Instruction Manual GLB3026!2!2426gr Crane1-4

INSTRUCTION MANUAL Project No.
Page
Dept. C7250 Date: 2009-01-16 2/07103.01HOC 1(6)
TABLE OF CONTENTS
No. of manuals 6 pcs
Certificate for
crane issued by: DNV
Certificate for
foundation issued by: DNV
IMO No. L9483188
Name of ship
Newbuilding No. S001
Shipyard Hyundai-Vinashin
Owners E.R. Sciffahrt
Project No. 2/07103.01HOC
Mfg. No. Crane 1 62508699; Crane 2 62508700; Crane 3 62508701, Crane 4 62508702
Type of crane GLB3026-2/2426gr
Order specification 490 6373-801-804/D
Mechanical spec. 490 6561-801-804 /-
Hydraulic spec. 490 6563-801-804 /C
Electrical spec. 490 6562-801-804 /B
Slewing spec. 490 6432-801 /A
SAFETY DOCUMENTS
Document names written with bold letters are documents with safety aspects.
INSTRUCTION NO. REV NAME OF INSTRUCTION
GENERAL 1 1.000.4 E b SAFETY INSTRUCTIONS

1.005 E e PREFACE
1.009 E a GENERAL INSTRUCTIONS, CLEANLINESS IN HYDRAULIC SYSTEMS
1.102 E c CONVERSION FACTORS
1.518.3 ED d HYDRAULIC AND ELECTRIC SYMBOLS
TECHN. DESCRIP. 2 2/07103.01HOC - TECHNICAL DATA

2.007.91 E - TECHNICAL DESCRIPTION
FUNCTION 3 3.110.96 E a HYDRAULIC FUNCTION

3.131.29 E - STARTING AND STOPPING, ELECTRIC SAFETY FUNCTIONS, SINGLE CRANES
3.142.35 E - CRANE CONTROL SYSTEM CC3000, SINGLE CRANE WITH ONE OUTREACH
3.155.3 E - THERMOSTATIC CONTROLLED VENTILATION FAN
OPERATION 4 PM40 1863-E00 b CREW CHECK LIST

PM40 5500-E00 b OPERATING INSTRUCTION
PM40 6462-E00 - OPERATING INSTRUCTION
PM40 6879-E00 - CONTROLS AND INDICATORS
PM41 0001-E - EMERGENCY ESCAPE INSTRUCTIONS
PM41 0014-E00 - EMERGENCY ESCAPE INSTRUCTIONS, ROPE LADDER/FIXED LADDERS
4.620.26 E a PARKING THE CRANE, SEA STOWING, GENERAL INSTRUCTION
4.630 E - HANDLING HATCHES BY DECK CRANE
MAINTENANCE 5 5.005.55 E c MAINTENANCE CHART

5.018 E b INSPECTION OF STRESSED COMPONENTS AND STRUCTURES
The Original Manufacturer of HÄGGLUNDS Cranes

INSTRUCTION MANUAL Project No. Page
Dept. C7250 Date: 2009-01-16 2/07103.01HOC 2(6)
TABLE OF CONTENTS
MAINTENANCE 5 PM51 1709-E00 b LUBRICATING CHART, CRANE

5.150.4 E - LUBRICATING AND MAINTENANCE, CRANES TYPE GLB
5.301.13 E - FILTERS
5.315 E a SAMPLING OF OIL TO VERIFY THE CLEANLINESS IN HYDRAULIC SYSTEM
5.302.24 E - HYDRAULIC OIL TANK
5.421.40 E d LUBRICANTS FOR DECK MACHINERY
SERVICE 6
6.0 6.000 E c HOW TO ORDER SPARE PARTS

