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Dept.

C7250

INSTRUCTION MANUAL

Project No.

Date: 2008-11-27

2/08006.01DAL-3

Page
1(3)

TABLE OF CONTENTS
No. of manuals

6 pcs, CD-ROM 2 pcs

Certificate for
crane issued by:

DNV

Certificate for
foundation issued by:

DNV

IMO No.

L9408683

Name of ship

PROFIT

Newbuilding No.

1022

Shipyard

Jiangsu Rongsheng Heavy Ind.

Owners

Geden

Project No.

2/08006.01DAL-3

Mfg. No.

62509352 - Right crane

Type of crane

GP 160-0516-2

Order specification

490 6594-803 /A

Mechanical spec.

490 5435-801 /-

Hydraulic spec.

490 6619-803 /B

Electrical spec.

490 6620-803 /-

Slewing spec.

SAFETY DOCUMENTS
Document names written with bold letters are documents with safety aspects.
INSTRUCTION NO.
GENERAL

TECHN. DESCRIP.

FUNCTION

OPERATION

MAINTENANCE

SERVICE

REV

NAME OF INSTRUCTION

1.005 E

PREFACE

1.009 E

GENERAL INSTRUCTIONS, CLEANLINESS IN HYDRAULIC SYSTEMS

1.102 E

CONVERSION FACTORS

1.518.3 ED

HYDRAULIC AND ELECTRIC SYMBOLS

2/08006.01DAL-3

TECHNICAL DATA

2.007.56 E

TECHNICAL DESCRIPTION

3.110.70 E

HYDRAULIC FUNCTION

3.142.10 E

CRANE CONTROL SYSTEM

PM40 0815-E00

OPERATING INSTRUCTION

PM40 1822-E00

CREW CHECKLIST BEFORE TAKING CRANE INTO OPERATION

4.620.13 E

PARKING THE CRANE, SEA STOWING

5.005.25 E

MAINTENANCE CHART

5.019 E

INSPECTION OF STRESSED COMPONENTS AND STRUCTURES

PM51 1217-E00

LUBRICATING CHART, GP AND HH CRANES

5.302.15 E

CRANE HOUSING / HYDRAULIC OIL TANK

5.421.16 E

LUBRICANTS FOR DECK MACHINERY

6.000 E

HOW TO ORDER SPARE PARTS

6.000.1 E

STATEMENT REGARDING DELIVERY OF SPARE PARTS TO SWIVELS, LIFTING B

6.000.2 E

RETURN FORM

6
6.0

The Original Manufacturer of HGGLUNDS Cranes

Dept. C7250

INSTRUCTION MANUAL

Project No.

Date: 2008-11-27

2/08006.01DAL-3

Page
2(3)

TABLE OF CONTENTS
6.0

6.1

6.2

6.3

INSTRUCTION NO.

REV NAME OF INSTRUCTION

6.004.1 E

ba

MacGREGOR GLOBAL SERVICES

6.008.2 E

INTRODUCTION

6.100 E

MEASURES BEFORE STARTING, DURING AND AFTER COMPLETED SERVICE/M

6.120.15 E

SLEWING GEARSET

6.120.62 E

HYDRAULIC MOTORS, HOISTING AND SLEWING

6.120.96 E

WINCH

6.142.5 E

RECOMMENDATION FOR INSPECTION AND REPLACEMENT OF HYDRAULIC HO

6.214 E

TIGHTENING TORQUES STUDS/SCREWS AND BOLTS

6.216.69 E

ROPE REEVING DIAGRAM FOR CRANES TYPE GP AND HH

6.222.1 E

HANDLING, INSTALLATION AND MAINTENANCE OF STEEL WIRE ROPES

625/1473 E

INDENTATION AND WEAR ON WIRE SHEAVES

625/1560 E

LIFTING BLOCK/BEAM

625/1618 E

MEASURING PROCEDURE FOR WEAR IN SLEWING BEARINGS FOR CRANE ...

6.305.11 E

ELECTRICAL EQUIPMENT, GENERAL MAINTENANCE

6.990.54 E

EMERGENCY LOWERING IN CASE OF COMPLETE POWER FAILURE OPERAT

EXTRA EQUIPMENT 7
APPENDICES

SPARE PARTS

SEE SEPARATE TABLE OF CONTENTS

The Original Manufacturer of HGGLUNDS Cranes

Dept. C7250

PARTS MANUAL

Project No.

Date: 2008-11-27

2/08006.01DAL-3

Page
3(3)

TABLE OF CONTENTS
GROUP DESCRIPTION

PART NUMBER

FIG

9
9.0

HOW TO ORDER SPARE PARTS

9.1

WINCH ASSEMBLY
WINCH

9.2

9.3

9.4

6.000 E

289 3951-801

A/

625-1440.102

289 3815-801

B/

625-1450.091

HYDRAULIC MOTOR

188 1769-801

A/

625-2205.016

SLEWING GEAR

289 3822-801

A/

625-3255.022

HYDRAULIC MOTOR

188 1227-801

A/

625-2205.017

PUMP DRIVE

289 0543-801

B/

625-4935.067A

PUMP

188 1097-801

A/

625-4945.012

CYLINDER ASSEMBLY

289 4027-801

-/

625-5882.037

JIB TOP

288 0136-801

A/

625-6244.001B

JIB BEARING ASSEMBLY

287 9974-801

B/

625-6253A

HOOK BLOCK

388 7531-801

E/

625-7013.005D

GENERAL ARRANGEMENT

189 7279-801

A/

189 7279

CRANE ASSEMBLY, RIGHT

189 7315-801

-/

189 7315

SLEWING ASSEMBLY

289 3961-801

-/

289 3961

SLEWING BEARING

388 7097-801

C/

388 7097

LOAD WIRE ROPE; SEE TECHNICAL DATA

390 9790-808

N/

DIRECTION VALVE

188 1338-801

-/

625-7322.011

BALANCE VALVE

388 6376-801

B/

625-7330.001

BALANCE VALVE

289 0839-801

B/

625-7330.006A

MOTOR VALVE

388 6358-801

D/

625-7331

LIMIT VALVE

388 6361-801

A/

625-7334

FILTER

287 9463-801

B/

625-7335

BALL VALVE

389 4128-801

-/

625-7620.004

HYDRAULIC CYLINDER

289 3178-801

A/

625-7990.044

HYDRAULIC CIRCUIT DIAGRAM

289 5232

A/

289 5232

HYDR.INST HOUSE JIB, RIGHT

189 5696-801

A/

189 5696
189 5167

HYDRAULIC HOSES

9.5

9.7

625-7970G

LIMIT ARRANGEMENT VALVES,RIGHT

189 5167-801

B/

LIMIT ARRANGEMENT CAMS R

189 7337-801

-/

EL. CENTRAL/STARTER

324 1150-801

A/

625-8630.050A

ELECTRICAL SYSTEM

324 1134

-/

324 1134

HAND PUMP

189 3090-801

D/

624-2494B

The Original Manufacturer of HGGLUNDS Cranes

GENERAL

1.005 E rev.: e 2003-09-09

Preface
This instruction manual covers the MacGREGOR
hydraulic deck crane. We hope that it will prove a
valuable companion to everyone concerned with the
operation of the crane or otherwise in a responsible
position.

Spare parts
General advice how to order spare parts; spare parts
lists and illustrations.

Every manual belongs to a specific crane or piece of


equipment. The identification can be found on the label
on the manuals back.
The manual contains nine sections. The various
sections cover the following subjects:
General
Contents list; Safety; Conversion tables; Hydraulic
and electric symbols.
Technical description
Technical data; description of crane design.
Function
Electric and hydraulic functions of the crane.
Operation
Operating instructions; crane operators checklist.
Maintenance
Lubricating chart and maintenance instructions.
Service
General service instructions for the hydraulic system,
mechanical, control system and electrical equipment.
Extra equipment
Extra equipment, if any; e.g. cargo handling equipment.
Appendices
Other information, which cannot be referred to any of
the above mentioned sections.

The Original Manufacturer of HGGLUNDS Cranes

1 (2)

GENERAL

1.005 E rev.: e 2003-09-09

THIS PAGE IS INTENTIONALLY LEFT BLANK

2 (2)

The Original Manufacturer of HGGLUNDS Cranes

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
hydraulic systems and components is absolute
cleanliness.
Many components, e.g. valves and pumps, have
very narrow tolerances, therefore microscopic impurities, invisible to the human eye, may have disastrous effect on the function of a hydraulic system.
The hydraulic system installation contains a cleaner
with a cartridge designed to stop impurities produced within the hydraulic system during operation.
Every care must be taken to prevent external impurities from entering the system when servicing or
repairing it.

Use a brush for cleaning, wipe off with a nonlinting rag, repeat the cleaning if necessary. Finish by spraying the area of operations - hose connections etc. - with the solvent.
4. Mount protective covers immediately after removing a component, a pipe or a hose. Components,
shall also be fitted with covers and plugs in order
to prevent ingress of dirt.
These covers must be kept in clean and closed
packages. After use, covers are to be cleaned in
the workshop.
5. Observe minute cleanliness when handling all
types of quick-release connectors. Spray both
connectors with solvent before making up a connection. Clean all covers before reinstallation.
Storing and filling up of hydraulic oil

This also applies for components that have been


removed and or to be reinstalled. Sooner or later, a
component that has been replaced will be inspected
in a test equipment somewhere. It is important that
the component stays in the same condition as it was
when it was removed, as it may otherwise be
impossible to decide the real cause of a malfunction.
It may also be possible that a component sent in
for inspection is not defective at all, and will be
returned.
Rules when working on the hydraulic system
The following fast rules shall be observed during
working on the hydraulic system:
1. Carry out a rough general clean-up.
2. Protect the area where work shall be done. Use
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 surroundings from where accumulated dirt may be
transferred in to the repair area. Do not forget to
clean the tools to be used.

1. Store barrels, hoses and pump as clean as possible and best of all in a warm room. The oil viscosity will then be considerably lower, which
make the filling through filter easier.
2. Barrels, hoses and pump must be carefully handled and cleaned when necessary.
3. Store barrels horizontally, so plugs (or cocks) are
below the liquid level and impurities (e.g., damped
air) does not penetrate the barrels.
4. Observe minute cleanliness when filling up oil carelessness is one of the greatest sources when
impurities penetrates the hydraulic system.
5. Fill up hydraulic oil. See separate instruction.
6. Never use the last drop in the barrel, as it often
consists of water and other impurities dependent on how many times the barrel has been
opened.

The Original Manufacturer of HGGLUNDS Cranes

1 (2)

GENERAL

1.009 E rev.: a 1996-05-20

THIS PAGE IS INTENTIONALLY LEFT BLANK

2 (2)

The Original Manufacturer of HGGLUNDS Cranes

GENERAL

1.102 E rev.: c 1999-09-14

Conversion Factors

Pressure

Length
1
1
1
1

mm
m
in
ft (fot)

=
=
=
=

0,0393701 in (tum)
3,28084 ft (fot)
25,4 mm
304,8 mm

Volume
1
1
1
1

dm3
dm3
gallon
gallon

= 1 litre = 0,219969 gallon (UK)


= 1 litre = 0,264172 gallon (US)
(UK)= 4,54609 dm3
(US)= 3,78541 dm3

Mass
1
1
1
1
1

kg
lb
ton
ton
ton

= 2,20463 lb
= 0,45359 kg
(metric) = 1000 kg
(UK)
= 1 longton (US)
(UK)
= 1016,05 kg

1 atm
=
1 atm
=
1 atm
=
1 bar
=
1 at
=
1 at
=
10 lbf/in2 =
10 lbf/in2 =
1 bar
=
1 bar
=
2
1 kp/cm =
1 bar
=
1 Pa
=
1 Pa
=
1 Pa
=
1 Pa
=
1 kp/cm2 =

14,6959 lbf/in2 (psi)


1,01325 bar
1,03323 at
0,986923 atm
14,2233 lbf/in2 (psi)
0,980665 bar
0,689476 bar
0,70307 at
1,01972 at
14,5038 lbf/in2 (psi)
14,2233 lbf/in2
100 kPa = 0,1 MPa
1 N/m2
10,2 10-6 kp/cm 2
0,145 10 -6 lbf/in2
7,5 10-3 mm Hg
98,07 103 Pa

Power
Force
1 kp
1 kp
1 lbf
1 lbf
1N
1N

=
=
=
=
=
=

1
1
1
1
1
1

2,20462 lbf
9,80665 N
4,44822 N
0,453592 kp
0,101972 kp
0,224809 lbf

kW = 1,35962 hk
kW = 1,34102 hp (UK, US)
hk = 0,986320 hp (UK, US)
hp (UK, US) = 1,01387 hk
hk
= 0,735499 kW
hp (UK, US) = 0,745700 kW

Temperature
Moment of force
1 kpm=
1 kpm=
1 Nm
1 lbf ft
1 lbf ft
1 lbf ft
1 daNm
1 daNm

0C
0C
0F
0F
0K
0K

9,80665 Nm
7,23301 lbf ft
= 0,737562 lbf ft
= 0,135582 daNm
= 1,35582 Nm
= 0,13825 kpm
= 1,01972 kpm
= 7,37562 lbf ft

C =

=
=
=
=
=
=

32F
273,15 K
-17,7778C
255,3722 K
-273,15C
-459,67F

1
(F - 32)
1,8

F = 1,8 (K - 273,15) + 32

F = C 1,8 + 32
Moment of inertia

K=

1
(F - 32) + 273,15
1,8

C = K - 273,15

1 kg m 2 = 3417,17 lb in2
1 lb in 2 = 0,00029264 kg m2

K = C + 273,15

The Original Manufacturer of HGGLUNDS Cranes

1 (2)

1.102 E rev.: c 1999-09-14

THIS PAGE IS INTENTIONALLY LEFT BLANK

2 (2)

The Original Manufacturer of HGGLUNDS Cranes

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Hydraulic and Electric Symbols


Hydraulische und elektrische Bildzeichen

This section covers a part of the symbols and port markings commonly
used in MacGREGOR (SWE) AB, Service Division hydraulic and electric
circuits, divided into three parts:
Diese Sammlung umfat einen Teil der allgemeinen Bild- und
Anschluzeichen, die in MacGREGOR (SWE) AB, Service Division,
hydraulischen und elektrischen Schemas vorkommen, unterteilt in drei
Gruppen:

1. Hydraulic symbols, basic.


Hydraulische Bildzeichen, einfach.

2. Hydraulic symbols, composite.


Hydraulische Bildzeichen, kombiniert.

3. Electric symbols.
Elektrische Schaltzeichen.

The Original Manufacturer of HGGLUNDS Cranes

1 (30)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Hydraulic symbols and valve assemblies


Hydraulische Bildzeichen und VentilBaugruppen

1. Hydraulic Symbols
Hydraulische Bildzeichen

Working oil line.


Arbeitsdruckleitung.
Pilot line.
Steuerdruckleitung.
Drain line.
Lecklleitung .

Plug, plugged connection (alternative symbols).


Verschluchraube, Sperrung (wahlweise).

Fixed restriction.
Feste Blende, feste Drosselung.

Variable restriction.
Regelblende, regelbare Drosselung.

Restriction unaffected by viscosity.


Temperaturunabhngige Drosselung.

Flexible hose.
Schlauch, biegsame Leitung.

2 (30)

The Original Manufacturer of HGGLUNDS Cranes

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Pipe junction.
Leitungsverbindung.

Crossed pipes, no connection.


Kreuzende Leitungen, ohne Verbindung.

Rotary connection.
Dreh-Verbindung.

Tank line, tank.


Tankleitung, Tank.

Regulation or variability.
Regelbar oder nachstellbar.

Enclosure of component assembly.


Umri eines Mehrkomponentenblocks.

Mechanical connection.
Mechanische Verbindung.

Pump, fixed displacement, 1 direction of flow.


Pumpe, konstantes Deplacement, 1 Stromrichtung.

Pump, variable displacement, 2 directions of flow.


Pumpe, variables Deplacement, 2 Stromrichtungen.

The Original Manufacturer of HGGLUNDS Cranes

3 (30)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Motor, fixed displacement, 2 directions of flow, external 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.

Filter.
Filter.

Filter with contamination indicator.


Filter mit Anzeiger.

Filter with by-pass valve.


Filter mit Rckschlagventil.

4 (30)

The Original Manufacturer of HGGLUNDS Cranes

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Air breather.
Luftreiniger.

Pressure electric switch, normally open.


Druckschalter, druckgesteuert, normal offen.

Pressure electric switch, normally closed, adjustable.


Druckschalter, druckgesteuert, normal geschlossen,
regelbar.

Non-return valve.
Rckschlagventil.

Non-return valve, spring loaded with certain opening


pressure difference.
Rckschlagventil, federvorbelastet mit gewisser
ffnungsdruckdifferenz.

Non-return valve, spring loaded with certain closing


pressure difference.
Rckschlagventil, federvorbelastet mit gewisser
Schlieungsdruckdifferenz.

The Original Manufacturer of HGGLUNDS Cranes

5 (30)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Quick coupling or gauge connection.


Schnellkupplung oder Meanschlu.

Gauge connection.
Meanschlu.

Ventilation valve.
Entlftungsventil.

Non-return valve with variable restriction.


Drosselrckschlagventil, regelbar.

Shuttle valve.
Wechselventil.

Brake cylinder.
Bremszylinder.

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


Zylinder, doppelt wirkend mit konstanter Dmpfung
auf einer Seite.

