspected after every use. The control boxes must be
useful. Relevant block diagrams and detailed circuit stored in a compartment that is well protected against
diagrams are placed in section 9, SPARE PARTS. moisture. Remove moisture that may have collected
in the boxes, and find out how it entered.
Start the crane and try out all combinations of move-
ments that are practicable. This will show if the electric - Clean contacts, insulating parts, cams, contact rolls,
functions are satisfactory. and rotary potentiometers.
- Make sure that all cable connnections are clean
Inspect all electrical equipment cabinets, and com- and securely tightened.
ponents. Any defective component must be repaired - Clean the control levers, and grease their sliding
or replaced without delay. A detailed inspection and surfaces.
overhaul at two-year intervals is recommended. Check - Check on the return springs and grease lightly so
that all screws and nuts are securely tightened in the that no grease transfers to the contacts.
contactor cabinets, that all switches and pushbuttons
operate correctly, and that cable connections are per-
fectly tight and all insulating parts intact. Make sure
that inspection door gaskets seal perfectly.
Earth connection, hull

Verify that the protective earth connection of the crane
is made to the ship’s hull.
Clean contact surfaces, when required.
Earth connection, crane

Check crane system earth connections, and clean
contact surfaces as required.
1 (2)
SERVICE 6.305.11 E rev.: - 1999-06-08
2 (2)
SERVICE 6.320.391 E rev.: - 2011-11-04
Limit Switches for Hoisting Winch
General
The limit switches stops hook movements at chosen There are two cams, one for low hook limit "Empty
safety limits. drum" and an upper hook limit "Full drum", see Figs.
2 and 4.
The limit switches of the hoisting winch are in a limit
switch box, see Fig. 1. Each switch function is set sepa- Luffing limits are controlled by the luffing cylinder and
rately with a rotating cam which controls a hydraulic can not be set, exept for cranes with optional luffing/
switch. The cams are rotated by the winch geared slewing limits.
down by a gearbox.
1
C-00232
1. Limit switches box, hoisting winch
Fig. 1. Position of limit switches box, GP/HH cranes.
1 (4)
SERVICE 6.320.391 E rev.: - 2011-11-04
Empty drum limit
Empty drum limit must be at least three locking turns

of wire around the winch drum, see Figs. 2 and 3.
1
C-00233
1. Maximum Hook Travel (HT), see Technical Data

2. Empty drum limit, at least three locking turns
Fig. 2. Empty drum limit
2 (4)
SERVICE 6.320.391 E rev.: - 2011-11-04
C-00234
Fig. 3. Three locking turns
Full drum limit
Full drum limit are found on the drawing "General ar-

rangement" in section 9.3 in the manual, see Fig 4.
1
C-00235
1. Full drum limit, see "General Arrangement"
Fig. 4. Full drum limit
3 (4)
SERVICE 6.320.391 E rev.: - 2011-11-04
Set limit switches - hoisting winch 2. Remove clamping screws and remove both cams
and the spacer.
Tools: 3. Operate the winch to "Full drum" limit, refer to
* Socket wrench SW8 "General arrangement" in section 9.3 and Fig. 4.
* Hexagonal recess spanner 2,5 mm. 4. Install the inner cam for "Full drum". Remove set
* Hexagonal recess spanner 5 mm. screw cover and adjust cam with the set screw.
5. Operate the winch to "Empty drum" limit, with at
Secure screws with Loctite 243 and correct tightning least three full locking turns wire on winch.
torque, refer to instruction "Tightning Torque". 6. Install spacer.
7. Install the outer cam for "Empty drum". Remove
Note! set screw cover and adjust cam with the set screw.
If only small adjustments have to be done the cams 8. Install clamping screws and washers.
does not need to be removed and installed, only ad- 9. Operate the crane to both "Empty drum" and "Full
justed with the set screw. drum" limits to make sure that both limits are cor-
rect, adjust if necessary.
1. Remove cover and seal from limit switches box. 10. Install seal and cover, and set screw covers.
Refer to Fig. 5
1 2 3 4 5 6 7
C-00236
1. Cover and seal

2. Set screw cover, Empty drum
3. Set screw cover, Full drum
4. Limit switches (2x)
5. Cams (2x)
6. Clamping screws with washers (3x)
7. Set screw
Fig. 5. Limit switches box
4 (4)
SERVICE 6.990.58 E rev.: b 2012-05-28
Emergency Operation in Case of Complete Power Failure
Introduction Note!
For reference see hydraulic circuit diagram in section
9.4 in the parts manual. All hydraulic components
CAUTION!
mentioned in this instruction can be found in the dia-
- This work has to be done by skilled people and
gram.
with great caution.
- Only one function to be activated at a time.
- Make sure that no people are in the working area
General
of the crane.
The hand pump is placed on the operator's platform
when operated. One hose is connected to the oil tank
This instruction describes how to perform an emer- and the other hose is connected to slewing machinery
gency operation in case of a complete power failure. or hoisting winch. The release of the brakes is done
Slewing and winch lowering may be operated to a by producing hydraulic pressure using the hand pump.
limited extent by releasing their respective brakes
with the hand pump. The jib can be lowered without The jib is lowered by releasing pressure in the luffing
use of hand pump. cylinder.
8
2 7
10
7 4
5 9
10
3 9
3
8
11
1
6
1. Pump 7. Hydraulic hose connected to motion

2. Handle 8. Quick connection
3. Pressure relief valve (setting 35 bar) 9. Pressure gauge
4. Safety valve 10. Valve block
5. Safety valve button 11. J-hooks
6. Hydraulic hose connected to oil tank
Fig. 1. Hand pump and hydraulic diagram representation.
1 (6)
SERVICE 6.990.58 E rev.: b 2012-05-28
Secure the hand pump
1. Place hand pump on platform according to Fig. 2.