6.000.1 E c STATEMENT REGARDING DELIVERY OF SPARE PARTS TO SWIVELS, LIFTING B
6.000.2 E c RETURN FORM
6.004.1 E ba MacGREGOR GLOBAL SERVICES
6.005.7 E - INTRODUCTION
6.1 6.100 E b MEASURES BEFORE STARTING, DURING AND AFTER COMPLETED SERVICE/M
6.106.4 E - TROUBLE-SHOOTING CHART, OVERHEATING
6.117 E b TROUBLE SHOOTING, PUMPS
6.120.15 E d SLEWING GEARSET
6.120.64 E m HYDRAULIC MOTORS, HOISTING, LUFFING AND SLEWING CIRCUITS
6.120.107 E - WINCHES, HOISTING/LUFFING
6.121.3 E a TROUBLE-SHOOTING CHART, HYDRAULIC HIGH SPEED MOTORS
6.127.50 E a HIGH PRESSURE PUMPS
6.132.18 E - REPLACEMENT OF FEED PUMP, CRANE TYPE GLB
6.142.5 E a RECOMMENDATION FOR INSPECTION AND REPLACEMENT OF HYDRAULIC HO
6.189 E f HYDRAULIC PISTON ACCUMULATORS
6.2 6.209.15 E - INSPECTION OF CLIMB PROTECTION, JIB AND CRANE HOUSE TOP
6.214 E i TIGHTENING TORQUES STUDS/SCREWS AND BOLTS
6.215.21 E b SERVICE DOOR (OPENING AND CLOSING), SERVICE AND LUBRICATION OF DO
6.216.82 E b ROPE REEVING DIAGRAM FOR CRANES TYPE GLB-2
6.222.1 E a HANDLING, INSTALLATION AND MAINTENANCE OF STEEL WIRE ROPES
6.223.11 E a REPLACEMENT OF WIRES, ONE OR TWO FALL RIGGING
625/1473 E b INDENTATION AND WEAR ON WIRE SHEAVES
625/1560 E e LIFTING BLOCK/BEAM
625/1579 E g MEASURING PROCEDURE FOR WEAR IN SLEWING BEARINGS FOR ROPE LUFF
6.3 6.303.48 E a ABSOLUTE ENCODER CALIBRATION, CC3000

6.303.49 E a TROUBLESHOOTING, CRANE CONTROL SYSTEM CC3000
424 0738 - SIGNAL OVERVIEW, CRANE CONTROL SYSTEM CC3000
424 0739 - ERROR MESSAGES, SINGLE AND TWIN CRANES, CRANE CONTROL SYSTEM C
6.305.16 E - ELECTRICAL EQUIPMENT, GENERAL MAINTENANCE
6.307.14 E - SLIP-RING UNIT
6.311.12 E - OIL LEVEL FLOAT SWITCH AND OVERHEATING PROTECTOR
6.320.367 E a LIMIT SWITCHES IN HOISTING AND LUFFING WINCH SYSTEMS, CC3000
6.321.13 E a SLACK WIRE SAFETY SWITCH HOISTING AND LUFFING WINCHES
6.990.56 E - EMERGENCY LOWERING IN CASE OF COMPLETE POWER FAILURE, OPERA
EXTRA EQUIPMENT 7 7.075.8 E a MacHEAVYVISOR, RELEASE 3.0

7.076.2 E b USER MANUAL COMPUTER, CC PILOT XS
7.082.1 E - INSTALLATION OF MAINTENANCE PLATFORM ON FOUNDATION, (CUSTOMER D

INSTRUCTION MANUAL Project No. Page
Dept. C7250 Date: 2009-01-16 2/07103.01HOC 3(6)
TABLE OF CONTENTS
APPENDICES 8
SPARE PARTS 9 SEE SEPARATE TABLE OF CONTENTS

PARTS MANUAL Project No. Page
Dept. C7250 Date: 2009-01-16 2/07103.01HOC 4(6)
TABLE OF CONTENTS
GROUP DESCRIPTION PART NUMBER FIG
9.0 HOW TO ORDER SPARE PARTS c 6.000 E
9.1 HOISTING WINCH 189 2796-801 E/ 625-1440.047

HOISTING WINCH 189 2255-801 B/ 625-1450.055A
PRESSURE ROLLER, COMPLETE 875 13030-006 -/ 625-1451.010
HYDRAULIC MOTOR 189 2418-801 A/ 625-2205.021
LUFFING WINCH, C 189 1625-801 A/ 625-1440.046
LUFFING WINCH 189 1622-801 B/ 625-1450.056A
HYDRAULIC MOTOR 188 1221-801 B/ 625-2205.009A
WINCH MOUNTING SET 289 1944-801 -/ 625-2250.008
SLEWING GEAR ASSEMBLY SET 391 0246-801 B/ 625-3254.023B
SLEWING GEAR ASSEMBLY 391 0279-801 A/ 625-3254.022A
SLEWING GEAR 289 1853-801 A/ 625-3255.010
HYDRAULIC MOTOR 188 1223-801 B/ 625-2205.010
9.2 PUMP UNIT 189 5104-801 -/- 625-4935.160