Pressure gauge.
Manometer.

Thermometer.
Thermometer.

6 (30)

The Original Manufacturer of HGGLUNDS Cranes

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Oli cooler.
lkhler.

Accumulator.
Druckspeicher.

Shut-off valve.
Absperrventil.

Valve, basic symbol.


Schieber, Grundzeichen.

Electrically controlled valve.


Schieber, elektromagnetisch gesteuert.

Pressure controlled valve.


Schieber, druckgesteuert.

Pilot controlled valve, internal pressure supply.


Schieber, vorgesteuert, interner Steuerdruck.

Pilot controlled valve, external pressure supply.


Schieber, vorgesteuert, externer Steuerdruck.

Lever controlled valve.


Schieber, knppelgesteuert.

The Original Manufacturer of HGGLUNDS Cranes

7 (30)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Mechanically controlled valve.


Schieber, mechanisch gesteuert.

Valve with spring return.


Schieber mit Feder-Rckfhrung.

Valve with detent.


Schieber mit Lagehalter.

4/2 direction valve


Electrically controlled four-way, two-position valve,
spring return to neutral position.

4/2-Wegeventil
4-Wegeschieber mit 2 Arbeitsstellungen, FederRckfhrung in die Nullstellung.

4/3 direction valve


Electrically controlled four-way, three-position valve,
spring centred.
4/3-Wegeventil
4-Wegeschieber mit 3 Arbeitsstellungen, federzentriert.

Proportional valve.
Proportionalventil.

Servo valve.
Servoventil.

8 (30)

The Original Manufacturer of HGGLUNDS Cranes

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Balance valve (GP- and HH-cranes)


Ausgleichsventil(GP- und HH-Krne)

Flow regulator, adjustable.


Flu Regulator, regelbar.

Flow regulator with non-return valve.


Flu Regulator mit Rckschlagventil.

Cartridge valve.
Patronenventil.

Pressure limiting valve, adjustable.


Druckbegrenzungsventil, regelbar.

The Original Manufacturer of HGGLUNDS Cranes

9 (30)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Pressure limiting valve with remote opening or closing.


Druckbegrenzungsventil mit ferngesteuerter ffnung
oder Schlieung.

Pressure reducing valve.


Druckreduzierventil.

Pressure reducing valve with T-port.


Druckreduzierventil mit T-Anschlu.

10 (30)

The Original Manufacturer of HGGLUNDS Cranes

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

2. Valve Assemblies
Ventil-Baugruppen

Filter unit with by-pass valve.


Filtereinheit mit Shuntventil.

Filter unit with by-pass valve and electric filter indication.


Filtereinheit mit Shuntventil und Zustandsanzeige.

Filter unit with pressure limiting valve.


Filtereinheit mit Druckbegrenzungsventil.

The Original Manufacturer of HGGLUNDS Cranes

11 (30)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Filter unit with pressure limiting valve.


Filtereinheit mit Druckbegrenzungsventil.

Filter unit with by-pass valve and electric filter indication.


Filtereinheit mit Shuntventil und Zustandsanzeige.

12 (30)

The Original Manufacturer of HGGLUNDS Cranes

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Pump for hoisting winch.


Pumpe fr Lastwinde.

Pump for hoisting winch.


Pumpe fr Lastwinde.

The Original Manufacturer of HGGLUNDS Cranes

13 (30)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Pump for hoisting winch.


Pumpe fr Lastwinde.

Pump for luffing winch.


Pumpe fr Einziehwinde.

14 (30)

The Original Manufacturer of HGGLUNDS Cranes

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Pump for luffing winch.


Pumpe fr Einziehwinde.

Pump for luffing or slewing.


Pumpe fr Einziehwinde oder Schwenkantrieb.

The Original Manufacturer of HGGLUNDS Cranes

15 (30)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Pump for slewing or luffing.


Pumpe fr Schwenkantrieb oder Einziehwinde.

Pump for slewing.


Pumpe fr Schwenkantrieb.

16 (30)

The Original Manufacturer of HGGLUNDS Cranes

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Hoisting winch with 84-series motor and motor valve.


Lastwinde mit Motor Typ 84 und MotorUmschaltventil.

Hoisting winch with 63/64-series motor and motor


valve.
Lastwinde mit Motor Typ 63/64 und Motor-Umschaltventil.

The Original Manufacturer of HGGLUNDS Cranes

17 (30)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Hoisting winch with variable high speed hydraulic motor.


Lastwinde mit variabel schnellaufendem hydraulischem Motor.

Luffing winch with 63/64-series motor and motor valve.


Einziehwinde mit Motor Typ 63/64 und MotorUmschaltventil.

18 (30)

The Original Manufacturer of HGGLUNDS Cranes

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Unloading and flushing valve, slewing.


Entlastungs- und Splventil, Schwenkantrieb.

Unloading and flushing unit, hoisting and slewing.


Entlastungs- und Splventil, Lastwinde und Schwenkantrieb.

Flushing valve.
Splventil.

The Original Manufacturer of HGGLUNDS Cranes

19 (30)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Valve unit for stabilizing winch.


Ventileinheit fr Stabilisierungswinde.

Unloading unit for feed pump.


Entlastungsventil fr Speisepumpe.

20 (30)

The Original Manufacturer of HGGLUNDS Cranes

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Valve unit, cylinder luffing.


Ventileinheit, Zylinder-Einziehung.

Valve unit, cylinder luffing.


Ventileinheit, Zylinder-Einziehung.

The Original Manufacturer of HGGLUNDS Cranes

21 (30)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

3. Electric Symbols
Elektrische Schaltzeichen

Conductor junction, permanent.


Leitungsverbindung, fest.

Conductor junction, separable.


Leitungsverbindung, trennbar.

Crossed conductor, no connection.


Kreuzende Leitungen, ohne Verbindung.

Slip ring with brush.


Schleifring mit Brste.

Fuse, supply side indicated.


Sicherung, Zufhrungsseite markiert.

Magnetic relay, contactor.


Steuergert, elektromagnetische Erregerwicklung.

Make contact.
Arbeitskontakt.

Break contact.
Schaltkontakt.

22 (30)

The Original Manufacturer of HGGLUNDS Cranes

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Main contact.
Hauptkontakt.

Contact, manually operated.


Kontakt, von Hand bettigt.

Contact, manually operated without automatic return.


Kontakt, von Hand bettigt, nicht selbstrckstellend.

Emergency stop.
Notschalter.

Contact with delayed opening.


Kontakt mit Ausschalt-Verzgerung.

Contact with delayed closing.


Kontakt mit Einschalt-Verzgerung.

Contact with delayed opening/closing.


Kontakt mit Ein- und Ausschalt-Verzgerung.

Limit switch.
Endschalter.

Contact, thermal controlled.


Kontakt, thermisch gesteuert.

The Original Manufacturer of HGGLUNDS Cranes

23 (30)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Pressostat.
Pressostat.

Level switch.
lstandswchter.

Temperature switch, thermostat.


Temperaturwchter, Thermostat.

Touch free contact.


Berhrungsfreier Geber.

Inductive contact.
Induktiver Geber.

Ammeter.
Strommesser.

Voltmeter.
Voltmesser.

Hour counter.
Stundenzhler.

Earth (hull) connection.


Massenverbindung (Rumpf).

24 (30)

The Original Manufacturer of HGGLUNDS Cranes

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Rectifier.
Gleichrichter.

Transformer with two windings.


Transformator mit zwei Wicklungen.

Transformer with several secondary windings, with


screen between primary and secondary windings.
Transformator mit mehreren Sekundrwicklungen, mit
Schirm zwischen den Primr- und Sekundr-Wicklungen.

Triple-pole thermal relay (overcurrent) circuit breaker.


Dreipoliges thermisches Relais (berstrom-Auslsung).

Frequency converter.
Frequenzumformer.

The Original Manufacturer of HGGLUNDS Cranes

25 (30)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Diode.
Diode.

Light emitting diode.


Leuchtdiode.

Pilot lamp.
Meldeleuchte.

Light.
Beleuchtung.

Flood light.
Scheinwerfer.

Alarm signal.
Alarmsignal.

Alarmsiren.
Alarmhupe.

Single-phase outlet.
Steckdose, einphasig.

26 (30)

The Original Manufacturer of HGGLUNDS Cranes

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Position encoder.
Drehfeldgeber.

Puls/speed encoder
Geschwindigkeitsgeber

Flexible lead connector.


Steckverbindung.

Resistor.
Widerstand.

Resistor, non-linear.
Widerstand, spannungsabhngig.

Variable resistor.
Widerstand, regelbar.

Potentiometer with slider and a fixed tap.


Potentiometer mit Schleifer und einer Festanzapfung.

Heater.
Heizkrper.

Motor.
Motor.

The Original Manufacturer of HGGLUNDS Cranes

27 (30)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Condenser.
Kondensator.

Heater, cabin.
Heizkrper in der Fahrerkabine.

Air condition.
Klimaanlageapparat.

VL . . . .
Solenoid valve.
Magnetventil.

Oil tank heater.


lbehlterheizer.

28 (30)

The Original Manufacturer of HGGLUNDS Cranes

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Controller, hoisting.
Steuerknppel, Lastwinde.

Controller, luffing and slewing.


Steuerknppel, Einziehwinde und Schwenkantrieb.

The Original Manufacturer of HGGLUNDS Cranes

29 (30)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

THIS PAGE IS INTENTIONALLY LEFT BLANK

30 (30)

The Original Manufacturer of HGGLUNDS Cranes

TECHNICAL DATA
(2.001.4 E)

Project No.: 2/08006.01DAL-3 rev:- 2008-11-17

GENERAL
TYPE OF CRANE

GP 160-0516-2

WO

2/08006.01DAL-3

SERIAL NUMBER

62509352 Right crane

WEIGHT

TYPE OF FREQUENCY

3 ~ 60 Hz

SUPPLY VOLTAGE

440 V

CONTROL VOLTAGE

230 V

MECHANICAL DATA
SWL

5,0 tonnes

JIB RADIUS

MAX

16,0 m

JIB RADIUS

MIN

3.2 m

LIFTING HEIGHT HOOK TRAVEL


HOISTING CAPACITY, NORMAL OPERATION
HOISTING SPEED

45 m
MAX 5,0 tonnes
10 m/min

LUFFING TIME FROM MAX TO MIN JIB RADIUS


SLEWING SPEED

40 sec.
MAX 1.6 rev/min

STEEL ROPE

13 mm L = 110 m
No 390 9790-808

ELECTRICAL DATA
EL. MOTOR

289 2428-801

TYPE OF FREQUENCY

3 ~ 60 Hz

RATED POWER, CONT.

63 kW

RATED POWER, S6 40% INT.

92 kW

SPEED

1772 rev/min

RATED VOLTAGE

440 V

STARTING CURRENT

435 A

The Original Manufacturer of HGGLUNDS Cranes

1 (2)

TECHNICAL DATA
(2.001.4 E)

Project No.: 2/08006.01DAL-3 rev:- 2008-11-17

HYDRAULIC DATA
PUMP TYPE

188 1108-801
90 cm3/rev

DISPLACEMENT
MAX. SPEED

1800 rpm

HOISTING CIRCUIT
HYDRAULIC MOTOR

188 1769-801
56.1 cm3/rev

DISPLACEMENT

LUFFING CIRCUIT
HYDRAULIC CYLINDER

289 3178-801

SLEWING CIRCUIT
HYDRAULIC MOTOR

188 1227-801
28.1 cm3/rev

DISPLACEMENT
OIL TANK
OIL VOLUME; OIL FILLING

550 litres

SLEWING GEAR, PLANETARY GEAR BOX


OIL VOLUME; OIL FILLING

6.5 litres

HOISTING WINCH
OIL VOLUME; OIL FILLING

1.5 litres

The Original Manufacturer of HGGLUNDS Cranes

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
control panel

Slewing limits
(optional)

Oil tank

Heating fan
Pump
Cardan shaft
Main electric motor

Fig. 1. Crane types GP and HH.

The Original Manufacturer of HGGLUNDS Cranes

1 (4)

TECHNICAL DESCRIPTION

The MacGREGOR Cranes hydraulic slewing


cranes type GP and HH are delivered as complete
units, installed on pedestals, tested electrically, hydraulically and mechanically.

2.007.56 E rev.: c 2007-07-21

The hydraulic oil circuit has a full flow return filter with
changeable filter insert.
The tank is provided with an oil level indicator, a temperature gauge and an air breather.

Crane control
The crane is controlled from an open platform above
the slewing ring. Entrance to the platform is by ladder.
All motions have stepless speed control from 0 to
max. Two motions can be operated at the same
time with full capacity, but with reduced speed.

Electric pump motor

Remote control (optional)

Electric starter

The remote control system allows the crane operator


to drive the crane from a position on deck.

A.D.O.L. starter for location in the deck housing will


be supplied as a separate item.

Load limiting system


Each hydraulic circuit is provided with equipment for
limiting the hydraulic pressure to preset values
corresponding to the crane capacity.

The electric pump motor is of a marine type, with class


"F" insulation (standardmotor) and provided with an
anti-condensation heater for 220V.
Motor enclosure IP54.
Duty: S6-40% ID.

The starter includes as standard: ammeter,


hourmeter, start/stop buttons, main switch and running lamp in the front door.
Slewing machinery

Limit switches
Hook Travel Up: The crane is provided with an automatic hook stop at the top position.

The crane is provided with a slewing ring designed


for marine application. The gearing is internal.
Hoisting machinery

Luffing Up - Down: The luffing cylinder is designed


for safe buffering in the extreme positions.
Slewing Limits (optional): The crane is provided with
limit switches for limiting of slewing angle.
Combined Slewing - Luffing Limits (optional):
The crane is equipped with an arrangement for reducing allowable outreach through a certain angle.
Electro-hydraulic power pack
The crane is provided with a built-in power pack.
The electric pump motor is located in the centre of
the pedestal with output shaft pointing upwards and
driving the hydraulic pump through a cardan shaft.

The winch unit consists of:


- Drum with bearing and bracket.
- Winch gear with hydraulically operated fail-safe
brake.
- Hydraulic motor with safety valve to "freeze"
movement in case of pressure drop.
Wire rope is of the non-rotating type and galvanized.
Minimum safety factor is according to classification rules.
The wire sheaves are provided with heavy duty roller
bearings on steel axles.
All bearings have grease nipple lubrication.

The slewing column steel structure is utilized as


tank for the hydraulic oil.

2 (4)

The Original Manufacturer of HGGLUNDS Cranes

TECHNICAL DESCRIPTION

2.007.56 E rev.: c 2007-07-21

Fig. 2. Crane system. Main components.

Jib cylinder

Surface treatment

The jib cylinder is designed for marine use and has


spherical bronze bearings on steel axles.

All surfaces of the crane are carefully prepared by


sandblasting before being given a coat of primer.
As standard, the crane is painted with an
anticorrosive system based on a two-component
epoxy paint and an acrylic finishing coat.

The front part of the piston rod is made of stainless


steel to prevent rust formation when the crane is
parked.

Heating (valid for cranes working in an


ambient temperature below -20C.)

Steel structure
The steel quality selected is in accordance with
classification society recommendations to obtain
necessary ductility for the lower temperature design
limit.

The crane is equipped with a heating fan located


in the foundation to warm up the hydraulic oil tank
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.

The Original Manufacturer of HGGLUNDS Cranes

3 (4)

TECHNICAL DESCRIPTION

2.007.56 E rev.: c 2007-07-21

THIS PAGE IS INTENTIONALLY LEFT BLANK

4 (4)

The Original Manufacturer of HGGLUNDS Cranes

FUNCTION

3.110.70 E rev.: a 1999-01-07

Hydraulic Function
General
The following description refers to
MacGREGOR service crane type GP/HH.

Three hydraulic work circuits, ie, main hoisting


circuit, luffing circuit and slewing circuit make up
the complete crane operating system.

the

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
hydraulic reservoir which is integrated with the
cranehouse.

A complete hydraulic circuit diagram relating


specifically to your crane will be found in the
instruction manual, Spare Parts, Group 9.4.

Hoisting

Luffing

Slewing

Pump

Fig. 1. Identifying hydraulic circuits

The Original Manufacturer of HGGLUNDS Cranes

1 (8)

FUNCTION

3.110.70 E rev.: a 1999-01-07

The system has also a common main directional


valve with three sections, one for each circuit, and
one common base shunt section with main pressure
limitation.
The main directional valve is a pressure
compensated valve, which gives load independant
speed control. The speed is only depending on the
control lever position. The load sensing function in
the valve (LS-signal) controls the system pressure
to the level just above the highest required
momentary pressure.
Identifying circuits in the hydraulic diagram
Figure 1 shows the arrangement of the three work
circuits; main hoisting circuit, luffing circuit and
slewing circuit. The circuits appear in the same
order in the hydraulic diagram.
Symbols
Every hydraulic component is represented by a
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.

Hoisting winch circuit


Introduction
Figure 2 shows a hoisting winch circuit diagram with
the following main components:
Pump (common)
Hydraulic motor
Brake unit
Main motor valve
Main directional valve (common)

The high-speed motor has a fixed displacement in


the hoisting circuit and is fitted to the winch via a
flange.
Transmission of torque to the winch drum is made
via planetary gearing.
The brake opens by the system pressure via
sequence valve 104-2, see Fig. 2.

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...
2...
3...