2. Secure hand pump to platform with two J-hooks.
1. Platform
2. J-hook (2 pcs)
Fig. 2. Securing of hand pump.
2 (6)
SERVICE 6.990.58 E rev.: b 2012-05-28
Connect to oil tank
Before operation After operation

1. Connect the shorter hydraulic hose to quick cou- 1. Close ball valve 015.
pling 016 on oil tank according to Fig. 3. 2. Disconnect hand pump from oil tank.
2. Open ball valve 015.
Operation
1. Operate emergency slewing or emergency lowering
of winch according to following instruction.
1. Quick coupling 016

2. Ball valve 015
Fig. 3. Connection of hand pump to oil tank.
3 (6)
SERVICE 6.990.58 E rev.: b 2012-05-28
Emergency slewing
Before operation 1. To release the brake, press and hold the safety
1. Make sure that the hand pump is secured to plat- valve button on the hand pump unit, and pump by
form and connected to hydraulic oil tank according hand until the brake begins to open.
to Fig. 2 and 3. 2. The crane can then be slewed to the necessary
2. Close the brake line to tank by closing ball valve position by means of another crane while the pres-
307. sure is kept up by pumping.
After operation
4. Connect the longer hose from the hand pump to
1. Close ball valve 309.
quick coupling 308.
3. If no further movements are necessary, close ball
Operation valve 015.
Note! The brake opens when pressure from hand 4. Disconnect hand pump from oil tank.
pump reaches 12 bar.
2
3
1. Ball valve 307

2. Ball valve 309
Fig. 4. Connection of hand pump to slewing machinery.
4 (6)
SERVICE 6.990.58 E rev.: b 2012-05-28
Emergency winch lowering
Before operation 2. To release the brake, press and hold the safety
1. Make sure that the hand pump is secured to plat- valve button on the hand pump unit, and pump by
form and connected to hydraulic oil tank according hand until the brake begins to open.
to Fig. 2 and 3. 3. When the winch starts to move take great care
2. Open ball valve 105 on the winch. so that the speed is not too high. If the speed
3. Connect hand pump to quick coupling 108. increases too much, release the safety valve
button and the brake will close immediately.
Operation
Note! The brake opens when pressure from hand After operation
pump reaches 12 bar. 1. Close ball valve 105.
2. Disconnect hand pump from quick coupling 108.
1. Lock control lever for hoisting in lowering position 3. If no further movements are necessary, close ball
(forward) by holding it or strapping it in position. valve 015.
4. Disconnect hand pump from oil tank.
2
1
1. Ball valve 105

3. Control lever 1A for hoisting at directional valve 002
Fig. 5. Connection of hand pump to hoisting winch.
5 (6)
SERVICE 6.990.58 E rev.: b 2012-05-28
Emergency lowering of jib
Before operation 2. Measure distance "A" on valve 204 with a slide-

1. Slew the crane to a suitable position. calliper and note the value. The measure must be
within 0.5 mm precision. See Fig. 7.
3. Loosen the locking nut on valve 204.
Operation
4. Loosen the set screw carefully on valve 204, until
CAUTION! the jib begins to lower slowly. Carefully count the
Valve 204 is a safety valve that must be correctly number of loosening turns while loosening the set
adjusted after an emergency lowering of the jib. If screw.
not adjusted correctly the luffing movements might
not work correctly and the crane can be damaged.
After operation
Contact Cargotec Service Organization to adjust
1. Tighten the set screw until distance A exactly reach-
and seal the valve if you are not sure of adjustment
es its former noted value. Verify with the number
after an emergency lowering.
of tightening turns.
2. Tighten the locking nut.
1. Break the seal and remove protective cap on valve
3. Put back the protective cap.
204.
2 3 4
1. Valve 204 3. Set screw

2. Locking nut 4. Protective cap
Fig. 7. Valve 204 on luffing cylinder.
6 (6)
9.0 How to order
spare parts
Cargotec Sweden AB
MacGregor Cranes
Sjögatan 4G
Telephone: 46 - 660 - 29 40 00 9.1 Machinery
Telefax: 46 - 660 - 139 77
www.cargotec.com
Spare Parts Manual 9.2 Pump unit

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

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

Please use this form whenever assistance is needed. Service request
Confirmation of
phone call/conv.
From: .. ............................................................. E-mail address: ................................................
.............................................................. Phone no.: ......................................................
.............................................................. Telefax no.: ......................................................
Re: M/V ........................................................ IMO /Lloyd's no.: ..............................................
Crane type: ............................................. Serial no: .........................................................
Crane place: ........................................... Our ref.: ..........................................................
For following spares we would like to: have your quotation
place order, deadline for arrival :................................
Part no. Qty Description Fig./Drwg. Item
1. .......................................... ..... ............................................ .............................. ..............
2. ........................................... ..... ............................................ .............................. ..............
3. ........................................... ..... ............................................ .............................. ..............
4. ........................................... ..... ............................................ .............................. ..............
5. ........................................... ..... ............................................ .............................. ..............
6. See enclosure
Delivery/Agent's address: ............................................................................................................
............................................................................................................
............................................................................................................
...................................................................................................................
Name/ Title/
PARTS MANUAL Date Group Fig. Page
2006-01-13 9.1 625-1440.090A 1 (2)
WINCH MOUNTING
2006-01-13 9.1 625-1440.090A 2 (2)
WINCH MOUNTING
Item Qty Article no Description Supplementary data
000 1 289 3954-801 WINCH MOUNTING
001 1 289 3817-801 . WINCH SEE FIG. 625-1450.087
002 1 188 1769-801 . HYDRAULIC MOTOR SEE FIG. 625-2205.016
003 8 489 4472-001 . WASHER
004 4 2151 2052-178 . WASHER TBRB 13 x 24 FZB
005 4 2121 2030-789 . SCREW M6S 30 x 160 -10.9
006 4 2121 2034-540 . SCREW M6S 12 x 40 -A4-80
007 4 2126 2038-130 . NUT M6M 30 -10