MOUNTING PRESSURE SENSOR 490 3738-801 C/ 625-4936.001
GEAR BOX 390 6453-801 B/ 625-4940.027B
HYDRAULIC PUMP 289 1460-801 D/ 625-4945.023A
HYDRAULIC PUMP 289 1461-801 C/ 625-4945.024A
VANE PUMP 390 2422-801 G/ 625-4945.037
SERVO VALVE 390 2840-801 B/ 625-4948.001
DISTANCE PIECE 390 7952-801 -/ 625-4963.012
DISTANCE PIECE 390 7953-801 -/ 625-4963.013
OIL COOLER 287 8763-801 K/ 625-5738G
OIL COOLER ASSEMBLY SET 391 0300-801 -/ 625-5740.022
OIL COOLER ASSEMBLY 391 0283-801 -/ 625-5740.024
9.3 OIL TANK ASSEMBLY 189 3871-801 -/ 625-5865.046

CRANE HOUSE ASSEMBLY 189 7593-801 -/ 625-6102.473
SLEWING SPECIFICATION 490 6432-801 A/ 625-6122.029
COVER MOUNTING 390 3274-801 -/ 625-6169.005
COVER ASSEMBLY 390 3282-801 -/ 625-6169.006
JIB BEARING MOUNTING 390 6852-801 -/ 625-6170.045A
JIB BEARING HOUSING 390 6853-801 -/ 625-6170.046
JIB TOP MOUNTING 289 2559-801 -/ 625-6244.033
LIMIT SWITCHES BOX 289 5449-801 -/ 625-6245.643
LIMIT SWITCHES BOX 289 5323-801 -/ 625-6245.635A
LIMIT SWITCHES BOX, MOUNT. 489 6415-801 A/ 625-6248.001A
SLACK WIRE DEVICE 289 3396-801 -/ 625-6250.023
CRANE JIB, YARD MOUNTING 489 5409-801 B/ 625-6275.004C
MOUNTING WIRE LOCK JIB TOP 390 3374-801 -/ 625-6404.001
CRANE JIB MOUNTING 289 2558-801 A/ 625-6408.074
CRANE TOP MOUNTING 289 2555-801 A/ 625-6459.029A
PROTECTIVE PLATE MOUNT. 390 7581-801 -/ 625-6459.051
INCLINOMETER, C 388 0176-801 B/B 625-6509A
CAB INSTALLATION 289 5447-801 -/ 625-6540.024
CAB ASSEMBLY 189 5721-801 A/A 625-6545.060
EMERGENCY DOOR ASSY 390 4053-801 -/ 625-6546.001

Dept. C7250 Date: 2009-01-16 2/07103.01HOC 5(6)
TABLE OF CONTENTS
9.3 CAB DOOR ASSEMBLY 390 8573-801 -/ 625-6546.008

CAB CUPOLA ASSEMBLY 289 4557-801 -/ 625-6560.009
WINDSCREEN CLEANER 387 6227-802 F/F 625-6561.001C
VENTILATION FAN ASSEMBLY SET 289 4601-801 -/ 625-6625.022
VENTILATION FAN 388 9464-801 -/ 625-6625.015
LIFTING BLOCK 289 1943-801 A/ 625-7013.075A
JIB WELDING 189 7850-801 -/ 189 7850
SLEWING BEARING 289 5663-801 -/ 289 5663
SLEWING BEARING MOUNTING 391 0032-801 A/ 391 0032
SLEWING BEARING YARD MOUNTING 391 0033-801 A/ 391 0033
LOAD WIRE ROPE;SEE TECHNICAL DATA 391 1689-805 D/ -
LUFFING WIRE ROPE; SEE TECHNICAL DATA 391 1690-805 C/ -
LIMIT SWITCH 5661 4116-512 -
LIMIT SWITCH 5661 4126-001 -
9.4 VALVE UNIT 289 1639-801 A/ 625-7207.006