Main hoisting circuit


Luffing circuit/Luffing cylinder
Slewing circuit

Legend
MMHO
CLU
MSL

2 (8)

001
102
103
104
002

Hydraulic motor, main hoisting circuit


Hydraulic cylinder, luffing circuit
Hydraulic motor, slewing circuit

The Original Manufacturer of HGGLUNDS Cranes

FUNCTION

3.110.70 E rev.: a 1999-01-07

Fig. 2. Hoisting winch circuit diagram

The Original Manufacturer of HGGLUNDS Cranes

3 (8)

FUNCTION

3.110.70 E rev.: a 1999-01-07

Safety system

Function

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
running, the hoisting winch performs no actual work.
The speed is controlled by the hand lever (direct
connected) integrated with the main directional
valve.
The control lever can be moved in two directions,
backwards or forwards, see Fig. 3.
Hoisting and lowering
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
system pressure increases up to the needed level
for the current load and the winch brake will open
at a certain system pressure level and the winch
starts to move in hoisting 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 is controlled by the
control lever and increases continously in proportion
to the lever position.
To lower the load the lever has to be moved
forwards in similar way as for hoisting.

Luffing circuit
Introduction
Fig. 4 shows a luffing circuit diagram, i.e. the circuit
that controls the movement of the jib and with the
following main components:
Cylinder
202
Balance valve
204
Pump (common) 001 and main directional valve
(common) 002, see Fig. 2.
Luffing
To luff in, move the control lever backwards from
neutral position. This will move the spool for luffing
002-1B and connect the pump to the cylinder. The
system pressure increases up to the needed level
for the current load and the jib starts to move in
hoisting 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 luff out the jib the lever has to be moved forwards
in similar way as for luffing in.

Slewing

Luffing

Hoisting

Safety system
Pressure limiting functions: Main pressure limiting
valves 002-6B and 002-7B.

Fig. 3. Control lever movements

4 (8)

The Original Manufacturer of HGGLUNDS Cranes

FUNCTION

3.110.70 E rev.: a 1999-01-07

002

Fig. 4. Luffing circuit diagram

The Original Manufacturer of HGGLUNDS Cranes

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
Brake
Balance valve

302
303
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
Pressure limiting functions: Main pressure limiting
valves 002-6C and 002-7C.

6 (8)

The Original Manufacturer of HGGLUNDS Cranes

FUNCTION

3.110.70 E rev.: a 1999-01-07

002

Fig. 5. Slewing circuit diagram

The Original Manufacturer of HGGLUNDS Cranes

7 (8)

FUNCTION

3.110.70 E rev.: a 1999-01-07

THIS PAGE IS INTENTIONALLY LEFT BLANK

8 (8)

The Original Manufacturer of HGGLUNDS Cranes

FUNCTION

3.142.10 E rev.: c 2008-09-22

Crane Control System

The control system is based upon three control


levers (main direction valve) operated from the
outside crane housing/oil tank. The right lever
controls the hoisting winch, the middle controls the
luffing and the left lever controls the slewing
movement. All movements except for the luffing
movement are driven by hydraulic motors. The
luffing movement is driven by a hydraulic cylinder.

Hydraulic motors
The hydraulic motors may be reversed by changing
the direction of the oil flow. They deliver constant
torque over their entire speed range.
Limit switch box, hoisting
Controls stop for full drum.

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.

The Original Manufacturer of HGGLUNDS Cranes

1 (2)

FUNCTION

3.142.10 E rev.: c 2008-09-22

THIS PAGE IS INTENTIONALLY LEFT BLANK

2 (2)

The Original Manufacturer of HGGLUNDS Cranes

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


box, in position "1".
The white indicator lamp for main
supply illuminates.
The yellow lamp for anti condensation
heater illuminates.

Press the green "I" button on starter


box.
The green indicator lamp for crane
running illuminates.
The yellow indicator lamp for anti
condensation heater goes out.

Press green "Start" button or red


"Stop" button on remote start/stop
box, placed on the crane foundation.

START
START

Main switch should be switched


on approx. 10 hours before the
crane is taken in operation.

STOP

STOP

Press the red "0" button on Starter


box.
The green indicator lamp for crane
running goes out.
The yellow lamp for anti
condensation heater illuminates.

AFTER STOPPING
Set main switch in position "0".

STOP

Emergency stop

STARTER BOX

A. Main switch
B. Stop button
A

150

200

100

50
0

00000250 h

C. Start button
D. Crane running lamp

B C

D E

F
E. Main supply lamp

F. Anti condensation heater lamp

The Original Manufacturer of HGGLUNDS Cranes

1 (2)

OPERATION

PM40 0815-E00 rev.: - 2008-02-18

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


Moving the control lever forwards or
backwards will operate the slewing
movements.

2. Control lever Luffing


Moving the control lever forwards or
backwards will operate the luffing
movements.

3. Control lever Hoisting


Moving the control lever forwards or
backwards will operate the hoisting
movements.

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)

The Original Manufacturer of HGGLUNDS Cranes

OPERATION

PM40 1822-E00 rev.: d 2008-09-22

Crew Checklist before Taking Crane into Operation

List
Verify that ship does not
list more than 5 degrees.

Wires and sheaves


Max. 5

Verify that wires run


correctly in the sheaves
and that the wire ends
are securely clamped.

Jib and hook release

Oil level

Loosen hook and jib from its parking position


manually before raising jib from its parking support.

Verify that hydraulic oil level is between min. and


max. on oil level dipstick.

MAX

MIN

The Original Manufacturer of HGGLUNDS Cranes

1 (2)

OPERATION

PM40 1822-E00 rev.: d 2008-09-22

THIS PAGE IS INTENTIONALLY LEFT BLANK

2 (2)

The Original Manufacturer of HGGLUNDS Cranes

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
its parking support, see Fig. 1. If the hook is to be
stowed to deck, fibre strops with low ultimate load or
manual "stretching screw" are to be used, see Fig. 3.
Tighten hook attachment manually to make sure that
the wire rope does not slack between the winch and
the jib top. Maximum tightening force between hook
and deck is dependent on work load and reeving,
see Table 1.

Caution!
The wire ropes must not be tightened by the winch.
The wire ropes, sheaves, and winches are subject to
heavy stress during sea voyage.
Note! Before operation release hook from sea
stowing position manually. Make sure that hook and
crane jib are loose before raising the jib from its
parking support.

Fig. 1. Crane in sea stowing position.

Fig. 2. Wire rope must not slack between winch and jib top.

The Original Manufacturer of HGGLUNDS Cranes

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.

SWL (T)

Reeving
05
58
8 20
20 25

1-part
5
5
5
-

2-part
5
10
10
-

3-part
15
-

4-part
15
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)

The Original Manufacturer of HGGLUNDS Cranes

MAINTENANCE

5.005.25 E rev.: g 2007-01-15

Maintenance Chart

Lubricate crane according to LUBRICATING


CHART.

Every time before taking crane into


operation

slacken, tighten all screws with a torque wrench.


See drwg. "Slewing assembly", section 9.3.

After 200 operating hours (running in


period)

Crane housing/Hydraulic oil tank


Slewing gear case

- Check oil level

- The first oil change.


Oil filter
- Check oil pressure. See "Lubricating Chart",
section 5.

Winch
- The first oil change.

Slewing gear case


- Check oil level. See instruction "Slewing
Gearset", section 6.1. The oil quantity is marked
on the name plate and in "Technical Data",
section 2.
- Check visually all sides. Check for leakage,
particularly on the bottom shaft seal ring.
Winch
- Check oil level. See instruction "Winch", section
6.1. The oil quantity is marked on the name plate
and in "Technical Data", section 2.

Every six months or every 500 working


hours
Wire ropes, wire rope clamps
- Inspect for wear. See instruction "Handling and
Checking Steel Wire Ropes" under section 6.2.
- Wire ropes are inspected according to
stipulations issued by Classification Associations
and National Bodies.
Bottom plate
- Check for leakage.

Loose gear
- Check that block, beam, hook, swivel and shackle
are intact.
Check according to instruction "Lifting Block/Beam",
section 6.2.

Wire sheaves
- Inspect for wear
Loose gear
- Check that hook and swivel are intact.

Every two
months or every 200
operating hours
Slewing rim screws
- Inspect visually the slewing rim screws from the
deck. If any screw shows any tendency to

Electrical equipment
- Inspect according to Electrical Equipment,
General Maintenance under section 6.3,
Service.

The Original Manufacturer of HGGLUNDS Cranes

1 (4)

MAINTENANCE

5.005.25 E rev.: g 2007-01-15

Crane house, foundation and jib welding joints


- Inspect for any sign of crack. See "Inspection of
Stressed Components and Structures", section 5.

Every two years or every 2000 hours of


operation
Crane housing/Hydraulic oil tank; oil change
and cleaning

Hydraulic system
- Measure the pressures according to the hydraulic
circuit diagrams adjoining list, section 9.4.
- Reset as required.
Oil analysis
- Sample oil and analyse every six months.
- If no oil analysis is done the oil must be changed
every two years or every 2000 hours of operation.
See separate instruction section 5.
Slewing rim
- Check seals.

- Drain oil and clean the reservoir. (See Hydraulic


Oil Tank, section 5.)
- Top up with fresh oil according to Lubricants for
Deck Machinery, section 5.
- Change oil filter cartridge.
- Change air filter.
Multiple disc brake, winch
- Check for leakage.
- Check discs.
Check according to instruction "Hoisting Winch"
under section 6.1.
Multiple disc brake, slewing gearset

Slewing gear, pinion

- Check for leakage.


- Check discs.
Check according to instruction "Slewing Gearset"
under section 6.1.

- Check backlash.

Every 1000 operating hours or at least


every year

Hydraulic hoses and couplings outside crane


house
- Inspect for damage and leakage.

Slewing gear case


- Change oil. Gear box.
- Change oil. Disc-room.
- Check motor spline shaft for deformations or
wear.
See instruction "Slewing Gearset", section 6.1.
Winch
- Oil analysis.
- Change oil. Gear box.
- Change oil. Room between motor and gear.
See instruction "Hoisting Winch", section 6.1.

Every four years


Slewing rim studs/screws
- Tighten all studs/screws with a torque wrench.
Tightening torque, see separate drawing,
"Slewing assembly", section 9.3
- Consult MacGREGOR (SWE) AB, Service
Division before replacing studs/screws with any
other specifications than recommended.

Air filter
- Check and change air filter.

2 (4)

The Original Manufacturer of HGGLUNDS Cranes

MAINTENANCE

5.005.25 E rev.: g 2007-01-15

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.

The Original Manufacturer of HGGLUNDS Cranes

3 (4)

MAINTENANCE

5.005.25 E rev.: g 2007-01-15

THIS PAGE IS INTENTIONALLY LEFT BLANK

4 (4)

The Original Manufacturer of HGGLUNDS Cranes

MAINTENANCE

5.019 E rev.: a 2007-01-12

Inspection of Stressed Components and Structures


Introduction
Stressed parts of the crane structure subjected to
high loads require inspection for signs of cracks and
other damage at regular intervals.
Cracks detected at an early stage do not generally
impair the handling safety of the crane unless they
are not repaired.
For safety reasons, service routines should include
a regular inspection of the entire crane, with particular attention paid to stressed parts.
Inspection
A thorough visual inspection is fairly easy to carry
out as cracks will generally show by cracking or
flaking of the paint followed by a brownish discoloration by rust.
(Inspect welds and surrounding material.)

This inspection should be performed at intervals according to the Maintenance Chart.


Note!
Rust on a painted surface does not necessarily
mean that there is a crack in the underlying material.
Remedy
When rust is found on top of or near a weld, grind
the topmost surface layer away to expose the crack
clearly. When in doubt, use a liquid penetrant to
identify the crack.
Before repairing of a crack in a stressed part, always
contact MacGREGOR (SWE) AB, Service Division
for advice.

Fig. 1. Crane Structure.

The Original Manufacturer of HGGLUNDS Cranes

1 (2)

MAINTENANCE

5.019 E rev.: a 2007-01-12

THIS PAGE IS INTENTIONALLY LEFT BLANK

2 (2)

The Original Manufacturer of HGGLUNDS Cranes

LUBRICATING CHART

PM51 1217-E00 rev.: b 2007-02-06

GP- and HH-cranes


Key to symbols

PART OF CRANE

a Daily or before taking crane into operation.


b Every 50 working hours (item 7 and 14*).
After more than 48 hours off duty (item 14*).
c Every 100 working hours.
d Every two months or every 200 working hours.
e Every six months or every 500 working hours.
f Every year or every 1000 working hours.
g Every two years or every 2000 working hour.

1 WIRE SHEAVES AND THIMBLE, JIB TOP, 3-4 NIPPLES


2 WIRE ROPE
3 LIFTING EQUIPMENT, 1-3 NIPPLE(S)
4 HOISTING WINCH BEARING, 1 NIPPLE
5 AIR BREATHER
6 OIL DRAIN PLUG (IN PUMP BRACKET)

1)

BEARING, SLEWING RIM, 3-8 NIPPLES,


7
SEE DRWG. PARTS MANUAL SEC. 9.3

2)

8 SLEWING RIM TEETH

Key to symbols

9 JIB BEARINGS, 2 OR 4 NIPPLES

Grease for ball and roller bearings


Grease for wire ropes

10 OIL LEVEL TEMPERATURE GAUGE

Grease for open spur gears


Check oil level
Cylinders
Oil filter, check/change
Check air breather
Hydraulic oil tank, oil change
Sample oil and analyse every six months. If
necessary change oil and clean tank
Slewing gear case, oil change
The first oil change after 200 working hours.
Winch, oil change
The first oil change after 200 working hours.
Winch + slewing gear
Motor flange/shaft coupling; oil change.

12 WINCH GEAR BOX, OIL CHANGE.

11 SLEWING GEAR CASE, OIL CHANGE

13 WINCH + SLEWING GEAR


14 LUFFING CYLINDER BEARINGS, 4 NIPPLES (INNER)
15

12 13

14

3)

16 PISTON SEALING, 1-3 NIPPLE(S)

4)

17 OIL FILTER
18 CARDAN SHAFT, 2 NIPPLES
19 OPEN GEAR
20 DRAIN COCK, HYDRAULIC OIL DRAIN
21

ELECTRIC MOTOR, UPPER AND LOWER BEARING,


NIPPLES

22 OIL FILLING

Maintenance intervals: See "Maintenance Chart",


section 5.
Lubricants: See "Lubricants for Deck Machinery",
section 5.
Oil volumes: See tables page 2.
* Four times a year if the crane is off duty for a longer
period (item 14).

LUFFING CYLINDER BEARINGS,


4 NIPPLES (OUTER)

1) Open oil drain plug after oil tank is drained through drain cock.
2) Relubrication should be performed under slewing motion. If that
is not possible relubricate bearing through all grease fittings,
than turn bearing approx. 200 mm and relubricate again. Repeat
this procedure until overlap of greasing is achieved and the
whole bearing circumference is filled with new grease at the
gaps and seals. (Five rotations/greasings should be sufficient.)
3) Cylinder to be lubricated only at assembly/replacement.
4) Check pressure on the manometer every time before taking
crane into operation. The pressure must not exceed 1.5 bar
(0.15 MPa). If necessary, change filter.

(1. Alternative to
central lubrication.)

2
9
5

22
10

(14. Alternative to
central lubrication.)

17
14
15

11

16
15

8
20

18
21

Jib support

3
19

3
(1. Alternative to
central lubrication.)

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.

The Original Manufacturer of HGGLUNDS Cranes

1 (2)

MAINTENANCE

PM51 1217-E00 rev.: b 2007-02-06

Oil volumes
Crane size

63
100
160
250
320
400
500
630
800

Oil volume
(litres)
Total hydraulic
system
250
500
600
750
1050
1100
1250
1250
2050

Oil volume
(litres)
Oil tank
200
450
550
700
950
950
1100
1100
1800

Oil volume
(litres)
Slewing gear
2.2
NA
6.5
8.0
8.0
16.0
16.0
2 x 8.0
2 x 8.0

Table 1.

SWL
(tonnes)
>0 to 3
>3 to 5
>5 to 8
>8 to10
>10 to15
>15 to 20
>20 to 25

Winch*
(litres)
1.5
1.5
2.0
NA
2.5
NA
NA

* For exact volume, oil filling, see


Technical Data in section 2.

Table 2.

NA = Not applicable.

2 (2)

The Original Manufacturer of HGGLUNDS Cranes

MAINTENANCE

5.302.15 E rev.: e 2003-09-11

Crane Housing / Hydraulic Oil Tank


General

Cleaning the crane housing/oil tank

The crane housing, with the pump situated inside,


functions as an oil tank.

Before cleaning the crane housing/oil tank, immobilise


the crane jib in a suitable manner and stop the electric
motor. Open the drain cock and drain off the oil into
clean empty barrels or drums then open the oil drain
plug on pump bracket and drain off oil left.

Checking oil level


The crane housing/oil tank has an oil sight glass.
Check that oil level is between min. and max. See
Fig. 1.
Filling oil

Remove the tank cover. Scrape off sediment, if any,


from the tank bottom and sides using a rubber scraper.
Flush the tank with white spirit.

Oil is filled into the crane housing/oil tank. When filling


oil the hydraulic machinery must be at rest, crane jib
in parking position (cylinder not projected) and the
electric main switch open. Fill oil to just under the
MAX mark, see Fig. 1. Use oil according to instruction
Lubricants for Deck Machinery".
Caution! Oil filled in the tank must be filtered to ISO
16/13 or better. Filling of oil to be made at horizontal
jib and/or cylinder in bottom position.