2009-10-27 9.1 625-1450.087A 1 (2)
WINCH
24 1 22 97
80 Nm
275 Nm
80 Nm 80 Nm 220
404 205
60 405 221 223
46 Nm
402
1000000010986
289 3817-801
625-1450.087 /A
Right-hand crane Weight 355 kg
2009-10-27 9.1 625-1450.087A 2 (2)
WINCH
000 1 289 3817-801 WINCH 10 T, RIGHT-HAND CRANE
001 1 875 13019-132 . GEAR, COMPLETE SEE FIG. 625-1451.176
022 1 875 13021-034 . FLANGE, COMPLETE SEE FIG. 625-1451.097
024 1 875 13004-142 . DRIVE IN, COMPLETE SEE FIG. 625-1451.175
060 1 875 13009-082 . OIL PIPE, COMPLETE SEE FIG. 625-1451.106
097 1 875 13035-007 . CAM LIMIT SWITCH, COMPLETE SEE FIG. 625-1451.100
205 1 875 13017-020 . CABLE FIXING
220 24 2121 2032-536 . SCREW M6S 12 x 30 -8.8 FZB; DIN 933
221 24 2121 2032-536 . SCREW M6S 12 x 30 -8.8 FZB; DIN 933
223 4 875 13018-019 . SCREW M12 x 35
402 6 2121 2032-495 . SCREW M6S 10 x 30 -8.8 FZB; DIN 933
404 16 2121 2030-628 . SCREW M6S 16 x 40 - 10.9; DIN 933
405 16 875 13014-022 . WASHER

2009-10-23 9.1 625-1451.100 1 (2)
CAM LIMIT SWITCH, COMPLETE
6 Nm 11
Full drum
Empty drum
6 Nm
6 Nm
9 10
22
7 26
5
20
8
17 18
6 Nm
60
50
10 Nm 1000000007196
23
10 Nm
20
27 28
875 13035-007
625-1451.100 /0
Weight 7 kg
2009-10-23 9.1 625-1451.100 2 (2)
CAM LIMIT SWITCH, COMPLETE

000 1 875 13035-007 CAM LIMIT SWITCH, COMPLETE Ratio 101.41
005 1 875 13026-018 . FLANGE
007 1 875 13035-004 . COVER
008 1 875 13025-009 . PIN 4.0 x 26; DIN 1481
009 3 2121 2532-333 . SCREW MC6S 5 x 25 - 8.8 fzb; DIN 912
010 3 2126 2032-114 . NUT M6M 5 -8 FZB; DIN 934
011 4 2121 2536-325 . SCREW MLC6S 5x10 - 8.8 fzb; DIN 7984
017 3 2121 2032-337 . SCREW M6S 5 x 35 - 8.8 fzb; DIN 933
018 3 2151 2022-146 . WASHER BRB 5.3 x 10 FZB; DIN 125
020 2 875 13018-020 . SCREW M5 x 20, spec.
022 4 2121 2032-325 . SCREW M6S 5 x 10 -8.8 FZB; DIN 933
023 2 2121 2532-382 . SCREW MC6S 6 x 60 - 8.8 fzb; DIN 912
026 1 875 13035-005 . SEALING
027 2 875 13006-003 . PLUG M10
028 2 875 13007-007 . SEALING
050 3 2121 2532-370 . SCREW MC6S 6 x 20 -8.8 FZB; DIN 912
060 1 875 13035-006 . CONTROL BLOCK

2009-10-20 9.1 625-1451.176 1 (2)
GEAR, COMPLETE
NOTE:
In order to replace item 31 and 41,
the complete gearbox must be disassembled.
41
520 521
31
444
473
454
491
11
192002932
46 Nm
80 Nm
21 27
875 13019-132
110 Nm
625-1451.176 /0
Weight 75 kg
2009-10-20 9.1 625-1451.176 2 (2)
GEAR, COMPLETE
000 1 875 13019-132 GEAR, COMPLETE
002 18 2121 2532-554 . SCREW MC6S 12x110 -8.8 FZB; DIN 912
021 18 2121 2545-548 . SCREW MC6S 12 x 80 -10.9; DIN 912
027 18 875 13014-081 . WASHER
031 1 875 13007-045 . SHAFT SEALING
041 x 875 13020-011 . SEALING BAND L = 0.9 m
444 1 875 13012-032 . CIRCLIP
454 1 875 13007-032 . SHAFT SEALING
473 3 875 13014-074 . SHIM
491 1 875 13014-044 . WASHER
520 2 875 13038-001 . PLUG WITH OIL VALVE M18
521 2 875 13007-008 . SEALING

2006-10-20 9.1 625-1451.097 1 (2)
FLANGE, COMPLETE
6 3 4
401
13
5
9
12
10
23 Nm
191000397
875 13021-034
625-1451.097 /0
Weight 21 kg
2006-10-20 9.1 625-1451.097 2 (2)
FLANGE, COMPLETE
000 1 875 13021-034 FLANGE, COMPLETE
001 1 875 13026-014 . FLANGE
003 1 875 13014-046 . WASHER
004 1 875 13012-009 . CIRCLIP
005 x 875 13022-001 . FELT STRIP L = 300 mm
006 1 875 13011-027 . BEARING
008 1 875 13023-011 . COVER
009 1 875 13024-003 . DRIVER
012 1 875 13025-008 . PIN 3 x 12; DIN 1481
013 1 875 13025-003 . PIN 5 x 16; DIN 1481
401 1 875 13032-002 . GREASE NIPPLE M10 x 1; DIN 71412

2009-10-12 9.1 625-1451.175 1 (2)
DRIVE IN, COMPLETE
46 Nm 46 Nm
75 97
60 61 76 98 22 20
67
58
59
40
30
53
41
4 50
70
43
192001251
64 7 95 96 69
Disc arrangement, 65
item 97 + 98
Outer discs
Motor side
Gear side
Inner discs
Center line
875 13004-142
625-1451.175 /0
Weight 23 kg
2009-10-12 9.1 625-1451.175 2 (2)
DRIVE IN, COMPLETE