VALVE UNIT 289 2557-801 -/- 625-7207.007
FLUSHING VALVE 388 3579-801 F/F 625-7287C
UNLOADING UNIT 388 3576-801 B/B 625-7291C
FILTER UNIT, INLET 189 1558-801 A/ 625-7314.007A
FILTER UNIT OUTLET 189 1559-801 A/ 625-7314.008A
DIRECTION VALVE 289 1597-801 A/ 625-7322.047
DIRECTION VALVE 289 1598-801 -/ 625-7322.048
FLUSH AND UNLOADING UNIT 388 3580-801 C/C 625-7449B
UNLOADING UNIT 388 3576-803 B/B 625-7802.004
ACCUMULATOR 388 0362-803 G/ 625-7951.005
HYDRAULIC HOSES 625-7970G
FILTER ELEMENT 489 3104-801 C/ -
HYDRAULIC CIRCUIT DIAGRAM 189 7255 -/ 189 7255
TUBING EXTRA OVERLOAD 288 1436-801 -/ 288 1436
9.5 POWER SUPPLY 324 0440-801 B/B 625-8562.008

DRIVER'S DESK 124 0766-801 A/ 625-8563.045
CONTROLLER, HOISTING 314 2005-802 D/ 625-8591C
CONTROLLER, LUFFING/SLEWING 314 2006-802 D/ 625-8592C
CONTROLLER 414 6792-801 A/A 625-8596
CONTROL PANEL RIGHT CT3 224 0430-801 A/ 625-8597.039
EL. CABINET (CT1/CT2) 224 0414-801 C/ 625-8598.069A
ASSEMBLY CT2-PLATE 324 1656-801 D/ 625-8607.010
SLIPRING UNIT 314 3985-801 B/ 625-8750.005C
MC-CARD WITH SOFTWARE 324 1675-801 -/ -
CC-CARD WITH SOFTWARE 324 1680-801 -/ -
INST. POWER/CABLE CONNECTION 324 1792-801 A/ 324 1792
ELECTRIC SYSTEM 324 1881 A/ 324 1881
EL. INST CABIN DECK LIGHT 324 1722-801 -/ 324 1722
9.7 MOUNTING ENCODER 390 9851-801 A/ 624-2180.014

MOUNTING ENCODER 390 9852-801 A/ 624-2180.015
HAND PUMP EMERG 189 1952-801 B/ 624-2492B
FIRE EXTINGUISHER, MOUNT 490 4074-801 A/ 624-2524

Dept. C7250 Date: 2009-01-16 2/07103.01HOC 6(6)
TABLE OF CONTENTS
9.7 LIFE LINE 388 0962-801 -/ -

EL.INST.CRANE FORCE LIMIT 124 0386-801 B/ 124 0386
EL. INST. JIB LIGHT, CRANE 124 0647-801 -/ 124 0647
EL. INST. JIB LIGHT, PACKING 124 0648-801 -/ 124 0648
EL. INST. ANGLE/SP.ENCODER 124 0770-801 A/ 124 0770
EL.INST.DISPLAY CABLES (CRANE) 124 0771-801 -/ 124 0771
EL.INST LIGHTING PEDESTAL 124 0801-801 -/ 124 0801
EL.INST CABLE ASSY. PEDESTAL 124 0802-801 -/ 124 0802
EL.INST LIGHTING PEDESTAL 124 0803-801 -/ 124 0803
EL INST. CABLE ASSY. PEDESTAL 124 0804-801 -/ 124 0804
EL. INST. IMPULSE RELAY (CT1) 224 0116-801 -/ 224 0116
EL. INST. CARD RELAY (CT2) 224 0118-801 A/ 224 0118
EL. INST. FORCE LIMIT GRAB 324 1724-801 -/ 324 1724
EL.INST.DISPLAY (CAB) 324 1876-801 A/ 324 1876
DISPLAY 424 0715-801 -/ 424 0715

GENERAL 1.000.4 E rev.: c 2009-05-18
Safety Instructions
Cargo Handling Equipment

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

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

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

crane. MacGREGOR will take responsibility only for
its own professional services. Our product guarantee
The Original Manufacturer of HÄGGLUNDS Cranes 1 (14)

GENERAL 1.000.4 E rev.: c 2009-05-18
Functions, Installations and Equipment Safety Functions and Equipment
General Specific safety equipment is installed and delivered