Wipe the tank dry with clean rags. DO NOT USE


COTTON WASTE, or other linting material. Apply new
sealing compound and reinstall the tank cover.
If the drained oil is in good condition and can be used
anew, it should be filtered before refilling.
Pump and hoses used for filling must be perfectly
clean.
Fill oil to just under the MAX mark. Use oil according
to instruction Lubricants for Deck Machinery".

Inspection
Oil sight
Oil filling

Max

Drain
cock

Drain plug on pump bracket

Min

Fig. 1. Crane housing / Hydraulic oil tank.

The Original Manufacturer of HGGLUNDS Cranes

1 (2)

MAINTENANCE

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2 (2)

The Original Manufacturer of HGGLUNDS Cranes

MAINTENANCE

5.421.16 E rev.: e 2007-01-03

Lubricants for Deck Machinery

B. GREASES

A. OILS
The oil shall be refined oil containing additives against
oxidation, rust and foaming, as well as wear inhibitor
and/or EP additives.
Hoisting winch gear box, slewing gear case
Oils with oil film reinforcing additives.
Viscosity approx. 220 cSt/40o C (ISO VG 220 HM).
Solidification point -15o C or better.
Example: SHELL OMALA 220

Roller bearings. Crane jib bearing


Grease with EP additives.
NOTE!
MUST NOT contain molybdenum disulphide.
Must withstand wet conditions.
Example: SHELL Alvania EP (LF) 2 (-20 to +130 C)
Arctic climate: SHELL Albida PPS2.
Ropes

Hoisting winch; motor flange


Slewing gear; motor flange
Half the motor flange should be filled with hydraulic oil
to prevent wear/rust on motor shaft/coupling.
NOTE!
When replacing brake discs the new discs should be
slightly wet with ATF-oil.
Crane hydraulic system
Viscosity approx. 46 cSt/40o C (ISO VG 46 HV).
Viscosity index (VI) approx. 150.
Solidification point -45o C or better.
Example: SHELL TELLUS T46.

Please contact MacGREGOR (SWE) AB, Service


Division, when choosing lubricants for extreme temperatures.

Grease resistant to salt water and with antirust


properties. (Very thin.)
Temperature range -30 to +100C.
Viscosity 9.8 cSt/40C
Example: FUCHS CEDRACON
Arctic climate: FUCHS Ceplattyn
Open spur gear units
Grease with good adhesion properties.
Example: SHELL MALLEUS GL95 (-15 to +150 C)
SHELL MALLEUS GL65 (-30 to +150 C)
Cylinder
(Only for cranes with cylinder luffing)
A lithium/calcium-based grease with base oil viscosity
150 - 200 cSt/40C.
NOTE!
MUST NOT contain molybdenum disulphide.
Example: SHELL CALITHA EP T2

The Original Manufacturer of HGGLUNDS Cranes

1 (2)

MAINTENANCE

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2 (2)

The Original Manufacturer of HGGLUNDS Cranes

How to order
spare parts

6.0

Hydraulic system

6.1

Mechanical
equipment

6.2

Electrical
equipment

6.3

E 2007-05-02

SERVICE

Address:
MacGREGOR (SWE) AB
SE-891 85 RNSKLDSVIK, Sweden
Telephone: 46 - 660 - 29 40 00
Telefax:
46 - 660 - 139 77
(Spare Parts, Technical Services &
Technical Documentation Services)
www.macgregor-group.com/cranes

The Original Manufacturer of HGGLUNDS Cranes

SERVICE

6.000 E rev.: c 2007-01-02

How to Order Spare Parts

Important details when enquiring or ordering spare parts


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
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:
MacGREGOR (SWE) AB, Service Division
SE-891 85 RNSKLDSVIK, Sweden
Telephone: 46 - 660 - 29 40 00
Telefax: 46 - 660 - 139 77

The Original Manufacturer of HGGLUNDS Cranes

1 (2)

6.000 E rev.: c 2007-01-02 page 2 (2)

SE-891 85 RNSKLDSVIK, SWEDEN

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: .. .............................................................
..............................................................

Fax no:

......................................

Tlx 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/

The Original Manufacturer of HGGLUNDS Cranes

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 HEALTH IN DOCK WORK, section A, B and
D.

Section D

Section A

Due to the difficulties for the shipowner to perform


adequate proof load test certified by a competent
person, in general MacGREGOR (SWE) AB,
rnskldsvik, cannot supply separate spare parts
to hook blocks, swivels, lifting beams etc. to the
owner or managers. However, it is possible to
deliver such parts to the MacGREGOR service
organization, if they can guarantee that the proof
load test and appreciate inspection according to ILO
will be performed under their responsibility.

Paragraph A.1.1 stipulates that every lifting


appliance should be with the provisions of section
D.1:
(a)
(b)
(c)

before taking in to use the first time


after the renewal or repair of any stress bearing
part; and
at regular four-year intervals, after the date on
which the appliance was first taken in to use.

Paragraph A.1.2 stipulates that the following


exceptions to the requirements of paragraph A.1.1
may nevertheless be allowed:
(a)

where any part is renewed or repaired, it should


be considered sufficient to subject that part,
by separate means, to the same stress as
would have been imposed on if it had been
tested in-situ during the testing of the
complete appliance.

Section D stipulates the Test loading is needed.

MacGREGOR (SWE) AB, rnskldsvik


Quality Department

Gunnar Tjrnstrm
Quality Manager

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)
(b)

before it is taken in to use the first time


after any renewal or repair of a stress-bearing
part.

The Original Manufacturer of HGGLUNDS Cranes

1 (2)

SERVICE

6.000.1 E rev.: c 2007-01-08

THIS PAGE IS INTENTIONALLY LEFT BLANK

2 (2)

The Original Manufacturer of HGGLUNDS Cranes

SERVICE

6.000.2 E rev.: c 2007-05-16

RETURN FORM
How to return parts from deck crane manufacturing,
installation or guarantee exchange

Delivery address:

MacGREGOR (SWE) AB
Att.: Mr Daniel Lundberg
Bjrnavgen 2
SE-891 41 RNSKLDSVIK
SWEDEN

Transport means, if necessary: Advised by us on request.


Phone no.: 46-660-29 40 00
Fax no.: 46-660-124 55
E-mail: daniel.lundberg@macgregor-group.com

Identification:

Absolutly necessary is a paper inside the return


shipment, shortly describing:
1) the part
2) from where it has been taken and
3) why it is returned.

Claim:

Detailed claim can be sent separately and does not


have to be enclosed.
The above refers only to the return shipment as such.

The Original Manufacturer of HGGLUNDS Cranes

1 (2)

SERVICE

6.000.2 E rev.: c 2007-05-16

RETURN FORM
To be packed inside return box or parcel
Date:

Sent by:

Newbuilding no.:
Ships name:
IMO no.:

Crane place on board:


Crane serial no.:

Returned parts
drawing or article
no, serial no.:
Part description:

Serial no. of unit


from which the part
is taken:
Unit description:

Reason for return: *

*) Please note: To be filled in with short but specific details. Faulty is not enough, a much better
description is leaking, not adjustable, cracked, earthing fault, short circuit if the reason is obvious,
or, a circumstantial evidence pointing to the returned part as the reason for malfunction, like luffing
movement too slow in one direction.
(Service/guarantee: 662 5000-706)

2 (2)

The Original Manufacturer of HGGLUNDS Cranes

SERVICE & PARTS

6.004.1 E rev.: ba 2008-05-08

MacGREGOR Global Services

BELGIUM

CHINA

DENMARK

Antwerpen, (S) (P)


MacGREGOR (NLD) B.V.

Hong Kong, (P)


MacGREGOR (SGP) Pte Ltd.

Copenhagen, (S) (P)


MacGREGOR (DNK) A/S

Luithagen-Haven 2E
B-2030 ANTWERPEN
Phone: (+32) 3-546 46 40
Telefax: (+32) 3-542 4772

Unit 3119, 31/F, Tower 1,


Millennium City 1,
388 Kwun Tong Road, Kowloon
HONG KONG
Phone: (+852) 2394 1008
Telefax: (+852) 2787 7652
Telefax: (+852) 2787 9878 (cranes)

Smedeholm 11,
DK-2730 HERLEV
Phone: (+45) 44-53 84 84
Telefax: (+45) 44-53 84 10

BRAZIL
Rio de Janeiro, (S)
MacGREGOR Brasil Ltda

Shanghai, (S) (P)


MacGREGOR (SHA)
Trading Co. Ltd.

Avenida Rio Branco 31


salas 1913 & 1914
Edif. Julio Lima
CEP 20090-003 Centro RIO DE
JANEIRO R.J.
Phone: (+55) 21-2516 1790
Telefax: (+55) 21-2516 1743

Room 1701, Cross Tower


318 Fu Zhou Road
200001 SHANGHAI
Phone: (+86) 21-6391 2798
Telefax (+86) 21-6391 2276

CANADA

CROATIA

Vancouver, (S)
Nagesco Ltd.

Rijeka, (S) (P)


MacGREGOR (HRV) d.o.o.

961A West 1st Street


NORTH VANCOUVER, B.C., V7P 1A5
Phone: (+1) 604-985 61 73
Telefax: (+1) 604-980 44 76

Vrh Martinscice 93B


HR-51221 KOSTRENA-RIJEKA
Phone: (+385) 51-289 717 / 718
Telefax: (+385) 51-287 154

CHILE

CYPRUS

Santiago (Valparaiso), (S)


EXIMTEC Ltda.

Limassol, (P)
MacGREGOR (CYPRUS) Ltd.
Titos Building, Office 201
58 Gladstone Street
CY 3041 LIMASSOL

Neveria 4444 - Piso 9


Las Condes
SANTIAGO
Phone: (+56) 2-207 65 90
Telefax (+56) 2-207 65 91

Phone: (+357) 25 763 670


Telefax (+357) 25 763 671

FINLAND
Turku, (P)
MacGREGOR (FIN) OY
Hallimestarinkatu 6
FI-20780 KAARINA
Phone: (+358) 2-412 11
Telefax: (+358) 2-4121 517

FRANCE
Marseille, (P)
MacGREGOR (FRA) S.A.
Porte 4, Cap Janet
13314 MARSEILLE Cedex 15
Phone: (+33) 491-09 52 52
Telefax: (+33) 491-095 240

GERMANY
Hamburg, (S) (P) (LCE)
MacGREGOR (DEU) GmbH
Normannenweg 24
D-20537 HAMBURG
Phone: (+49) 40-25 44 40
Telefax: (+49) 40-25 44 44 44

Hamburg LCE
MacGREGOR Logistic Centre
c/o Khne & Nagel (AG & Co.) KG
Altenwerder Hauptstrae 1
D-21129 HAMBURG
Phone: (+49) 40-30 333 6290
Telefax: (+49) 40-30 333 6210

Codes for available services from branches


(S)
= Branch with specially trained crane service engineers
(LCE) = Central spare parts stock
(LC) = Regional parts stock, servicing many countries in the same region
(P)
= Branch with spare parts sales resources

(S) (P)

MacGREGOR (SWE) AB
Service Division
www.macgregor-group.com/cranes

Address
SE-891 85 RNSKLDSVIK
Sweden

Telephone
(+46) 660-29 40 00

The Original Manufacturer of HGGLUNDS Cranes

Telefax
(+46) 660-139 77

1 (4)

SERVICE & PARTS

6.004.1 E rev.: ba 2008-05-08

GREECE

KOREA

Piraeus, (S) (P)


MacGREGOR (GRC) Ltd.

SINGAPORE

Busan, (S) (P)


MacGREGOR (KOR) Ltd.

4-6 Efplias Street


GR-185 37 PIRAEUS
Phone: (+30) 210-42 83 838
Telefax: (+30) 210-42 83 839

Singapore, (S) (P) (LC)


MacGREGOR (SGP) Pte. Ltd.

173-5, Songjeong-dong
Haeundae-gu
612-040 BUSAN
Phone: (+82) 51-704 0844
Telefax: (+82) 51-704 0414

9 Kian Teck Drive


628826 SINGAPORE
Phone: (+65) 626 52 322
Telefax: (+65) 626 41 261

INDIA

SPAIN

NETHERLANDS

Bombay, (S)
Renascent Enterprises
Flat 8, Building D/6-9
Radha Nagar, Barave Road
KALYAN (WEST), Pin - 421 301
Phone: (+91) 251 232 30 65
Telefax: (+91) 251 232 06 43

Rotterdam, (S) (P)


MacGREGOR (NLD) B.V.
Albert Plesmanweg 95-97
3088 GC ROTTERDAM
Phone: (+31) 10-283 2121
Telefax: (+31) 10-42 93 219

Bilbao, (P)
MacGREGOR (ESP) S.A.
Edificio Inbisa
Amaya, 2 - 1o, Leioa
ES-48940 VIZCAYA
Phone: (+34) 94-480 7339
Telefax: (+34) 94-431 6945

Bombay, (S)
Kalmar India Private Limited

NORWAY

Alicante, (S)

903-905, Plot No. 66, Greate


Eastern Summit Building "B" Wing
9th Floor, sector-a5, CBD Belapur
400 614 NAVI MUMBAI
Phone: (+91) 22 2758 2222
Telefax: (+91) 22 2758 2227

Oslo, (P)
MacGREGOR (NOR) A/S
Skur 39, Vippetangen
NOR-0150 OSLO
Phone: (+47) 23-10 34 00
Telefax: (+47) 23-10 34 01

Stanley van der Pers


c/o Vanpershydro S.L.
Apartado de Correos No. 7
ES-03170 ROJALES - ALICANTE
Phone/telefax: (+34) 9667 13665
Mobile: (+34) 620 953 722

ITALY

Bergen, (S)
MacGREGOR (NOR) A/S

Genoa, (S) (P)


MacGREGOR (ITA) S.p.A.

Bleivassvegen 105
N-5363 GOTNES
Phone: (+47) 55-56-31 33 00
Telefax: (+47) 55-56-31 33 23

Via Al Molo Giano


I-16128 GENOA/PORTO
Phone: (+39) 010-254 631
Telefax: (+39) 010-2461 194

POLAND

JAPAN
Tokyo, (S) (P)
MacGREGOR-Kayaba Ltd. Head Office
9/F, Suzue Baydium Bldg.
1-15-1, Kaigan, Minato-Ku
105 - 0022 TOKYO
Phone: (+81) 3-5403 1966
Telefax: (+81) 3-5403 1953

SWEDEN
rnskldsvik, (S) (P)
MacGREGOR (SWE) AB
Service Division
Sjgatan 4 G
SE-891 85 RNSKLDSVIK
Phone: (+46) 660-29 40 00
Telefax: (+46) 660-139 77

Gdynia, (P)
MacGREGOR (POL) Sp. z. o.o.

www.macgregor-group.com/cranes

ul. Luzycka 8
PL-81-537 GDYNIA
Phone: (+48) 58-7855 110
Telefax: (+48) 58-7855 111

Gothenburg, (S) (P)


MacGREGOR (SWE) AB
Warehouse, Atlashuset,
Banehagsliden 2
SE-414 58 GOTHENBURG
Phone: (+46) 31 850 700
Telefax: (+46) 31 424 946

Codes for available services from branches


(S)
= Branch with specially trained crane service engineers
(LCE) = Central spare parts stock
(LC) = Regional parts stock, servicing many countries in the same region
(P)
= Branch with spare parts sales resources

(S) (P)

MacGREGOR (SWE) AB
Service Division
www.macgregor-group.com/cranes

2 (4)

Address
SE-891 85 RNSKLDSVIK
Sweden

Telephone
(+46) 660-29 40 00

The Original Manufacturer of HGGLUNDS Cranes

Telefax
(+46) 660-139 77

SERVICE & PARTS

6.004.1 E rev.: ba 2008-05-08

U. A. E.
Dubai, (S) (P)
Cargotec (ARE) LLC.
P.O. Box 30029
Al Quoz Industrial Area 4
Street 14B
Between Interchanges 3 and 4
DUBAI
Phone: +971-4-34 13 933
Telefax: +971-4-34 13 110
24h phone: +971-50-65 10 371

UNITED KINGDOM
Newcastle, (P)
MacGREGOR (GBR) Ltd.
1st Floor, Power House
Silverlink Business Park
Wallsend
NE28 9ND TYNE & WEAR
Phone: (+44) 191-295 2180
Telefax: (+44) 191-295 2188

USA
Norfolk, (S) (P) (LCE)
MacGREGOR (USA) Inc.
1220-E Fleetway Drive
VA 23323 CHESAPEAKE
Phone: (+1) 757-558-4580
Telefax: (+1) 757-558-4581

New Orleans, (S)


MacGREGOR (USA) Inc.
4757 River Road
Jefferson
70121 LOUISIANA
Phone: (+1) 504-733-3321
Telefax: (+1) 504-733-3360

Codes for available services from branches


(S)
= Branch with specially trained crane service engineers
(LCE) = Central spare parts stock
(LC) = Regional parts stock, servicing many countries in the same region
(P)
= Branch with spare parts sales resources

(S) (P)

MacGREGOR (SWE) AB
Service Division
www.macgregor-group.com/cranes

Address
SE-891 85 RNSKLDSVIK
Sweden

Telephone
(+46) 660-29 40 00

The Original Manufacturer of HGGLUNDS Cranes

Telefax
(+46) 660-139 77

3 (4)

SERVICE & PARTS

6.004.1 E rev.: ba 2008-05-08

THIS PAGE IS INTENTIONALLY LEFT BLANK

Codes for available services from branches


(S)
= Branch with specially trained crane service engineers
(LCE) = Central spare parts stock
(LC) = Regional parts stock, servicing many countries in the same region
(P)
= Branch with spare parts sales resources

(S) (P)

MacGREGOR (SWE) AB
Service Division
www.macgregor-group.com/cranes

4 (4)

Address
SE-891 85 RNSKLDSVIK
Sweden

Telephone
(+46) 660-29 40 00

The Original Manufacturer of HGGLUNDS Cranes

Telefax
(+46) 660-139 77

6.008.2 E rev.: a 2007-01-12

SERVICE

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
may vary, but the purpose is always the same: to
find the fault quickly and methodically in order to put
it right.