000 1 875 13004-142 DRIVE IN, COMPLETE
004 1 875 13013-016 . DRIVING SLEEVE
007 1 875 13027-006 . MOTOR FLANGE
030 1 875 13011-003 . BEARING
040 1 875 13012-006 . CIRCLIP
041 1 875 13012-005 . CIRCLIP
043 1 875 13012-038 . CIRCLIP
050 1 875 13007-022 . SHAFT SEALING
053 1 875 13007-023 . SHAFT SEALING
058 1 875 13015-030 . O-RING 130 x 3.0
059 1 875 13015-009 . O-RING 126 x 3.0
060 1 875 13006-003 . PLUG M10
061 1 875 13007-007 . SEALING
064 1 875 13006-004 . PLUG M18
065 1 875 13007-008 . SEALING
067 6 875 13020-012 . SEALING PLUG
069 1 875 13008-011 . VENTILATION FILTER M10
070 8 875 13014-047 . SHIM
075 20 875 13002-001 . SPRING Change all springs at the same time.
095 1 875 13003-001 . PRESSURE UNIT
096 1 875 13028-002 . DISC CARRIER
097 9 875 13001-001 . MULTIPLE DISC, OUTER Change all discs at the same time.
098 7 875 13001-002 . MULTIPLE DISC, INNER Change all discs at the same time.
2007-01-02 9.1 625-1451.106 1 (2)
OIL PIPE, COMPLETE

2007-01-02 9.1 625-1451.106 2 (2)
OIL PIPE, COMPLETE

000 1 875 13009-082 OIL PIPE, COMPLETE
051 1 2528 2762-150 . PLUG
052 1 2528 2772-150 . NUT
080 1 875 13007-017 . SEALING
090 1 875 13008-015 . OIL DIPSTICK 1/2"
100 2 875 13007-008 . SEALING

1999-06-28 9.1 625-2205.016 1 (2)
HYDRAULIC MOTOR
1999-06-28 9.1 625-2205.016 2 (2)
HYDRAULIC MOTOR
001 1 188 1769-801 HYDRAULIC MOTOR
002 1 489 6118-801 . GASKET SET

2008-12-03 9.1 625-3255.023A 1 (2)
SLEWING GEAR
40
360 361 362 363
289 3823-801
625-3255.023 /A
Weight 210 kg
2008-12-03 9.1 625-3255.023A 2 (2)
SLEWING GEAR
000 1 289 3823-801 SLEWING GEAR MODULE 14
040 1 875 13004-129 . DRIVE IN, COMPLETE SEE FIG. 625-3256.009
360 1 875 13006-001 . PLUG, MAGNETIC M22
361 1 875 13007-001 . SEALING
362 3 875 13006-002 . PLUG M22
363 3 875 13007-001 . SEALING

2008-11-10 9.1 625-3256.009 1 (4)
DRIVE IN, COMPLETE
46 Nm 22 59 7
69 64 65
95
75 76 96
62 63
97 98
71
73 74
67 68
72
46 Nm 21
80 Nm
20
1000000007311
50 40 30 41 43 70
Disc arrangement,
item 97 + 98
Motor side
Outer discs
Center line
Inner discs
Gear side
875 13004-129
625-3256.009 /0
Weight 34 kg
2008-11-10 9.1 625-3256.009 2 (4)
DRIVE IN, COMPLETE

000 1 875 13004-129 DRIVE IN, COMPLETE
007 1 875 13027-006 . MOTOR FLANGE
030 1 875 13011-002 . BEARING
040 1 875 13012-003 . CIRCLIP
041 1 875 13012-004 . CIRCLIP
043 2 875 13012-019 . CIRCLIP
050 1 875 13007-003 . SHAFT SEALING
059 1 875 13015-009 . O-RING 126 x 3.0
060 1 875 13006-003 . PLUG M10
061 1 875 13007-007 . SEALING
062 1 875 13006-025 . PLUG M12
063 1 875 13007-011 . SEALING
064 2 875 13006-004 . PLUG M18
065 2 875 13007-008 . SEALING
067 2 875 13006-002 . PLUG M22
068 2 875 13007-001 . SEALING
069 1 875 13008-001 . VENTILATION FILTER M10; 0.04 bar
070 4 875 13014-037 . SHIM
071 1 875 13008-016 . VENTILATION FILTER M12; 0.2 bar
072 2 875 13005-001 . OIL SIGHT GLASS M22
073 1 875 13010-020 . COUPLING

2008-11-10 9.1 625-3256.009 3 (4)
DRIVE IN, COMPLETE
46 Nm 22 59 7
69 64 65
95
75 76 96
62 63
97 98
71
73 74
67 68
72
46 Nm 21
80 Nm
20
1000000007311
50 40 30 41 43 70
Disc arrangement,
item 97 + 98
Motor side
Outer discs
Center line
Inner discs
Gear side
875 13004-129
625-3256.009 /0
Weight 34 kg
2008-11-10 9.1 625-3256.009 4 (4)
DRIVE IN, COMPLETE

074 1 875 13007-008 . SEALING
095 1 875 13003-001 . PRESSURE UNIT
096 1 875 13028-002 . DISC CARRIER
097 9 875 13001-001 . MULTIPLE DISC, OUTER Change all discs at the same time.
098 7 875 13001-002 . MULTIPLE DISC, INNER Change all discs at the same time.
2000-05-08 9.1 625-2205.018 1 (2)
HYDRAULIC MOTOR
2000-05-08 9.1 625-2205.018 2 (2)
HYDRAULIC MOTOR
001 1 188 1250-801 HYDRAULIC MOTOR
002 1 489 6124-801 . GASKET SET

2006-03-09 9.2 625-4935.150 1 (2)
PUMP DRIVE
2006-03-09 9.2 625-4935.150 2 (2)
PUMP DRIVE
000 1 289 4178-801 PUMP DRIVE
001 1 188 1098-801 . HYDRAULIC PUMP
003 1 288 1629-801 . ELECTRIC MOTOR
005 1 388 6362-801 . CARDAN SHAFT
006 1 388 6364-002 . FLANGE
007 1 388 6366-004 . FLANGE
008 1 388 7217-001 . PUMP BRACKET
009 1 389 4494-801 . INTAKE PIPE
011 1 489 4369-801 . FLANGE BOLT FITTINGS
012 1 489 4417-003 . WASHER
013 1 489 4451-001 . SIGN ARROW
015 1 0662 0882-004 . PROTECTIVE FOIL
024 2 2121 2032-493 . SCREW M6S 10 x 25 -8.8 FZB; DIN 933
025 1 2121 2032-536 . SCREW M6S 12 x 30 -8.8 FZB; DIN 933
026 8 2121 2032-540 . SCREW M6S 12 x 40 -8.8 FZB; DIN 933
027 4 2121 2032-544 . SCREW M6S 12 x 60 -8.8 FZB
029 4 2126 2636-122 . NUT M6M 12 -8 FZB
031 20 2151 2022-178 . WASHER BRB 13 x 24 FZB
033 1 2152 2115-526 . O-RING
034 1 2152 2115-555 . O-RING
035 2 2183 2022-126 . LIFTING EYE BOLT M20; DIN 580
037 1 2522 2105-012 . PLUG WITH SEAL

1998-11-09 9.2 625-4945.010 1 (2)
HYDRAULIC PUMP
1998-11-09 9.2 625-4945.010 2 (2)
HYDRAULIC PUMP
001 1 188 1098-801 HYDRAULIC PUMP
002 1 489 6145-801 . GASKET SET

2006-03-29 9.3 625-6244.051 1 (2)
JIB TOP MOUNTING

2006-03-29 9.3 625-6244.051 2 (2)
JIB TOP MOUNTING

000 1 289 4575-801 JIB TOP MOUNTING
001 1 388 7172-001 . SHAFT
002 1 390 8888-001 . SHAFT
003 1 388 7224-001 . SHAFT
004 3 388 7278-001 . CLIMB PROTECTION
005 2 489 4474-801 . WIRE SHEAVE
006 1 489 4345-002 . LOCKING PLATE
007 2 489 4345-003 . LOCKING PLATE
008 2 489 4465-001 . SPACER
009 20 489 4473-001 . WASHER
010 1 490 5475-001 . WASHER
011 3 2545 2110-001 . GREASE NIPPLE G 1/4 A2-50
013 6 2114 2014-201 . SPLIT PIN SP 4 x 40 -A4
014 3 2121 2034-493 . SCREW M6S 10 x 25 -8.8 FZB
015 2 2121 2034-532 . SCREW M6S 12 x 20 -A2 -70
016 4 2121 2034-622 . SCREW M6S 16 x 25 -A4-80
017 3 2154 2233-173 . LOCK WASHER 10.5 BR = 20 RF
018 2 2154 2233-178 . LOCK WASHER 13 RF
019 4 2154 2233-186 . LOCK WASHER 17 RF

2005-06-01 9.3 625-5882.034 1 (2)
CYLINDER ASSEMBLY
2005-06-01 9.3 625-5882.034 2 (2)
CYLINDER ASSEMBLY
000 1 289 3781-801 CYLINDER ASSEMBLY
002 2 388 8861-001 . SHAFT
003 2 489 4345-004 . LOCKING PLATE
004 2 489 4346-004 . LOCKING PLATE WELDED
005 4 2121 2034-672 . SCREW M6S 20 x 40 -A4-80
006 4 2151 2027-192 . WASHER RB 21 x 37 -A4
007 2 2545 2110-001 . GREASE NIPPLE G 1/4 A2-50

2010-12-28 9.3 625-7013.116 1 (2)
HOOK BLOCK
Important!
When replacing genuine parts, an overload
test of the complete unit has to be done.
New certificate to be issued.
See instruction 6.000.1 E.
1
3 3
2
(5)
(5)
5
6
(5)
(5)
9
10
11
391 1683-801
625-7013.116 /0
Weight 230 kg
2010-12-28 9.3 625-7013.116 2 (2)
HOOK BLOCK
000 1 391 1683-801 HOOK BLOCK SWL 7.4 tonnes
001 1 875 12401-007 . SHEAVE, COMPLETE Incl. bearing and lock rings.
002 1 875 12054-007 .. BEARING
003 2 875 12062-005 .. LOCK RING
005 1 875 12404-004 . SHAFT, COMPLETE Incl. retainer, screw, nipple.
006 1 2545 2011-025 .. GREASE NIPPLE M10 x 1; DIN 71412
007 4 875 12406-005 . SPACER, COMPLETE Incl. spacer tube, screw, nut.
008 1 875 12409-002 . CABLE LEADER, COMPLETE Incl. screws, nuts.
009 1 875 12073-001 . SHACKLE
010 1 875 12001-006 . HOOK, COMPLETE Incl. safety latch kit.
011 1 875 12064-020 .. SAFETY LATCH KIT Incl. spring, screw, nut.
2004-04-23 9.3 625-6170.004A 1 (2)
JIB BEARING
2004-04-23 9.3 625-6170.004A 2 (2)
JIB BEARING
000 1 288 0348-801 JIB BEARING
001 1 388 7848-001 . SHAFT
002 2 489 4658-001 . BEARING
003 1 489 4345-005 . LOCKING PLATE
004 1 489 4346-005 . LOCKING PLATE WELDED
005 2 2121 2034-672 . SCREW M6S 20 x 40 -A4-80
006 2 2151 2027-192 . WASHER RB 21 x 37 -A4
007 2 489 4453-001 . BOLT
008 2 2545 2110-001 . GREASE NIPPLE G 1/4 A2-50