Hydraulic circuit diagram

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?
- Was the operating speed first reduced, or did
the movement run irregularly?
- What manoeuvre immediately preceded the
failure?

Electric circuit diagram


Electric circuit diagram
Electric circuit diagram

Begin checking if there are any visible defects.

The Original Manufacturer of HGGLUNDS Cranes

1 (2)

6.008.2 E rev.: a 2007-01-12

SERVICE

When consulting MacGREGOR (SWE) AB, Service


Division for service or advice, always give the following
information at once:

Analysis of information collected


By methodical trouble-shooting, it is often possible to
find, at an early stage, the defect producing the faulty
operation, thereby avoiding unnecessary waste of time.

1. Which crane function has ceased to function?


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)

The Original Manufacturer of HGGLUNDS Cranes

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 authorized 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 parking 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, lighting etc., with the power switch(es) in the
ships engine room.
B. Warning signs must be hung on the switches
involved.
4. Make sure that the crane is completely without
power. If necessary, lock switches, take out fuses
etc. so nobody by mistake can start the crane.
5. When special work has to be done see separate
instruction or contact our service department.
6. If some special arrangements are done for testing 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.

The Original Manufacturer of HGGLUNDS Cranes

1 (2)

SERVICE

6.100 E rev.: b 1998-10-22

THIS PAGE IS INTENTIONALLY LEFT BLANK

The Original Manufacturer of HGGLUNDS Cranes

2 (2)

SERVICE

6.120.15 E rev.: d 2005-10-04

Slewing Gearset

Oil filling
Plug

Air filter
Expansion tank
a
Expansion pipe
Disc brake

Oil level sight


glass

Screws holding
gearset to crane
house floor

Oil outlet

- Fill gear oil as required (see lubricating instructions


for appropriate type; the approximate quantity
needed is given on the nameplate).
- Fill brake disc chamber with hydraulic oil; e.g. 0,1
litre ATF-oil, type A.
Brake surface sealed with Loctite type 573.
- Before assembling the drive motor, grease shaft
and gear teeth with a suitable grease for protection
against corrosion; we suggest OPTIMOLY PASTE
White T.
- Check function of slewing gearset with the drive
motor running, paying particular attention to the
function of the brake and the correct control of the
motor.

Maintenance
Lubrication
Fig. 1. Slewing gearset.

Assembly of slewing gearset


- Install slewing gearset in crane without using force.
- Use hand pump to release disc brake hydraulically.
Input drive sleeve must turn easily.
- Check slewing gear backlash (pinion-to-rim gear).
See description under Checking and adjusting
slewing rim backlash.
- The gear backlash may be adjusted by rotating the
gearset one or more screw hole divisions.
- Tighten the screws to torque recommended, secure
with Loctite 242 (or a similar compound). Applying
a suitable sealing compound, such as Loctite 640,
on the mating surfaces of the flanged connection,
is recommended.
- Remove threaded plug from top of expansion pipe
(for transport sealing only).
- After installation of gear unit fit supplied air filter
with oil expansion tank, at marked position a
(optional to fit with a tube turn). See Fig. 1.

The slewing gearset is splash lubricated. The output


shaft roller bearing is for-life lubricated with ball
bearing grease.
Oil level check
Inspect oil level when the gear is at rest with the brake
engaged.
Oil changes
Whenever practicable, let the oil drain off while still
hot; remove also the filler plug(s).
For oil change open both pipes. Remove air filter with
oil expansion tank at marked pos. a, see Fig 1.
At low ambient temperatures, flush out the gearcase
with a quantity of fresh oil to remove abraded matter
and contamination products.

The Original Manufacturer of HGGLUNDS Cranes

1 (4)

SERVICE

6.120.15 E rev.: d 2005-10-04

Gearcase and oil inspection


Sampling oil
Withdraw a sample of gearcase oil for inspection from
the filling drained off at intervals as described in the
Maintenance Chart. To obtain a representative
sample, drain the gearcase during operation and with
the oil at operating temperature.
Oil discoloration
A darkish or black colour of the used oil suggests that
temperatures in excess of 100o C did occur in operation, causing accelerated aging of the oil and impaired
lubricating properties. In this case the oil should be
changed at shorter intervals.
If the oil sample displays a cloudy aspect, it may be
that water has managed to seep into the oil. The oil
must then be changed a t o n c e, and the gearcase
flushed out very thoroughly several times with fresh
oil.
The gearcase should preferably be dismantled for
inspection beginning at the input side, and the
components examined for signs of corrosion.

If coarser abraded matter (above 25 ) or flake off


material from the gear teeth is found, the gearset must
be dismantled, irrespective of the actual amount of
foreign matter present, beginning at the input end of
the gearset.

Hydraulic-Release Multiple-Disc Brake


Technical description
The brake comprises the following major components:
- Brake piston
- Brake cylinder
- Disc carrier
- Internal discs
- External discs
- Sealings
- Thrust spring
The brake housing is mounted on top of the gearcase,
with long assembly screws through the motor adapter housing and both parts of the brake housing.
The sleeve disc carrier, with the internal discs, is fixed
on the driven shaft with a shaft key or by splines.

Foreign solid matter


- As a first simple test, drop some of the used oil
onto the filter fleece specified. Coarse foreign matter, if
present, will then show up on inspection,
preferablythrough a magnifying glass.
- A better test may be made by diluting an oil sample
with n-heptane, passing it through a diaphragm
filter, washing and drying it, and weighing it to
determine the mass difference.

The disc assemblies are pressed together by a set


of thrust springs and the brake is disengaged by
hydraulic power.
Maintenance
The brake is self-adjusting.
Trouble-shooting

Overall assessment

a. Braking torque insufficient

The maximum permissible amount of foreign matter


carried by the oil is some 0.15 per cent of the total
mass of the oil in the gearcase. These impurities must
be, exclusively, very fine abraded matter (max 25 ).
If the contamination keeps within these limits,
continued operation of the gearset is permitted after
the oil has been changed.

2 (4)

Test of brake torque may be performed according to


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

The Original Manufacturer of HGGLUNDS Cranes

SERVICE

6.120.15 E rev.: d 2005-10-04

Motor side
Thrust spring

Brake piston

Brake cylinder

Pressure oil
connection

Sealing
Sealing
Total
thickness
of discs
Internal discs

Leakage oil
Disc carrier
External discs

Gear side

Fig. 2. Disc brake.


Attention: Please select the requisite number of thrust springs from parts list "gear".

- Inspect brake discs and replace if excessively


worn.
- If discs are coloured dark yellow to blue, the discs
have been overheated. Replace discs and springs.
- Inspect sealings for wear. If sealings are defect
replace brake cylinder and piston with sealings to
new ones.
b. Brake heats
Check the hydraulic pressure to make sure that it is
sufficient in order to disengage the brake completely.

Checking
backlash

and

setting

slewing

rim

An oversize backlash between the pinion and the


slewing rim will cause irregularities in the slewing
movement of the crane. Read this instruction carefully
prior to checking or resetting!

- Slew the crane 90 degrees and check.


- Proceed to check the backlash at four 90-degree
position in the rim.
- Put the dial gauge on the tooth of the pinion. By
manual turning at the input, the pinion can be moved
in both directions up to contact with the teeth. Now,
the tooth flank clearance can be exactly measured
on the dial gauge.
- Check the backlash at one spot
- Slew the crane 90. Check again
- Proceed to check the backlash at four 90-degree
positions in the rim
- Compare the four backlash values.
Backlash values: See drawing "Slewing
assembly".
The backlash shall be set at the position of the slewing
rim with the lowest backlash value.
Setting backlash
The backlash may be set by turning the entire gearset
one or more screw hole divisions.

Checking backlash
The backlash should be checked by a dial gauge or
a feeler. When slewing the crane, the backlash may
vary from one position to another due to some slight
excentricity of the slewing rim. It is therefore
recommended to check the backlash at four positions
of the slewing rim.
Proceed as follows:
- Check the backlash at one spot.

Proceed as follows:
- Slew the crane into the position with the lowest
backlash value.
- Remove all screws holding the gearset to crane
house floor.
- Release the disc brake hydraulically by means of a
manual pump.

The Original Manufacturer of HGGLUNDS Cranes

3 (4)

SERVICE

6.120.15 E rev.: d 2005-10-04

- Turn the entire gearset one or more screw hole


to achieve the desired setting.
To turn the gearset, remove the hydraulic motor
andturn the spline sleeve on top of the gear.
Note!
The turning of the entire gearset may be restricted by
the hoses connected or by space limitations. To overcome this problem, release the upper part of the
gearset by just removing the holding screws, see Fig.
3 Slewing gearset.

Upper part
Screws

Screws holding
gearset to crane
house floor

Make sure that the upper part can be turned freely.


Turn the entire gearset (except the upper part), until
the desired setting is achieved. Watch the hoses!
- Replace and tighten the screws holding the gearset
to the crane house floor using Loctite 242 or a
similar compound.
If the upper part has been removed
If the upper part has been removed, clean its contact
surfaces and apply Loctite 640 Sealant or a similar
compound. Make sure not to strain the hoses. Apply
Loctite 242 on the screws holding the upper part,
reinstall and tighten.

4 (4)

Fig. 3. Slewing gearset.

The Original Manufacturer of HGGLUNDS Cranes

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

Hydraulic Motor 188 1223-801

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:
56.1 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

The Original Manufacturer of HGGLUNDS Cranes

1 (4)

SERVICE

6.120.62 E rev.: f 2003-02-19

Hydraulic Motor 188 1227-801

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:
28.1 cm3/rev.
Pre-filling volume: 1.0 litre (Approx.)

Oil filling/Drain
connection

Hydraulic Motor 188 1250-801

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.
Oil filling/
Drain connection

Displacement:
63.0 cm3/rev.
Pre-filling volume: 1.0 litre. (Approx.)

Hydraulic Motor 188 1769-801

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:
56.1 cm3/rev.
Pre-filling volume: 1.0 litre. (Approx.)

Oil filling/
Drain connection

2 (4)

The Original Manufacturer of HGGLUNDS Cranes

SERVICE

6.120.62 E rev.: f 2003-03-19

Hydraulic Motor 189 1167-801

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:
63.0 cm3/rev.
Pre-filling volume: 1.0 litre. (Approx.)

Hydraulic Motor

288 0303-801
288 2158-801

Oil filling/
Drain connection

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 Vg: 54.8 - 0 cm3/rev.
Pre-filling volume: 1.0 litre. (Approx.)
Oil filling/
Drain connection

Hydraulic Motor 388 3127-801

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:
59.8 cm3/rev.
Pre-filling volume: 0.5 litre. (Approx.)

Oil filling/Drain connection

The Original Manufacturer of HGGLUNDS Cranes

3 (4)

SERVICE

6.120.62 E rev.: f 2003-02-19

THIS PAGE IS INTENTIONALLY LEFT BLANK

4 (4)

The Original Manufacturer of HGGLUNDS Cranes

SERVICE

6.120.96 E rev.: a 2007-01-12

Winch
Winch and gearbox
General
The hoisting winch is driven by a high speed hydraulic motor via a planetary gearbox.
The planetary gearbox has splash lubrication and is
normally filled with gear oil.
If the winch is supplied without oil, this is indicated
on a corresponding label.
A brake is integrated in each winch gear set. When
the winch is running, the brake is automatically
released by hydraulic pressure.
Assembly of winches
- Mount the winch together with winch support. The
clamping screws of the winch support must be
easily connectable.
- Tighten the screws according to torque
recommended. Secure with Loctite 242 or a similar compound.
- Remove the motor flange transport cover.

Journal
bearing
Oil filler inlet
Oil dipstick

- Connect brake line and release the disc brake


hydraulically. The drive sleeve in the drive unit
must turn easy.
- Remove plug from the drive sleeve of the drive
unit. For protection against corrosion, the drive
sleeve is provided with gear oil from the gear. The
plug prevents the motor flange filling with oil before
mounting the motor.
- Centre motor on the motor flange. Seal connection
surface with Loctite 572 or similar. Fix motor with
screws. Motor shaft must be grease-free.
- Before test-running, fill the motor flange completely
with gear oil.
- Check oil level with oil dipstick. Refill oil if
necessary.
- Be sure that jib is in horizontal position, see Fig. 2,
when checking oil level.
- Oil volume: See nameplate on winch or instruction
"Technical Data", section 2.
- Oil type: See instruction "Lubricants for Deck
Machinery", section 5.
- Check rope winch with running motor as to function.
Check above all the control and function of the
holding brake and the drive motor.
- After test-running, check oil level once more with
oil dipstick. During the test-running, the oil level in
the gear and motor flange adjusts itself and fills
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.

The Original Manufacturer of HGGLUNDS Cranes

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


hot. Remove the inlet plug (air filter). At low ambient
temperature, flush out the gearbox with a quantity of
fresh pre-heated oil to remove particles and sediment.

A darkish or black colour of the used oil suggests


that temperatures in excess of 100C have occurred
in operation, causing accelerated ageing of the oil
and impaired lubricating properties. In this case the
oil should be changed at shorter intervals.

Maintenance
- Change gearbox oil, see Fig 1.
- Grease journal bearing, see Fig 1.
- Check oil level, see Fig 1.
Note!
Oil level can only be inspected with non-running gears
and with jib in horizontal position, see Fig. 2.
Maintenace interval and number of grease nipples:
See "Lubricating Chart", section 5.

If the oil sample displays a cloudy aspect, it may be


that water has managed to seep into the oil. The oil
must then be changed at once, and the gearbox
flushed out very thoroughly several times with fresh
oil.
The gearbox should preferably be dismantled for
inspection beginning at the input side, and the
components examined for signs of corrosion.

Foreign solid matter

Sampling oil

As a first simple test, drop some of the used oil onto


the filter fleece specified. Coarse foreign matter, if
present, will then show up on inspection through
(preferably) a magnifying glass.
A better test can be made by diluting an oil sample
with n-heptane, passing it through a diaphragm
filter, washing and drying it, and weighing it to
determine the mass difference.

Take a sample of gearbox oil for analysis at intervals


as described in the "Maintenance Chart".

Overall assessment

Types of oil and grease:


See "Lubricants for Deck Machinery", section 5.
Oil volume:
See "Technical Data", section 2.

Procedure for oil sampling:


- The oil temperature in the gearbox should be
above +40 0C.
- Special oil sampling bottles should be used that
can be obtained from oil companies.
- The oil sample should be taken from the oil drain
on the winch, see Fig. 1.
- Drain 1-2 litres of oil into a bucket. This oil should
be disposed of.
- Fill the oil sample bottle.
- Send the oil sample to an oil company for analysis.
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)

The maximum permissible amount of foreign matter


carried by the oil is some 0.15 per cent of the total
mass of the oil in the gearbox. These impurities may
only consist of very finely abraded matter (max. 25
m). If the contamination keeps within these limits,
continued operation of the gear set is permitted after
the oil has been changed.
If coarser abraded matter (above 25 m) or flake-off
material from the gear teeth is found, the gear set
must be dismantled, irrespective of the actual amount
of foreign matter present, beginning at the input end
of the gear set.

The Original Manufacturer of HGGLUNDS Cranes

SERVICE

6.120.96 E rev.: a 2007-01-12

Hydraulic-Release Multiple-Disc Brake


Technical description

Trouble-shooting

The brake comprises the


components. See also Fig. 3.
-

following

major

Brake piston
Brake cylinder
Disc carrier
Inner discs
Outer discs
Hydr. part for disc brake
Compression spring

The brake housing is mounted on the input side of


the gearbox, with long assembly screws through the
motor adapter housing and both parts of the brake
housing.
The disc assemblies are pressed together by a set
of compression springs and the brake is disengaged
by hydraulic power.

Braking torque insufficient


Test of brake may be performed as follows:
- Drive winch hydraulic motors against closed brake.
The motor shall not be able to rotate.
Note! Test procedure shall be performed only for
a short period; a few seconds.
- Inspect brake discs and replace if excessively
worn. If brake discs are coloured dark yellow to
blue, the discs have been overheated. Replace
discs and springs.
- Inspect brake for leakage. If leakage appears in oil
pressure unit, the complete unit must be replaced.
Note! Sealings are not available as spare parts.
Brake heats
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
the brake discs

Inner discs

Disc carrier

Gear side

Fig. 3. Disc brake.