Last revised by: Sören Gidlund
Last revision date: 2012-02-20
Part Specification
Name Rev Title Spare Part Title State Name Rev State
1230868 - Crane Complete Release 1000021797 - Release
Part Specification
F/N Qty Unit Name Rev Title Spare Part Title State Name Rev State
001 1 PC 1230749 - Foundation Provision Cranes Release 1000021739 - Release
002 1 PC 189 6850-801 - Crane House Welding Release 189 6850 - Release
003 1 PC 188 0060-801 H Control Platform Release 188 0060 H Release
004 1 PC 189 5436-801 B Jib Welding Cylinder Luffing Release 189 5436 B Release
005 1 PC 289 1114-801 B Platform Crane Jib Assembly Release 289 1114 B Release
011 1 PC 288 0751-801 G Lubrication Cylinder Release 288 0751 G Release
012 1 PC 288 0353-801 E Sign Assembly Release 288 0353 E Release
015 1 PC 388 7231-801 C Cover Release 388 7231 C Release
016 1 PC 390 6045-801 - Ladder Assembly Release 390 6045 - Release
017 1 PC 390 5806-801 - Stay Assembly Release 390 5806 - Release
018 1 PC 390 5807-801 A Stay Assembly Release 390 5807 A Release
020 1 PC 289 6999-801 - Lubrication jib top Release 289 6999 - Release
025 1 PC 1230750 - Pedestal Welding Release 1000021740 - Release
1000021741 - Release
1000017006 - Release
028 1 PC 289 5167-801 - Hoop guard Release 289 5167 - Release
029 1 PC 289 6914-801 A Protection Rail Assembly Release 289 6914 A Release
030 1 PC 390 8420-801 - Ladder Release 390 8420 - Release
031 1 PC 189 3975-801 - Foundation Platform Release 189 3975 - Release
032 1 PC 188 1471-801 C Cover Platform Release 188 1471 C Release
033 1 PC 288 2434-801 D Cover Plate Release 288 2434 D Release
034 3 PC 289 1116-801 A Protection Cage Release 289 1116 A Release
036 0.000 L 1176 2060-001 - Paint Release 1176 2060 - Release
037 1 PC 390 0139-801 A Bracket Assembly Release 390 0139 A Release
038 1 PC 390 0140-801 A Bracket Assembly Release 390 0140 A Release
Item Description(s) moved to separate EBOM Report.
Last revised by:
Part Specification
289 3963-801 - Slewing Assembly Provision Crane Release 289 3963 - Release
Part Specification
001 1 PC 388 8844-801 C Slewing Bearing Release 388 8844 C Release
002 1 PC 289 3823-801 C Slewing Gear Release 289 3823 C Release
003 1 PC 188 1250-801 A Hydraulic Motor Release 188 1250 A Release
004 4 PC 2121 2034-540 L Hexagon Screw Release 2121 2034 M Release
005 4 PC 2151 2027-178 B Washer Release 2151 2027 C Release
006 24 PC 2121 2030-632 J Hexagon Screw Release 2121 2030 K Release
007 24 PC 487 2311-005 R Washer Release 487 2311 R Release
008 124 PC 388 7147-003 S Bolt Release 388 7147 S Release
009 4 PC 388 7147-004 S Bolt Release 388 7147 S Release
010 64 PC 489 4423-012 K Washer Release 489 4423 K Release
013 60 PC 2126 2038-129 B Hexagon Nut Release 2126 2038 B Release
014 0 PC 1236 2136-001 - Sealing Compound Release 1236 2136 - Release
015 0 PC 1234 2413-050 - Locking Fluid Release 1234 2413 A Release
016 0.000 L 1263 2078-001 - Modisulphide Paste Release 1263 2078 - Release
017 1 PC 1171 2013-303 - Hydraulic Oil Release 1171 2013 - Release
018 0 PC 1241 2156-001 - Rust Preventive Fluid Release 1241 2156 - Release
019 0 PC 390 2896-005 - Guide Pin, M27 L=250 Release 390 2896 - Release
1351 2411 C Release
020 0 PC 390 2896-006 - Guide Pin, M27 L=300 Release 390 2896 - Release
1351 2411 C Release
1999-06-23 9.4 625-7322.018 1 (2)
DIRECTION VALVE
1999-06-23 9.4 625-7322.018 2 (2)
DIRECTION VALVE
000 1 188 1343-801 DIRECTION VALVE
001 1 489 4422-801 . GASKET SET

1995-07-06 9.4 625-7331 1 (2)
MOTOR VALVE
1995-07-06 9.4 625-7331 2 (2)
MOTOR VALVE
000 1 388 6358-801 MOTOR VALVE
001 1 489 4437-801 . GASKET SET

1997-12-04 9.4 625-7330.001 1 (2)
BALANCE VALVE
1997-12-04 9.4 625-7330.001 2 (2)
BALANCE VALVE
001 1 388 6376-801 BALANCE VALVE
002 1 489 4539-801 . GASKET SET

1999-11-04 9.4 625-7330.005 1 (2)
BALANCE VALVE
1999-11-04 9.4 625-7330.005 2 (2)
BALANCE VALVE
001 1 289 0840-801 BALANCE VALVE
002 1 489 5703-801 . GASKET SET

1995-07-06 9.4 625-7334 1 (2)
LIMIT VALVE
1995-07-06 9.4 625-7334 2 (2)
LIMIT VALVE
000 1 388 6361-801 LIMIT VALVE
001 1 489 4439-801 . GASKET SET

1995-07-06 9.4 625-7335 1 (2)
FILTER - RETURN LINE

1995-07-06 9.4 625-7335 2 (2)
FILTER - RETURN LINE

000 1 287 9463-801 FILTER - RETURN LINE
001 1 489 4436-801 . FILTER ELEMENT

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

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

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

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

2011-09-22 9.4 625-7990.065A 1 (2)
HYDRAULIC CYLINDER
19 108
117
109
20
122
23
16 121
14 15
13
28
12
11
110
108
109
289 4177-801
625-7990.065 /A
Weight 1.450 kg
2011-09-22 9.4 625-7990.065A 2 (2)
HYDRAULIC CYLINDER
000 1 289 4177-801 HYDRAULIC CYLINDER 250 / 180
001 1 875 16403-017 . GASKET SET Includes item 7-28.
007 1 .. BEARING RING
011 1 .. PISTON SEAL
012 1 .. O-RING (approx. Ø115)
015 1 .. SUPPORT RING
016 2 .. ROD SEAL
019 1 .. ROD WIPER
108 2 875 16401-004 . BEARING
109 4 2545 2110-003 . GREASE NIPPLE A-M 10 x 1 -A2-50; DIN 71412
110 1 2122 2519-487 . SCREW MSK6SS 10 x 12 -A4; DIN 916
117 4 2121 2550-542 . SCREW MC6S 12 x 50 -A4-80; DIN 912
121 2 2522 2105-014 . PLUG WITH SEAL G 1/4; DIN 908
122 3 2545 2112-003 . GREASE NIPPLE C-M 10 x 1 -A2-50; DIN 71412

Last revised by: Dennis Dahlberg
Part Specification
189 7719-801 A Hydr inst house jib R Release 189 7719 A Release
Part Specification
001 1 PC 188 1343-801 - Directional valve PVG 32 Release 188 1343 - Release
003 1 PC 287 9463-801 B Return line filter Release 287 9463 B Release
004 1 PC 388 6358-801 D Motor valve Release 388 6358 D Release
005 1 PC 289 0840-801 A Balance valve Release 289 0840 A Release
006 1 PC 388 6376-801 B Balance valve Release 388 6376 B Release
007 1 PC 388 6356-801 C Air breathers Release 388 6356 C Release
008 1 PC 5695 1003-063 - Temperature Sensor Release 5695 1003 - Release
010 2 PC 388 7291-150 - Hydraulic hose Release 388 7291 - Release
012 1 PC 388 7291-360 - HYDRAULSL 755 19 Release 388 7291 - Release
016 1 PC 390 9505-801 - Oil level dipstick Release 390 9505 - Release
017 16 PC 487 2826-005 S Washer Release 487 2826 S Release
018 1 PC 487 5073-002 I Restriction screw, hole D=1,5 Release 487 5073 I Release
020 2 PC 488 4245-001 C Nipple Release 488 4245 C Release
022 2 PC 488 7824-001 G Nipple Release 488 7824 G Release
023 1 PC 488 7900-001 - Restriction union Release 488 7900 - Release
025 3 PC 489 2565-801 A Test nipple Release 489 2565 A Release
028 5 PC 489 2572-801 D Manometer-conn. Release 489 2572 D Release
030 1 PC 489 3066-001 B SAE-flange Release 489 3066 B Release
031 1 PC 489 4436-801 A Filter element Release 489 4436 A Release
032 1 PC 490 6105-801 A Flow regulator valve Release 490 6105 A Release
033 0 PC 1171 4512-001 - Grease Release 1171 4512 - Release
034 0 PC 1234 2413-050 - Locking Fluid Release 1234 2413 A Release
Part Specification
Part Specification
035 0.000 L 1263 2078-001 - Modisulphide Paste Release 1263 2078 - Release
046 2 PC 2121 2032-556 G Hexagon screw Release 2121 2032 K Release
047 12 PC 2121 2541-497 G Allen screw Release 2121 2541 G Release
052 54 PC 2126 2634-120 B Locking Nut Release 2126 2634 D Release
057 4 PC 2151 2052-173 C Washer Release 2151 2052 C Release
058 3 PC 2152 2118-877 F O-Ring Release 2152 2118 G Release
060 2 PC 2152 2151-178 C Seal ring Release 2152 2151 C Release
061 2 PC 2152 2151-200 C Seal Ring TT 20 Release 2152 2151 C Release
062 2 PC 2152 2151-181 C Seal Ring TT 014 Release 2152 2151 C Release
063 18 PC 2166 4139-222 F Clamp Release 2166 4139 F Release
Part Specification
Part Specification
066 2 PC 2166 4139-465 F Pipe clamp half Release 2166 4139 F Release
067 16 PC 2166 4140-004 - Cover plate Release 2166 4140 - Release
070 10 PC 2169 4165-260 C Cupel strop Release 2169 4165 C Release
071 1 PC 2515 6046-200 L Hydraulic hose Release 2515 XXXX M Release
074 1 PC 2515 6231-035 L Hydraulic Hose Release 2515 XXXX M Release
Part Specification
Part Specification
100 1 PC 2515 8274-740 L Hydraulc hose Release 2515 XXXX M Release
102 1 PC 2521 2135-110 D Nipple Release 2521 2135 D Release
104 1 PC 2521 2221-203 A Reducing Release 2521 2221 A Release
108 1 PC 2522 2105-014 B Plug Release 2522 2105 B Release
112 2 PC 2528 2512-610 G Pipe Coupling Release 2528 2512 J Release
119 5 PC 2528 2513-611 G Pipe coupling Release 2528 2513 H Release
Part Specification
Part Specification
125 1 PC 2528 2563-610 E Pipe coupling Release 2528 2563 E Release
129 1 PC 2528 2592-615 D Pipe coupling Release 2528 2592 D Release
130 5 PC 2528 2593-610 C Pipe coupling Release 2528 2593 C Release
132 1 PC 2528 3634-215 E Pipe Coupling Release 2528 3634 E Release
134 1 PC 2528 2746-100 B Pipe coupling Release 2528 2746 B Release
135 1 PC 2529 2558-113 B Connecting nipple Release 2529 2558 B Release
136 2 PC 2528 3426-151 B Pipe coupling Release 2528 3426 B Release
140 2 PC 2528 3427-161 D Pipe Coupling Release 2528 3427 D Release
142 1 PC 2528 3433-108 - Pipe coupling Release 2528 3433 - Release
143 1 PC 2528 3632-215 D Pipe Coupling Release 2528 3632 D Release
145 2 PC 2528 3633-215 C Pipe Coupling Release 2528 3633 C Release
147 1 PC 2528 4561-220 A Pipe coupling Release 2528 4561 A Release
149 1 PC 2528 4564-203 E Pipe coupling Release 2528 4564 F Release
151 1 PC 2541 4129-113 C Ball valve Release 2541 4129 C Release
152 1 PC 2539 2124-190 D Angle adaptor Release 2539 2124 D Release
153 2 PC 2528 3635-151 F Pipe coupling Release 2528 3635 F Release
Part Specification
Part Specification
154 1 PC 2528 3635-281 F Pipe coupling Release 2528 3635 F Release
157 2 PC 2528 4512-615 H Pipe Coupling Release 2528 4512 H Release
158 2 PC 2528 4512-616 H Pipe Coupling Release 2528 4512 H Release
163 1 PC 2528 4564-202 E Pipe coupling Release 2528 4564 F Release
164 1 PC 2529 2136-065 D Hose clamp Release 2529 2136 D Release
165 2 PC 2529 2558-111 B Connecting nipple Release 2529 2558 B Release
166 1 PC 2541 2506-117 C Wedge Valve Release 2541 2506 C Release
167 4 PC 2541 4129-110 C Ball valve Release 2541 4129 C Release
168 1 PC 5693 4150-004 C Pressure gauge Release 5693 4150 C Release
169 1 PC 6524 2106-280 F Non-return valve Release 6524 2106 F Release
170 1 PC 6524 2101-124 A Check valve Release 6524 2101 A Release
171 1 PC 6524 2142-060 - Check restriction valve Release 6524 2142 - Release
2007-01-23 9.5 625-8630.061A 1 (2)
EL. CENTRAL/STARTER
324 1326-801
625-8630.061
2007-01-23 9.5 625-8630.061A 2 (2)
EL. CENTRAL/STARTER
000 1 324 1326-801 EL. CENTRAL/STARTER
001 1 5829 4196-101 . EL. CABINET
002 1 324 1165-801 . TRANSFORMER
003 2 5354 4273-052 . CONTACTOR
004 1 5627 4216-052 . OVERCURRENT RELAY
005 1 5381 4227-080 . LOAD SWITCH
006 1 4762 4105-320 . CURRENT TRANSFORMER
007 1 5347 4262-203 . CIRCUIT BREAKER
008 1 5692 4740-221 . HOUR METER
009 1 5697 4337-200 . AMMETER
010 1 5298 2071-221 . PILOT LIGHT
011 1 5298 2071-220 . PILOT LIGHT
012 1 5298 2071-222 . PILOT LIGHT
013 1 5354 4273-031 . CONTACTOR
014 1 5347 4263-203 . CIRCUIT BREAKER
015 1 5372 2210-002 . PUSH BUTTON
016 1 5372 2210-001 . PUSH BUTTON
017 1 5632 4212-001 . ELECTRONIC TIME DELAYER
019 2 2669 4160-015 . END HOLDER
021 1 324 1199-801 . EARTH BAR
022 8 2647 4160-040 . EARTH CLAMP
023 4 2647 4160-350 . EARTH CLAMP
027 20 2663 4382-025 . TERMINAL BLOCK
028 2 2669 4160-015 . END HOLDER
029 2 2631 4123-252 . BRIDGE CONNECTOR
034 4 5354 4137-510 . AUXILIARY CONTACT BLOCK
035 6 5354 4137-501 . AUXILIARY CONTACT BLOCK
037 1 5381 4227-001 . HANDLE
038 1 5381 4227-002 . SHAFT
039 1 5381 4227-010 . COVER
061 1 424 0494-801 . SIGN
064 1 2183 2022-122 . LIFTING EYE BOLT M12; DIN 580