The Original Manufacturer of HGGLUNDS Cranes

3 (4)

SERVICE

6.120.96 E rev.: a 2007-01-12

THIS PAGE IS INTENTIONALLY LEFT BLANK

4 (4)

The Original Manufacturer of HGGLUNDS Cranes

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
should be inspected for damage every five (5) years,
see Maintenance Chart in section 5.
If the rubber in the hose is damaged so that the steel
core can be exposed to corrosion the hose should
be replaced.
The hose couplings should also be inspected for
damage and leakage. If the coupling is damaged or
severely corroded the hose should be changed.
If the coupling is leaking the coupling should be tightened at first. If tightening does not help, the hose and
the mating couplings should be changed, see Fig. 1.
If the coupling is of flange type the O-ring and screws
should be changed, see Fig. 2.

Hydraulic
hoses
and
couplings
assembled on outside of crane house
Hydraulic hoses assembled on outside of crane house
should be inspected for damage every two (2) years,
see Maintenance Chart in section 5.

If the rubber in the hose is damaged so that the steel


core can be exposed to corrosion the hose should be
replaced.
The hose couplings should also be inspected for
leakage and damage of the corrosion protective Densyl tape. If the corrosion protection is damaged so
that the coupling can be exposed to corrosion the
corrosion protection should be removed and the
coupling inspected for damage and severe corrosion.
If the coupling is damaged or severely corroded the
hose should be changed.
If the coupling is leaking the coupling should be tightened at first. If tightening does not help, the hose and
the mating couplings should be changed, see Fig. 1.
If the coupling is of flange type the O-ring and screws
should be changed, see Fig. 2.

Replacement of hydraulic hoses


All hydraulic hoses assembled inside crane house
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.

The Original Manufacturer of HGGLUNDS Cranes

1 (2)

SERVICE

6.142.5 E rev.: a 2002-01-09

THIS PAGE IS INTENTIONALLY LEFT BLANK

2 (2)

The Original Manufacturer of HGGLUNDS Cranes

SERVICE

6.214 E rev.: i 2007-03-02

Tightening Torques
Studs/Screws and Bolts
Introduction
This instruction applies to studs, screws and bolts
generally, if separate recommendations are not given. Apply Molykote R 1000 lubrication on the threads
and under the bolt head. For stainless elements and
hydraulic pipe couplings apply Gleitmo paste.
Slewing bearing, studs/screws

Note!
Threads that have been rolled after hardening have a
lower surface notch indicating that the permitted tension amplitude at fatigue can be about doubled
compared to threads that have been rolled before
hardening. If the screw has been loaded beyond the
yield limit, this feature will disappear.

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
M

UNC

4
5
6
7
8
10
12
1/2"
14
5/8"
16
3/4"
18
20
22
24
1"
27
30
1 1/4"
33
36
39
42

Tightening torque in Nm
10 Nm 1 kpm
8.8
10.9
12.9
2.5
4.9
8.4
13.8
20.6
40.4
69.7
80.8
110
159
169
280
237
331
445
572
670
826
1127
1308
1522
1961
2520
3130

3.4
7.0
12.0
19.8
28.4
55.9
98
114
156
224
238
393
332
465
626
804
942
1161
1582
1840
2133
2761
3543
4395

4.2
8.3
14.6
23.2
34.4
67.9
117
136
187
269
286
471
398
558
752
963
1131
1393
1901
2208
2563
3311
4248
5280

Thread
M

UNC

4
5
6
7
8
10
12
1/2"
14
5/8"
16
3/4"
18
20
22
24
1"
27
30
1 1/4"
33
36
39
42

Tightening torque in Nm
10 Nm 1 kpm
8.8
10.9
12.9
2.9
5.7
9.8
16.1
24.0
47.0
81.0
94.0
128
185
197
325
275
385
518
665
779
961
1310
1521
1770
2280
2930
3640

The Original Manufacturer of HGGLUNDS Cranes

4.0
8.1
14.0
23.0
33.0
65.0
114
132
181
260
277
457
386
541
728
935
1095
1350
1840
2140
2480
3210
4120
5110

4.9
9.7
17.0
27.0
40.0
79.0
136
158
217
312
333
548
463
649
874
1120
1315
1620
2210
2567
2980
3850
4940
6140

1 (4)

SERVICE

6.214 E rev.: i 2007-03-02

As a rule, always change screws with specified tightening torque on cranes in operation if the joint has to
be opened for some reasons.
If any joint has been opened apply Intertuf after tightening the joint to avoid rust damage.

SAE flange for high pressure hose couplings


Flange
6000 psi

Screw

3/4"
1"
1 1/4"
1 1/2"
2"

M10
M12
M14
M16
UNC 3/4

2 (4)

Tightening torque in Nm
10 Nm 1 kpm
Class H 10.9 and 12.9
54
94
150
230
377

Stainless bolts and hydraulic pipe couplings


greased with Gleitmo paste
Thread
d

6
8
10
12
14
16
18
20
22
24
27
30
33
36
39

Tightening torque in Nm
10 Nm 1 kpm
Austenite (A)
50
70
80
3.3
7
9.3
7.8
17
22
15
33
44
27
57
76
43
91
121
65
140
187
91
195
260
127
273
364
171
367
490
220
472
629
318
682
909
434
930
1240
585
1250
1670
755
1620
2160
969
2080
2770

The Original Manufacturer of HGGLUNDS Cranes

SERVICE

6.214 E rev.: i 2007-03-02

Strength of screws and bolts


Strength class
4.6
5.8
6.6
8.8
10.9
12.9

Min. ultimate strength


(kp/mm2)
N/mm2

Min. tensile strength


(kp/mm2)
N/mm2

400
500
600
800
1000
1200

240
400
360
640
900
1080

(40)
(50)
(60)
(80)
(100)
(120)

Corresponding strength
class of nuts

(24)
(40)
(36)
(64)
(90)
(108)

4
5
6
8
10
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
UNF-thread
Cold forged

UNC- and
UNF-thread
Forged

Strength class 10:

M-thread

UNC- and UNF-thread


Forged

The Original Manufacturer of HGGLUNDS Cranes

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
coupling
GE 10-LM
GE 10-LR
GE 12-LM
GE 12-LR
GE 15-LM
GE 15-LR
GE 18-LM
GE 18-LR
GE 22-LM
GE 22-LR
GE 28-LM
GE 28-LR
GE 35-LM
GE 35-LR
GE 42-LM
GE 42-LR

Thread
M and R

Tightening
torque in Nm

M 14x1,5
R 1/4
M 16x1,5
R 3/8
M 18x1,5
R 1/2
M 22x1,5
R 1/2
M 26x1,5
R 3/4
M 33x2
R1
R 42x2
R 1 1/4
M 48x2
R 1 1/2

ca 39
ca 39
ca 59
ca 59
ca 69
ca 108
ca 108
ca 108
ca 128
ca 157
ca 216
ca 265
ca 353
ca 392
ca 491
ca 491

Type of
coupling
GE 10-SM
GE 10-SR
GE 12-SM
GE 12-SR
GE 14-SM
GE 14-SR
GE 16-SM
GE 16-SR
GE 20-SM
GE 20-SR
GE 25-SM
GE 25-SR
GE 30-SM
GE 30-SR

Thread
M and R
M 16x1,5
R 3/8
M 18x1,5
R 3/8
M 20x1,5
R 1/2
M 22x1,5
R 1/2
M 27x2
R 3/4
M 33x2
R1
M 42x2
R 1 1/4

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

4 (4)

ca 59
ca 69
ca 78
ca 69
ca 108
ca 128
ca 128
ca 128
ca 196
ca 206
ca 294
ca 314
ca 491
ca 491

Table 2.
Example: GE 10 - LM

Table 1.

Tiightening
torque in Nm

Sealing

The Original Manufacturer of HGGLUNDS Cranes

SERVICE

6.216.69 E rev.: d 2005-06-23

Rope Reeving Diagram for Cranes Type GP and HH


1-Part Rigging

Hoisting wire rope

The Original Manufacturer of HGGLUNDS Cranes

1 (4)

SERVICE

6.216.69 E rev.: d 2005-06-23

Rope Reeving Diagram for Cranes Type GP and HH


2-Parts Rigging

Hoisting wire rope

Locking plate
Lock washer
Screw

Spacer
Wire thimble

Note! The wire rope thimble should be safely secured.

2 (4)

The Original Manufacturer of HGGLUNDS Cranes

SERVICE

6.216.69 E rev.: d 2005-06-23

Rope Reeving Diagram for Cranes Type GP and HH


3-Parts Rigging

Hoisting wire rope

Spacer

Bolt

Nut

Split pin

Note! The wire rope thimble should be safely secured.

The Original Manufacturer of HGGLUNDS Cranes

3 (4)

SERVICE

6.216.69 E rev.: d 2005-06-23

Rope Reeving Diagram for Cranes Type GP and HH


4-Parts Rigging

Hoisting wire rope

Locking plate
Lock washer
Screw

Spacer
Wire thimble

Note! The wire rope thimble should be safely secured.

4 (4)

The Original Manufacturer of HGGLUNDS Cranes

SERVICE

6.222.1 E rev.: a 1998-04-17

Handling, Installation and Maintenance


of Steel Wire Ropes

The Original Manufacturer of HGGLUNDS Cranes

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 textile webbing sling.

Storing steel wire ropes


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)

The Original Manufacturer of HGGLUNDS Cranes

SERVICE

6.222.1 E rev.: a 1998-04-17

If outdoor storage cannot be avoided the ropes must


be covered in a way that moisture cannot create
corrosion problems. Although plastic foil protects
the ropes from rain, condensation from beneath
might not be able to escape and could damage the
ropes permanently. To avoid condensation problems, it is advisable to use breathable water-proof
fabric covers readily available from tarpaulin manufactures.

Unwinding steel wire ropes from the reel


An unreeling stand (turnable) should be used to
unwind a wire rope from its reel.
Another accepted unreeling method is to mount the
reel on a shaft supported by two jacks or a stand.

When storing a number of spare ropes, the following 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
or reel without torsions and without any outer damage. The same applies to reeving the ropes into
the system.

Rolling the wire rope along the floor, as is sometimes recommended in the relevant literature, does
not work very well in practice because the reel always 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 surface is clean; sand or grit that sticks to the lubricant
might damage the wires when the rope travels or
sheaves.

The Original Manufacturer of HGGLUNDS Cranes

3 (12)

SERVICE

6.222.1 E rev.: a 1998-04-17

Under no circumstances must the rope be pulled


off a coil while it is lying on the ground or looped
over the head of the reel, because this will inevitably induce one torsion per wrap into the rope.

If one end of the ropes has a fitting attached, as it


is mostly the case with deck cranes, there is no
other possibility than pulling the loose rope end
through the whole reeving system.
The most common rope fittings for deck cranes are
shown below.

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 finally 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
and form loops. When pulled taut these loops will
result in irreparable kinks.

The aluminum ferrule with mechanical splice.

The cast steel ferrule with mechanical splice.

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


wire rope varies from crane to crane. In any case a
procedure should be chosen that (under justifiable
expenditure) guarentees the least risk of torsions
and avoids damage to the rope by contact with parts
of the construction.

Below is shown an example of a typical deck crane,


where the rope must be spooled from the reel via
sheaves S1 through S9 onto the drum.

With some cranes it may be advisable to discard


the old rope first and to install the new one afterwards. With other cranes, particularly with bigger
ones, it might be better to pull in the new rope attached 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 necessary 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)

The Original Manufacturer of HGGLUNDS Cranes

SERVICE

6.222.1 E rev.: a 1998-04-17

Here, special attention must be paid to the hook


block. It must be secured in an upright position so
that the rope can be spooled without any fleet angles occuring between the rope and the blocks
sheaves.

Winding the steel wire rope from the reel


onto the drum
During the manufacturing process every steel wire
rope receives its preferred bending direction when
being drawn from the wire rope closer by means of
a capstan. When delivered to the customer the rope
is bent in that direction. Make certain that it bends
in the same direction when it is wound from the reel
onto the drum.

If the rope is wound at the bottom of the drum, it


should leave the reel at the buttom and vice versa:
i.e., always reel from top to top or from bottom to
bottom.
If this procedure is not strictly followed, the rope
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.

Installing the rope with the help of the old


one or by a thinner rope
If the new rope is pulled in by the old one or by a
thinner rope one must make sure that the connection between these ropes is absolutely safe. In addition it must be ensured that the thinner rope cannot rotate. Rotation-resistant steel wire ropes or
three-strand ibre ropes for instance, can be recommended for this purpose. When using conven-

tional wire ropes one must at least make sure that


they have the same direction of lay as rope to be
installed.
If the new rope is pulled in with help of the used
one, the two rope ends are often buttwelded together. A connection of that kind can transfer the
twist of the old rope, built up in the reeving system,
into the new rope. By that method of installation the
new rope may be extremely damaged.
There are even more reasons why that procedure
is highly problematic: It is true, that when using special electrodes the welded connection presents
acceptable results in a pull test with a straight rope;
but because of the great length of rigid connection
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 problems are caused by connecting wire ropes with
welded-on pad eyes or
chain links, which are
joined by either strands or
thin wire ropes.

This connection provides satisfactory


load capacity, it is flexible and prevents 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 during the installation procedure.
Another possibility is connecting the
rope ends with Chinese fingers. These
are tubes made out of braided
strands, which are pulled over the
rope ends and then secured at their
ends with tape or seizing wire. Under
load the Chinese fingers will contract
and hold the rope ends by friction.

The Original Manufacturer of HGGLUNDS Cranes

5 (12)

SERVICE

6.222.1 E rev.: a 1998-04-17

When installing a lang lay rope one must take care


that the Chinese finger cannot unwind from the rope
like the nut from a screw. It is recommended to wrap
a tape around the whole rope length to be held by
the Chinese finger to increase the friction.

Under no circumstances should one attempt to generate the tensioning load by jamming the rope, for
instance between two boards. Structural changes
would deform the rope beyond repair.

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 layers under load. This could seriously damage the
rope. The unwinding rope might even be clamped,
so that the direction of spooling could suddenly be
reversed during the course of unwinding. The result could be the abrupt lifting of the load that was
actually travelling downwards.
The tensioning load should range from 1% to 2% of
the minimum breaking load of the wire ropes. In
many cases it might suffice to wind the rope quite
normally in order to unwind it and then rewind it
with the help of an outer load.
In other cases, however, the procedure mentioned
above is not possible. In these cases the tensioning
load must already be applied when installing the
rope.

Attaching the rope termination to the fix


point
After the rope has been pulled through the reeving
system, the rope termination (e.g. the mechanical
splice with the aluminum ferrule) must be brought
up to the fix point. A pulling jack can be used to pull
the rope termination to the fix point, where it must
secured with a bolt.
Prior to fixing, if necessary, the rope termination
may be aligned with the fix point by using a steel
bar. The bar should be attached to the rope by
means of a short length of chain. Under no circumstances should the rope be gripped with a wrench,
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 braking disk attached to the reel.

6 (12)

The Original Manufacturer of HGGLUNDS Cranes

SERVICE

6.222.1 E rev.: a 1998-04-17

"Breaking-in" the steel wire rope


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
operating conditions. It is most unfortunate 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 working load of the system.

The rope and this wire end are now wrapped moving away from the location of the intended cut.

The rope is tightly wrapped for a distance of approx.


three rope diameters.

Both ends of the seizing wire are then pulled tight


and twisted together for a length of one rope diameter.

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 required for larger sizes.
The best method is to use a high speed disk cutter.
Unless the rope is being scrapped the use of flame
cutting equipment is not recommended.
Careless cutting can result in the balance of tension in the rope being destroyed. This is particularly important when cutting rotation resistant ropes
where the strands may have been deliberately nonpreformed as part of the manufacturing specification.
In every case, each side of the cut must be properly seized to prevent strand disturbance. Insulating tape cannot prevent strand movement, so annealed (iron) wire should always be used.
After marking the position of the cut the end of the
seizing wire is laid along the rope axis leaving sufficient length to secure both ends by twisting when
the seizing complete.

The twisted connection is then hammered into a


gusset between the strands. After preparing the
other side of the intended cut accordingly the rope
can now be cut.

Instead of using one long seizing it is also possible


to apply at least three seizing the size of one rope
diameter each on both sides of the intended cut.

The maintenance of steel wire ropes


Steel wire ropes must be serviced regularly, the kind
of maintenance depending on the lifting device, its
use and the selected rope. Regular maintenance
may considerably increase the service life of a steel
wire rope.

The Original Manufacturer of HGGLUNDS Cranes

7 (12)

SERVICE

6.222.1 E rev.: a 1998-04-17

Relubricating steel wire ropes


During production the rope receives intensive lubrication. This in-process treatment will provide the
rope with ample protection against corrosion and is
meant to reduce the friction between the elements
which make up the rope as well as the friction between rope and sheaves or drums. This lubrication,
however, only lasts for a limited time and should be
re-applied periodically.
German Standard DIN 15 020, e. g. specifies: "Steel
wire ropes must be relubricated at regular intervals,
depending on their use, particularly along the zones
subjected to bending. If for operational reasons
relubrication cannot be carried out, shorter service
life of the rope is to be expected and the inspection
intervals have to be arranged accordingly."
When choosing the relubricant, it must be ensured
that it is in accordance with the recommendations
of the rope manufacturer.

It is important with all different methods of


relubrication of steel wire ropes that they are carried out regularly right from the beginning of the
service life of the rope and not only after the first
damage has been ascertained.

Cleaning steel wire ropes


DIN 15 020 recommends: "From time to time very
dirty steel wire ropes should be cleaned externally".
This applies particularly to ropes operating in extremely abrasive conditions and to those that take
up chemicals.
Effective cleaning without proper tools is quite a
laborious job. For cleaning steel wire ropes the Canadian Rigging Manual recommends an appliance
with three rotating wire brushes and an air blast
drying system to follow. An American manufacturer
offers a "rope porcupine", a sleeve equipped with
brushes, which is drawn along the steel wire rope.

There are several techniques of lubricant application: The most common ones at present are painting or swabbing.

Removing broken wires

Quite often the lubricant is applied at a sheave,


sometimes a continuous drip method is used. If only
a little lubricant is required, pressure spray nozzles
can be applied.

If during an inspection ends of broken wires are


detected which might cross adjacent wires and
destroy them when running over sheaves, these
broken wire ends must be removed.

Maximum penetration of the lubricant into the gaps


of the rope, can only be quaranteed if high pressure lubrication is applied with the help of a pressure lubricator.

Under no circumstances should the broken wire


ends be pinched off with a pair of nippers. The best
method is to move the wire ends backwards and
forwards until they break deep in the valley between
two outer strands. With thicker wires a tool should
be moved backwards and forwards on the surface
of the rope, thus bending the wires until they break.

With this method the two halfs of a sleeve, which is


equipped with rubber sealings, are clamped round
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)

The Original Manufacturer of HGGLUNDS Cranes

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 damaged, 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, shifting 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 subjected 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.

The Original Manufacturer of HGGLUNDS Cranes

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 examples 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 torsional stress.

High shock loads have caused outer layer to split


open exposing steel wire rope core between strands
that have come apart.

10 (12)

The Original Manufacturer of HGGLUNDS Cranes

SERVICE

6.222.1 E rev.: a 1998-04-17

Some examples of wire rupture

Contraction rupture caused by excessive stress,


(e.g., if a slack line suddenly snaps taut under full
load).

Wear and identations of surface wires also promote


fatigue and lead to premature wire rupture.

Crown wires of outer strands may wear so thin that


the residual cross sectional area of steel in the rope
will not support the normal design load and contraction rupture may ensue.

Corrosion may cause wire ropes to break. As a


safety measure, inspect ropes regularly and carefully to prevent catastrophes; observe manufacturer's instructions

Rupture from fatigue will often occur when undersize sheaves are used. Vibrations and torsional
stress loads in the rope accelerate fatigue rupture.

The Original Manufacturer of HGGLUNDS Cranes

11 (12)

SERVICE

6.222.1 E rev.: a 1998-04-17

THIS PAGE IS INTENTIONALLY LEFT BLANK

12 (12)

The Original Manufacturer of HGGLUNDS Cranes

S E RV I C E I N F O R M AT I O N
625/1473 E rev.: b 2008-04-18

Indentation and Wear on Wire Sheaves


General
To ensure safe working conditions and long lifetime of
the wire rope it is important to inspect the condition of
the wire sheaves.

The wear, see Table 1, can certainly occur on every


spot where the wire rope is in contact with the wire
sheave, not only on places shown in Fig. 1.

Wear criterias

Indentation

When the wear on the wire sheave exceeds 3mm, it


will according to our experience decrease the lifetime
of the wire rope. The wear of the wire sheave will also
reduce the load capacity. Maximum wear is therefore
25% of the wire sheave thickness (t) with a limit to
maximum 3mm, see Fig. 1.

A new wire rope and wire sheave are in contact on


certain spots, see Fig. 2. After some time the
indentation will have the shape shown in Fig. 3. This
is considered as normal wear.

Fig. 1. Wear on wire sheave.

Fig. 2. Contact spots.

a
max
4
3
2.5
2
1.5

t
16
12
10
8
6

Table 1.

Fig. 3. Good contact between an old wire rope and the


wire sheave.

The Original Manufacturer of HGGLUNDS Cranes

1 (2)

S E RV I C E I N F O R M AT I O N
625/1473 E rev.: b 2008-04-18

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)

The Original Manufacturer of HGGLUNDS Cranes

SERVICE INFORMATION
625/1560 E rev.: e 2007-01-02

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 before 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 following:


1. Wear in hook, centre pin, steel structure and
threads.
2. Play in sheave bushes or bearings.
3. Spacer bolts and nuts.
4. Check 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 examens
the equipment. Contact MacGREGOR (SWE) AB,
Service Division.

Fig. 3. Lifting beam for 4-rope crane.

The Original Manufacturer of HGGLUNDS Cranes

1 (2)

SERVICE INFORMATION
625/1560 E rev.: e 2007-01-02

NO welding should be carried out unless prior


authority is obtained.

working hours, see also separate lubrication chart.

If the holes in the sideplates, eyes and swivels are


enlarged by more than 5%, the part should be

Limitation of use
1. Safe working load should never be exceeded.
2. Crane blocks should be used in vertical lift only.
3. Shock or side loading should not be applied, unless equipment is desigend for that purpose.
4. Load should always be in seat of hook or eye.

Fig. 4. Lifting eye.

replaced or maybe repaired. Contact MacGREGOR


(SWE) AB, Service Division, for instructions.
All repairs should be carried out by responsible
personnel, and great care should be taken in the
re-assembly of the equipment and retaining parts,
i. e., grub screws, pins, etc. Check and refit only
correct sizes and threads.
Important:
When replacing genuine parts an overload test of
the complete unit must be performed and new certificate must be issued.

Lubrication
As a general rule sheaves, shafts and swivels
should be greased through nipples every 100

2 (2)

The Original Manufacturer of HGGLUNDS Cranes

SERVICE INFORMATION
625/1618 E rev.: b 2007-01-02

Measuring Procedure for Wear in Slewing Bearings


for Crane Types GP and HH
General
The slewing bearing is an essential part of the crane
and must be well maintained. Over the years the
slewing bearing will have some wear, and to be able
to know if there is a need for changing the slewing
bearing it is needed to keep a record of the wear.
The initial measurements should be taken when
the crane is installed at yard or within 2 months
from crane installation.
If the wear measurement shows wear, grease
samples can be taken for analyze. See procedure
on page 3.

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.
Reference points
On some cranes there are two machined surfaces in
the front and rear of the crane bottom plate, see Fig.1.
These surfaces should be used when measuring the
wear of the slewing bearing. If no such surfaces are
provided two reference points must be marked on
the crane bottom plate, see Fig. 2, to be used as
reference point in future measuring.
The first time a measurement is to be taken four
reference points must be marked on the foundation
Machined surface/
reference point

or lower face of slewing bearing (non rotating part).


The reference points should be made on fore,
starboard, aft and port side of the foundation/slewing
bearing.
These reference points must be made in a way that
ensures that they will last the lifetime of the bearing.
The reference points shall always be used at any
future measuring.
Procedure
Two measurements shall be taken on four positions
of the slewing bearing, if possible, with the jib pointing:
- forward to the ship
- starboard
- aft
- port side
See Fig. 3 or 4, depending on crane design.
It is important that the same position are used for all
further measurements to be able to compare the
measurements.
For maximum allowed wear, see table on page 4.
Enclosed table, on page 5, can be used to record the
measurements.
WARNING!
Do not enter the crane foundation during crane
operation.
Moving crane house and machine parts may suddenly
cause bodily injury or death.

Machined surface/
reference point
Jib

Fig. 1. Machined surface on crane bottom plate.

Fig. 2. Marking of reference points.

The Original Manufacturer of HGGLUNDS Cranes

1 (6)

SERVICE INFORMATION
625/1618 E rev.: b 2007-01-02

Jib direction

Measurement B
(back of crane)

Jib at maximum
outreach

Jib direction
Measurement A
(front of crane)

Machined surface/
reference point on
crane bottom plate

Reference point on
slewing bearing

Sliding caliper

Fig. 3. Measuring wear on slewing bearing.

2 (6)

The Original Manufacturer of HGGLUNDS Cranes

Empty hook

SERVICE INFORMATION
625/1618 E rev.: b 2007-01-02

Jib direction

Measurement B
(back of crane)

Jib at maximum
outreach

Empty hook

Measurement A
(front of crane)

Machined surface/
reference point on
crane bottom plate

Micrometer screw

Reference point
on foundation

Fig. 4. Measuring wear on slewing bearing.

The Original Manufacturer of HGGLUNDS Cranes

3 (6)

SERVICE INFORMATION
625/1618 E rev.: b 2007-01-02

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

- One sample should be taken in the area under jib


and one sample 180 in opposite direction.
- Clean the outer or inner seal close to the next
grease nipple. When cleaning the area of the seal,
prevent the cleaner from contacting the seals or
from entering the raceway's system.
- Push new grease into the grease nipples / bearing
without rotation and collect the first used grease
which will come out at the seal.
Attention: Do not take fresh grease for analyzing!
The required quantity of grease for analyzing is
approx. 2 cm3.

* Allowed wear is the maximum difference between


initial measurement and actual measurement, see
table on page 5.
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 MacGREGOR (SWE) AB, Service
Division.

Procedure for grease sampling


Following information is necessary in order to give a
correct statement and allow further advice:
1. Used grease (manufacturer and type).
2. Lubrication intervals.
3. Running hours.
4. Information where the samples are taken.
The correct procedure for grease sampling is very
important.
Procedure
Proceed as follows:
- The grease sample can be taken either at the inner
or outer seal of the bearing.

4 (6)

The Original Manufacturer of HGGLUNDS Cranes

SERVICE INFORMATION
625/1618 E rev.: b 2007-01-02

Measuring of wear on slewing bearing

Fore

Vessel name:

Ps

Crane No./Mfg. No.:

Stb

Aft
Initial Measurement (accuracy 0.1 mm)

Date

Jib direction

A1 (front of crane)

Allowed wear (see


B1 (back of crane) table on page 4)

Fore

mm

mm

mm

Stb

mm

mm

mm

Aft

mm

mm

mm

Ps

mm

mm

mm

Measured wear

Actual measurement (accuracy 0.1 mm)


Date

Jib direction

A (front of crane)

B (back of crane)

A - A1

Fore

mm

mm

mm

mm

Stb

mm

mm

mm

mm

Aft

mm

mm

mm

mm

Ps

mm

mm

mm

mm

Measured wear

Actual measurement (accuracy 0.1 mm)


Date

Jib direction

A (front of crane)

B (back of crane)

A - A1

B1 - B

Fore

mm

mm

mm

mm

Stb

mm

mm

mm

mm

Aft

mm

mm

mm

mm

Ps

mm

mm

mm

mm

Measured wear

Actual measurement (accuracy 0.1 mm)


Date

B1 - B

Jib direction

A (front of crane)

B (back of crane)

A - A1

B1 - B

Fore

mm

mm

mm

mm

Stb

mm

mm

mm

mm

Aft

mm

mm

mm

mm

Ps

mm

mm

mm

mm

The Original Manufacturer of HGGLUNDS Cranes

5 (6)

SERVICE INFORMATION
625/1618 E rev.: b 2007-01-02

THIS PAGE IS INTENTIONALLY LEFT BLANK

6 (6)

The Original Manufacturer of HGGLUNDS Cranes

SERVICE

6.305.11 E rev.: -

1999-06-08

Electrical Equipment, General Maintenance


Introduction

Portable control boxes

General maintenance of the electric equipment of


the crane is important in order to prevent unexpected
breakdowns. The following general advice may be
useful. Relevant block diagrams and detailed circuit
diagrams are placed in section 9, SPARE PARTS.

Control panels and remote control boxes may be


subjected to abuse an abnormal wear, and should be
inspected after every use. The control boxes must
be stored in a compartment that is well protected
against 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


movements that are practicable. This will show if the
electric functions are satisfactory.
Inspect all electrical equipment cabinets, and
components. Any defective component must be
repaired or replaced without delay. A detailed
inspection and overhaul at two-year intervals is
recommended. Check that all screws and nuts are
securely tightened in the contactor cabinets, that all
switches and pushbuttons operate correctly, and that
cable connections are perfectly tight and all insulating
parts intact. Make sure that inspection door gaskets
seal perfectly.

- Clean contacts, insulating parts, cams, contact


rolls, and rotary potentiometers.
- Make sure that all cable connnections are clean
and securely tightened.
- Clean the control levers, and grease their sliding
surfaces.
- Check on the return springs and grease lightly so
that no grease transfers to the contacts.

Earth connection, hull


Verify that the protective earth connection of the
crane is made to the ships hull.
Clean contact surfaces, when required.
Earth connection, crane
Check crane system earth connections, and clean
contact surfaces as required.

The Original Manufacturer of HGGLUNDS Cranes

1 (2)

SERVICE

6.305.11 E rev.: -

THIS PAGE IS INTENTIONALLY LEFT BLANK

2 (2)

The Original Manufacturer of HGGLUNDS Cranes

1999-06-08

SERVICE

6.990.54 E rev.: - 2008-04-02

Emergency Lowering in Case of Complete Power Failure


Operation of Crane Using a Hand Pump (Optional)
Introduction
In the case of a power failure the hoisting, luffing and
slewing circuits of a deck crane may still be operated to
a limited extent by releasing their respective brakes,
while observing the greatest care.
The release of the brakes must be done by means of
a separate hydraulic pressure source with variable
pressure.
This instruction describes an emergency brake
release of crane by using a hand pump.

CAUTION!
- This work has to be done by skilled persons with
great caution.
- Only one function to be activated at the time.
- Verify that no persons are within the working area
of the crane.
- Pump with the handle until the pressure reaches
30-33 bar (3,0-3,3 MPa) on the pressure gauge.
- Release the safety valve button. Now the pressure
should decrease rapidly.
14

Before taking pump into operation

5
1

Before using the pump for the first time the plug must
be removed and the air filter put in place, see Fig. 2.
During transportation the air filter must be replaced with
the plug to avoid oil leakage and filter contamination.
Check function of pump
- Press down the safety valve button and pump
with the handle until pressure reaches 30-33 bar
(3,0-3,3 MPa) on the pressure gauge.
- Stop pumping. Now the pressure should decrease
slowly.

2
3
16

33 bar

15

17

1.
2.
3.
5.
9.

Pump
Pressure relief valve
Safety valve
Hydraulic hose
Quick connection

14.
15.
16.
17.

Pressure gauge
Oil filling and air filter
Valve block
Tank

Fig. 1. Hand pump.


Oil cap/filling, with air filter

Pressure relief valve

Safety valve button

Handle
Pressure gauge

Plug, used for transport


Quick connection

Fig. 2. Hand pump.

The Original Manufacturer of HGGLUNDS Cranes

1 (6)

SERVICE

6.990.54 E rev.: - 2008-04-02

Hoisting circuit, Figs. 5, 6 and 7


Hoisting machinery with fixed or variable high speed
motor and multiple disc brake.
Preparation
- Open ball valve 105 on the winch, see Figs. 3
and 4.
- Connect hand pump to quick coupling 108, see
Fig. 5.
- Set handle 1A, on main valve 002, in lowering
position, 19.5, see Figs. 5, 6 and 7.

105

Fig. 4. Winch with variable motor.


Operation
- To release the brake, press and hold the safety
valve button on the hand pump unit, see Figs. 1
and 2, and start pumping oil into the multiple disc
brake until it begins to open.
- When the winch starts to move the greatest care
must be observed so that the speed is not too high.
If the speed increases too much the emergency
stop should be released immediately so that
the brake is closed.

19.5

After operation
- When the operation has been completed, close
the ball valve 105.
- Remove hand pump.

1A

Quick coupling 108

105
002

Hand pump

Fig. 3. Winch with fixed motor.

2 (6)

Fig. 5. Hand pump connected to main control valve.

The Original Manufacturer of HGGLUNDS Cranes

SERVICE

6.990.54 E rev.: - 2008-04-02

Example:
A complete hydraulic circuit diagram relating
specifically to your crane will be found in section
9.4 in the parts manual.

Fig. 6. Part of hoisting circuit with fixed hydraulic motor.

The Original Manufacturer of HGGLUNDS Cranes

3 (6)

SERVICE

6.990.54 E rev.: - 2008-04-02

Example:
A complete hydraulic circuit diagram relating
specifically to your crane will be found in section
9.4 in the parts manual.

Fig. 7. Part of hoisting circuit with variable hydraulic motor.

4 (6)

The Original Manufacturer of HGGLUNDS Cranes

SERVICE

6.990.54 E rev.: - 2008-04-02

Luffing circuit, Fig. 10


Slew the crane to a suitable position. Lowering of
the jib can be done as follows:
- Remove protective cap.
- Note measure A, see Fig. 9.
- Loosen the locking nut, then carefully loosen the
set screw on valve 204, see Figs. 9 and 10, until
the jib begins to lower slowly.
Note! After lowering of the jib tighten the set screw
to its position, measure A, and lock with the locking
nut.
Fig. 10. Part of luffing circuit.
Example:
A complete hydraulic circuit diagram relating
specifically to your crane will be found in section
9.4 in the parts manual.

Cap
Locking
Set
screw
nut

Fig. 9. Valve 204.

The Original Manufacturer of HGGLUNDS Cranes

5 (6)

SERVICE

6.990.54 E rev.: - 2008-04-02

Slewing circuit, Fig. 12


307

Slewing machinery with high speed motor and multiple


disc brake.
Preparation
- Close the brake line to tank by closing the shut-off
valve 307, Figs. 11 and 12.
- Open valve 309.
- Connect the hand pump to the quick coupling 308,
Figs. 11 and 12.