2008-07-01 9.7 624-2499.001 1 (2)
HAND PUMP
22
6 7
289 5234-801
624-2499.001 /0
2008-07-01 9.7 624-2499.001 2 (2)
HAND PUMP
000 1 289 5234-801 HAND PUMP
006 4 875 29101-001 . HOOK
007 4 2127 2413-116 . WING NUT
008 1 875 29101-002 . HANDLE
022 1 5693 4121-060 . MANOMETER 60 bar

Instr - Manual - GP 320-07.418.5-2 - GA7.412.5 - YZJ2007-820 - Crane 4

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Instr - Manual - GP 320-07.418.5-2 - GA7.412.5 - YZJ2007-820 - Crane 4

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Instruction and Spare Parts Manual

IMO No.: L9506394

GENERAL 1 1.005 E e PREFACE

TECHN. DESCRIP. 2 2/07063.02DAL - TECHNICAL DATA

FUNCTION 3 3.110.70 E a HYDRAULIC FUNCTION

OPERATION 4 PM40 0815-E00 - OPERATING INSTRUCTION

MAINTENANCE 5 5.005.25 E i MAINTENANCE CHART

6.0 6.000 E e HOW TO ORDER SPARE PARTS

6.2 6.214 E i TIGHTENING TORQUES STUDS/SCREWS AND BOLTS

6.3 6.305.11 E - ELECTRICAL EQUIPMENT, GENERAL MAINTENANCE

SPARE PARTS 9 SEE SEPARATE TABLE OF CONTENTS

9.0 HOW TO ORDER SPARE PARTS e 6.000 E

9.1 WINCH ASSEMBLY 289 3954-801 B/ 625-1440.090A

9.2 PUMP DRIVE 289 4178-801 B/ 625-4935.150

9.3 JIB TOP MOUNTING 289 4575-801 -/ 625-6244.051

9.4 DIRECTION VALVE 188 1343-801 -/ 625-7322.018

9.5 EL. CENTRAL/STARTER 324 1326-801 A/ 625-8630.061A

9.7 HAND PUMP 289 5234-801 -/ 624-2499.001

This instruction manual covers the MacGREGOR Spare parts

Every manual belongs to a specific crane or piece of

The manual contains nine sections. The various

THIS PAGE IS INTENTIONALLY LEFT BLANK

THIS PAGE IS INTENTIONALLY LEFT BLANK

THIS PAGE IS INTENTIONALLY LEFT BLANK

Hydraulic and Electric Symbols

Hydraulische und elektrische Bildzeichen

Diese Sammlung umfaßt einen Teil der allgemeinen Bild- und

1. Hydraulic symbols, basic.

Hydraulische Bildzeichen, einfach.

2. Hydraulic symbols, composite.

Hydraulische Bildzeichen, kombiniert.

Hydraulic symbols and valve assemblies

Hydraulische Bildzeichen und Ventil-

Working oil line.

Plug, plugged connection (alternative symbols).

Restriction unaffected by viscosity.

Crossed pipes, no connection.

Tank line, tank.

Enclosure of component assembly.

Pump, fixed displacement, 1 direction of flow.

Pump, variable displacement, 2 directions of flow.

Motor, fixed displacement, 2 directions of flow, exter-

Motor, 2 displacement, 2 directions of flow.

Motor, variable displacement, 2 directions of flow.

Filter with contamination indicator.

Filter with by-pass valve.

Pressure electric switch, normally open.

Pressure electric switch, normally closed, adjustable.

Non-return valve, spring loaded with certain opening

Non-return valve, spring loaded with certain closing

Quick coupling or gauge connection.

Non-return valve with variable restriction.

Cylinder, double-acting with fixed cushion at one side.

Valve, basic symbol.

Electrically controlled valve.

Pressure controlled valve.

Pilot controlled valve, internal pressure supply.

Pilot controlled valve, external pressure supply.

Lever controlled valve.

Mechanically controlled valve.

Valve with spring return.

Valve with detent.

4/2 direction valve