309

Quick
coupling 308

Operation
- Release the brake by pumping oil from the hand
pump into the disc brake so that slewing machinery
is released.
- The crane may now be slewed to the desired
position by means of another crane.

Hand pump

After operation
- Close valve 309.
Fig. 11. Hand pump connected to the slewing
machinery.

Example:
A complete hydraulic circuit diagram relating
specifically to your crane will be found in section
9.4 in the parts manual.

Fig. 12. Part of slewing circuit.

6 (6)

The Original Manufacturer of HGGLUNDS Cranes

Spare Parts Manual

9.0

How to order
spare parts

9.1

Machinery

9.2

Pump unit
Oil cooler

9.3

Mechanical
equipment

9.4

Hydraulic
components

9.5

Electric
components

2007-09-14

9.6

Address:
MacGREGOR (SWE) AB
SE-891 85 RNSKLDSVIK, Sweden
Telephone: 46 - 660 - 29 40 00
Telefax:
46 - 660 - 139 77
(Spare Parts, Technical Services &
(Technical Documentation Services)
www.macgregor-group.com/cranes

The Original Manufacturer of HGGLUNDS Cranes

9.7

Extra equipment

PARTS MANUAL

WINCH MOUNTING

Date

Group

Fig.

Page

2006-01-23

9.1

625-1440.102

1 (2)

PARTS MANUAL

Date

Group

Fig.

2006-01-23

9.1

625-1440.102

WINCH MOUNTING
Item

Qty

Article no

Description

Supplementary data

000

289 3951-801

WINCH MOUNTING

001

289 3815-801

. WINCH

SEE FIG. 625-1450.091

002

188 1769-801

. HYDRAULIC MOTOR

see fig. 625-2205.016

003

489 4472-001

. WASHER

004

2151 2052-178

. WASHER

TBRB 13 x 24 FZB

005

2121 2030-789

. SCREW

M6S 30 x 160 -10.9

006

2121 2034-540

. SCREW

M6S 12 x 40 -A4-70

007

2126 2038-130

. NUT

M6M 30 -10

Page
2 (2)

PARTS MANUAL

WINCH

Date

Group

Fig.

Page

2006-01-23

9.1

625-1450.091

1 (2)

PARTS MANUAL

Date

Group

Fig.

2006-01-23

9.1

625-1450.091

WINCH
Item

Qty

000

Article no

289 3815-801

Description

Supplementary data

WINCH

5 tonnes

Page
2 (2)

PARTS MANUAL

HYDRAULIC MOTOR

Date

Group

Fig.

Page

1999-06-28

9.1

625-2205.016

1 (2)

PARTS MANUAL

Date

Group

Fig.

Page

1999-06-28

9.1

625-2205.016

2 (2)

HYDRAULIC MOTOR
Item

Qty

Article no

Description

001

188 1769-801

HYDRAULIC MOTOR

002

489 6118-801

. GASKET SET

Supplementary data

PARTS MANUAL

SLEWING GEAR

Date

Group

Fig.

Page

2005-11-14

9.1

625-3255.022

1 (2)

PARTS MANUAL

Date

Group

Fig.

2005-11-14

9.1

625-3255.022

SLEWING GEAR
Item

Qty

001

Article no

289 3822-801

Description

SLEWING GEAR

Supplementary data

Page
2 (2)

PARTS MANUAL

HYDRAULIC MOTOR

Date

Group

Fig.

Page

2000-03-07

9.1

625-2205.017

1 (2)

PARTS MANUAL

Date

Group

Fig.

Page

2000-03-07

9.1

625-2205.017

2 (2)

HYDRAULIC MOTOR
Item

Qty

Article no

Description

001

188 1227-801

HYDRAULIC MOTOR

002

489 6120-801

. GASKET SET

Supplementary data

PARTS MANUAL

PUMP DRIVE

Date

Group

Fig.

Page

2005-12-19

9.2

625-4935.067A

1 (2)

PARTS MANUAL

Date

Group

Fig.

Page

2005-12-19

9.2

625-4935.067A

2 (2)

PUMP DRIVE
Item

Qty

Article no

Description

Supplementary data

000

289 0543-801

PUMP DRIVE

001

188 1097-801

. PUMP

002

288 1629-801

. ELECTRIC MOTOR

003

388 6362-801

. CARDAN SHAFT

004

388 7217-001

. PUMP BRACKET

005

489 4369-801

. FLANGE BOLT FITTINGS

006

2152 2115-555

. O-RING

007

2152 2115-526

. O-RING

008

2183 2022-126

. LIFTING EYE BOLT

M20; DIN 580

010

12

2121 2032-540

. SCREW

M6S 12 x 40 -8.8 FZB; DIN 933

011

12

2151 2022-178

. WASHER

BRB 13 x 24 FZB

012

2121 2032-544

. SCREW

M6S 12 x 60 -8.8 FZB

013

2126 2636-122

. NUT

NYLOC -M6M 12 -8 FZB

014

2151 2022-178

. WASHER

BRB 13 x 24 FZB

PARTS MANUAL

PUMP

Date

Group

Fig.

Page

1999-06-09

9.2

625-4945.012

1 (2)

PARTS MANUAL

Date

Group

Fig.

Page

1999-06-09

9.2

625-4945.012

2 (2)

PUMP
Item

Qty

Article no

Description

001

188 1097-801

PUMP

002

489 6144-801

. GASKET SET

Supplementary data

PARTS MANUAL

CYLINDER ASSEMBLY

Date

Group

Fig.

Page

2004-11-17

9.3

625-5882.037

1 (2)

PARTS MANUAL

Date

Group

Fig.

2004-11-17

9.3

625-5882.037

CYLINDER ASSEMBLY
Item

Qty

Article no

Description

Supplementary data

000

289 4027-801

CYLINDER ASSEMBLY

002

388 7100-001

. SHAFT

003

489 4345-003

. LOCKING PLATE

004

489 4346-003

. LOCKING PLATE

WELDED

005

2121 2034-624

. SCREW

M6S 16 x 30 -A4-80

006

2151 2027-185

. WASHER

RB 17 x 30 -A4-80

007

2545 2110-001

. GREASE NIPPLE

G 1/4 A2-50

Page
2 (2)

PARTS MANUAL

JIB TOP

Date

Group

Fig.

Page

2004-08-03

9.3

625-6244.001B

1 (2)

PARTS MANUAL

Date

Group

Fig.

Page

2004-08-03

9.3

625-6244.001B

2 (2)

JIB TOP
Item

Qty

Article no

Description

Supplementary data

000

288 0136-801

JIB TOP

001

388 7440-001

. SHAFT

002

388 7441-001

. SHAFT

003

388 7278-001

. CLIMB PROTECTION

004

489 4488-801

. WIRE SHEAVE

005

489 4345-002

. LOCKING PLATE

006

489 4345-001

. LOCKING PLATE

007

489 4465-008

. SPACER

008

2545 2110-001

. GREASE NIPPLE

G 1/4 A2-50

010

2114 2014-201

. SPLIT PIN

SP 4 x 40 A4

011

2121 2034-491

. SCREW

M6S 10 x 20 -A4-80

012

2121 2034-532

. SCREW

M6S 12 x 20 -A2 -70

013

2154 2233-178

. LOCK WASHER

13 RF

014

2154 2233-173

. LOCK WASHER

10.5 BR = 20 RF

015

15

489 4473-002

. WASHER

PARTS MANUAL

JIB BEARING ASSEMBLY

Date

Group

Fig.

Page

2004-06-04

9.3

625-6253A

1 (2)

PARTS MANUAL

Date

Group

Fig.

Page

2004-06-04

9.3

625-6253A

2 (2)

JIB BEARING ASSEMBLY


Item

Qty

Article no

Description

Supplementary data

000

287 9974-801

JIB BEARING ASSEMBLY

001

388 7099-001

. SHAFT JIB BEARING

002

489 4371-001

. FLANGE, BEARING

003

489 4345-004

. LOCKING PLATE

004

2151 2027-192

. WASHER

RB 21 x 37 -A4

005

2121 2034-672

. SCREW

M6S 20 x 40 -A4-80

006

489 4453-001

. BOLT

007

2545 2110-001

. GREASE NIPPLE

G 1/4 A2-50

PARTS MANUAL

HOOK BLOCK

Date

Group

Fig.

Page

1999-05-27

9.3

625-7013.005D

1 (2)

PARTS MANUAL

Date

Group

Fig.

Page

1999-05-27

9.3

625-7013.005D

2 (2)

HOOK BLOCK
Item

Qty

000

001

Article no

Description

Supplementary data

388 7531-801

HOOK BLOCK

SWL 5 tonnes

875 12401-005

. SHEAVE, COMPLETE

Incl. bearing and lock rings.

002

875 12054-006

.. BEARING

003

875 12062-004

.. LOCK RING

004

875 12009-001

.. SPACER

005

875 12404-003

. SHAFT, COMPLETE

Incl. retainer, screw, nipple.

006

2545 2011-025

.. GREASE NIPPLE

M10 x 1; DIN 71412

007

875 12406-004

. SPACER, COMPLETE

Incl. spacer tube, screw, nut.

008

875 12409-004

. CABLE LEADER, COMPLETE

Incl. screws, nuts.

009

875 12073-002

. SHACKLE

010

875 12001-004

. HOOK, COMPLETE

PARTS MANUAL

DIRECTION VALVE

Date

Group

Fig.

Page

1998-09-29

9.4

625-7322.011

1 (2)

PARTS MANUAL

Date

Group

Fig.

1998-09-29

9.4

625-7322.011

DIRECTION VALVE
Item

Qty

Article no

Description

Supplementary data

000

188 1338-801

DIRECTION VALVE

001

489 4422-801

. GASKET SET

002

. MECHANICAL ACTIVATION PVM

003

. END PLATE PVSI

004

. COVER FOR HYDR. ACTIVATION PVH

005

. BASIC MODULE PVB

SLEWING

006

. BASIC MODULE PVB

LUFFING

007

. BASIC MODULE PVB

HOISTING

008

. PUMP SIDE MODULE PVP

Page
2 (2)

PARTS MANUAL

BALANCE VALVE

Date

Group

Fig.

Page

1997-12-04

9.4

625-7330.001

1 (2)

PARTS MANUAL

Date

Group

Fig.

Page

1997-12-04

9.4

625-7330.001

2 (2)

BALANCE VALVE
Item

Qty

Article no

Description

001

388 6376-801

BALANCE VALVE

002

489 4539-801

. GASKET SET

Supplementary data

PARTS MANUAL

BALANCE VALVE

Date

Group

Fig.

Page

2004-03-03

9.4

625-7330.006A

1 (2)

PARTS MANUAL

Date

Group

Fig.

2004-03-03

9.4

625-7330.006A

BALANCE VALVE
Item

Qty

Article no

Description

001

289 0839-801

BALANCE VALVE

002

489 5703-801

. GASKET SET

Supplementary data

Page
2 (2)

PARTS MANUAL

MOTOR VALVE

Date

Group

Fig.

Page

1995-07-06

9.4

625-7331

1 (2)

PARTS MANUAL

Date

Group

Fig.

Page

1995-07-06

9.4

625-7331

2 (2)

MOTOR VALVE
Item

Qty

Article no

Description

000

388 6358-801

MOTOR VALVE

001

489 4437-801

. GASKET SET

Supplementary data

PARTS MANUAL

LIMIT VALVE

Date

Group

Fig.

Page

1995-07-06

9.4

625-7334

1 (2)

PARTS MANUAL

Date

Group

Fig.

Page

1995-07-06

9.4

625-7334

2 (2)

LIMIT VALVE
Item

Qty

Article no

Description

000

388 6361-801

LIMIT VALVE

001

489 4439-801

. GASKET SET

Supplementary data

P
AR
TS MANU
AL
PAR
ARTS
MANUAL

FILTER

Date

Group

Fig.

Page

1995-07-06

9.4

625-7335

1 (2)

P
AR
TS MANU
AL
PAR
ARTS
MANUAL

Date

Group

Fig.

Page

1995-07-06

9.4

625-7335

2 (2)

FILTER
Item

Qty

Article no

Description

000

287 9463-801

FILTER

001

489 4436-801

. FILTER ELEMENT

Supplementary data

PARTS MANUAL

BALL VALVE

Date

Group

Fig.

Page

1999-09-08

9.4

625-7620.004

1 (2)

PARTS MANUAL

Date

Group

Fig.

1999-09-08

9.4

625-7620.004

BALL VALVE
Item

Qty

Article no

Description

Supplementary data

000

389 4128-801

BALL VALVE

001

389 3199-001

. BRACKET

002

389 3201-801

. HANDLE

003

389 3352-801

. BALL VALVE

004

389 3369-801

. BALL VALVE BRACKET

005

489 6086-801

. BRACKET

006

489 6127-001

. TENSION SPRING

007

2121 2550-325

. SCREW

MC6S 5 x 10 A4-80

008

2121 2550-341

. SCREW

MC6S 5 x 50 A4-80

009

2126 2634-114

. NUT

M6M 5 -A4 -80

010

2151 2027-146

. WASHER

RB 5.3 x 10 -A4

Page
2 (2)

PARTS MANUAL

Date

Group

Fig.

Page

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

PARTS MANUAL

Date

Group

Fig.

Page

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 material.
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.

PARTS MANUAL

HYDRAULIC CYLINDER

Date

Group

Fig.

Page

2004-05-11

9.4

625-7990.044

1 (2)

PARTS MANUAL

Date

Group

Fig.

Page

2004-05-11

9.4

625-7990.044

2 (2)

HYDRAULIC CYLINDER
Item

Qty

Article no

Description

Supplementary data

000

289 3178-801

HYDRAULIC CYLINDER

180 / 125

001

875 16403-002

. GASKET SET

Includes item 11-25.

011

.. PISTON SEAL

012

.. O-RING

013

.. BEARING RING

014

.. O-RING

015

.. SUPPORT RING

016

.. ROD SEAL

019

.. ROD WIPER

025

.. O-RING

108

875 16401-002

. BEARING

109

2545 2110-003

. GREASE NIPPLE

A-M 10 x 1 -A2-50; DIN 71412

110

2122 2519-445

. SCREW

MSK6SS 8 x 10 -A4; DIN 916

120

2121 2550-374

. SCREW

MC6S 6 x 30 -A4-80

121

2522 2105-014

. PLUG WITH SEAL

G 1/4; DIN 908

122

2545 2112-003

. GREASE NIPPLE

C-M 10 x 1 -A2-50; DIN 71412

(approx. 90)

(approx. 170)

(approx. 125)

PARTS MANUAL

EL. CENTRAL STARTER

Date

Group

Fig.

Page

2007-11-09

9.5

625-8630.050A

1 (2)

PARTS MANUAL

Date

Group

Fig.

Page

2007-11-09

9.5

625-8630.050A

2 (2)

EL. CENTRAL STARTER


Item

Qty

Article no

Description

Supplementary data

000

324 1150-801

EL. CENTRAL STARTER

001

5829 4196-101

. EL. CABINET

002

324 1165-801

. TRANSFORMER

003

5354 4273-065

. CONTACTOR

004

5627 4216-054

. OVERLOAD RELAY

005

5381 4227-080

. LOAD SWITCH

006

4762 4105-075

. CURRENT TRANSFORMER

007

5347 4262-203

. CIRCUIT BREAKER

008

5692 4740-221

. HOUR METER

009

5697 4337-075

. AMMETER

010

5298 2071-221

. PILOT LIGHT

GREEN

011

5298 2071-220

. PILOT LIGHT

WHITE

012

5298 2071-222

. PILOT LIGHT

YELLOW

014

5347 4263-203

. CIRCUIT BREAKER

015

5372 2210-002

. PUSH BUTTON

RED

016

5372 2210-001

. PUSH BUTTON

GREEN

022

2647 4160-040

. EARTH CLAMP

023

2647 4160-350

. EARTH CLAMP

027

20

2663 4382-025

. TERMINAL BLOCK

029

2631 4123-252

. BRIDGE CONNECTOR

034

5354 4137-510

. AUXILIARY CONTACT BLOCK

035

5354 4137-501

. AUXILIARY CONTACT BLOCK

037

5381 4227-001

. HANDLE

038

5381 4227-002

. SHAFT

061

424 0494-801

. SIGN

064

2183 2022-122

. LIFTING EYE BOLT

PARTS MANUAL

Date

Group

Fig.

Page

2007-06-13

9.7

624-2494B

1 (2)

HAND PUMP

Oil

150

30

10
11

560

500

20

130

570

Separate part:
For new motor valves

189 3090-801
624-2494 /B

90

140

PARTS MANUAL

Date

Group

Fig.

Page

2007-06-13

9.7

624-2494B

2 (2)

HAND PUMP
Item

Qty

Article no

Description

Supplementary data

000

189 3090-801

HAND PUMP

010

875 29031-011

. PUMP

011

875 29031-012

. HANDLE

020

875 29031-006

. PRESSURE RELIEF VALVE

030

875 29031-015

. SAFETY VALVE, COMPLETE

090

2522 2132-108

. PLUG

NPTF 1/16"

130

2522 2105-012

. PLUG WITH SEAL

G 1/2"

140

875 29031-005

. MANOMETER

60 bar

150

875 29031-013

. OIL CAP WITH AIR FILTER

G 1/2"

500

875 29031-017

. HYDRAULIC HOSE WITH COUPLINGS

3/8" L = 3000

560

2529 2458-111

. QUICK COUPLING

G 3/8"

D = 45 cc

Setting 33 bar, seal-locked