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

GENERAL 1.000.4 E rev.: c 2009-05-18
4. If there is a multiple-disc failure caused by worn d. Mechanical functions:

out brake discs, sticking cylinder, brake pilot 1. Automatic sensors recognize dangerous wire
valve or valve spool, hydraulic braking by pumps slacks and stop hoisting and luffing movements
and motor is still available. that threaten safe control and the equipment
5. In case of overheating oil, a temperature sen- itself.
sor stops the control system, locking crane 2. Each working circuit has at least two independ-
operation. The electric motor continues in idling ent brake systems.
to maintain oil cooling. Dynamic braking, deceleration, is achieved by
6. Efficient oil filters protect the system from the regenerative function of motor and pump
harmful oil conditions. A warning light on the (hydraulic braking).
operator's panel indicates if the filter has to be True static braking (parking brakes) is pro-
changed. Dirty filter might cause mal function vided by multiple disc-brakes.
to the system. The mechanical brakes are automatically acti-
7. If the hydraulic oil tank oil level drops below the vated in the event of dangerous oil pressure.
minimum permissible level. Each winch is provided with one multiple disc-
A warning light on the operator’s panel is acti- brake.
vated. Each slewing gear unit is equipped with one
An indicator stops the main electric motor and multiple disc-brake.
crane functions are closed while all brake sys-
tems are automatically activated.
2. Safety Installations
a. Warning lights, measuring instruments and meters:
c. Electrical functions:
1. The operator’s panel is provided with warning
1. The crane control system protects the crane
lights which indicate clogged filters or low oil
from overload by using pressure sensors. See
level in the oil tank.
also section 3. Crane Control System ....
2. During crane start-up a warning light on the
2. During a complete power failure all solenoid
operator’s panel indicates that starting proce-
valves are de-energized, causing brakes to be
dures are still running and that working condi-
activated.
tions are not acceptable before the lamp goes
3. The electronic cabinets have power failure indi-
out. Maneuvres are not to be ordered before
cators. This function closes the electronic sig-
the warning light goes out.
nals down which automatically activates all
3. A pushbutton siren is located in the crane op-
mechanical brakes.
erator’s cabinet, allowing the operator to alert
4. Heat sensors located in the main electric motor
persons in the working area (e.g. against pro-
stop all crane operations and activate all brakes.
hibited riding on the load or against load move-
5. The overcurrent protections on all electric mo-
ments).
tors prevent the electric motors from overload-
4. Measuring instruments and meters (e.g. for
ing.
checking the crane functions, adjusting valve
The main electric motor overcurrent protection
positions, and setting functional positions) are
stops all crane operations and activates all
supplied as per agreement with the crane buyer/
brakes.
owner. Tools and equipment which are elimi-
6. A separate electrical feed for the crane house
nated from the original order to MacGREGOR
lights, operator’s cab and on jib, maintains func-
are delivered at the discretion of the owner.
tion of lights even during feed disruption to the
crane operating functions. As there is not a
b. Covers and houses:
separate emergency illuminating system for the
1. Unauthorized visitors in the crane house, es-
crane (this is dependent on the ship’s systems)
pecially during crane operation, is prohibited.
the owner of the crane must provide a battery
type flash-light for the operator’s cab.

GENERAL 1.000.4 E rev.: c 2009-05-18
The crane is a dangerous working area, and re- The fire extinguisher is for emergency use in-
quires special permission to enter. Instructions side the crane.
given by the superintendent or responsible of-
ficer must be followed. The equipment must be regularly inspected for
2. Covers for electric boxes must be opened only proper pressure reading at the meter and must
by authorized personnel. be serviced annually. This is to be supervised
by the responsible officer on board.
c. Alert and warning signs:
The crane is equipped with a system of danger, d. Test device:
warning, caution and notice signs. These signs At delivery, the MacGREGOR crane is
are presented on pages 6 - 15. equipped with two pressure gauges.
3. Safety Equipment
a. Locks, seals and keys:
1. Functions and equipment that are essential for
oil pressure settings, coordination of controls
and crane movements or expose dangerous
high-voltage electricity are locked. All keys to
locked positions and switches must be kept and
controlled by the responsible officer onboard and
are only to be used by qualified personnel.
2. Safety valves for hydraulic pressure settings
and switches for electric safety circuits are
sealed to secure correct position and trim.
Sealed equipment may be opened and positions
changed only after consulting the MacGREGOR
service organization for proper handling.
b. Safety belt, rescue line, safety chains:

1. For work or entry to the open-air crane top,
authorized personnel must wear a safety belt.
The connector hook should be anchored to rails
and fixed position while staying or working on
crane top.
2. The rescue line and equipment for emergency
evacuation of the crane operator must always
be easily accessible on the interior wall-side of
the crane cabin. The equipment status and
completeness must be inspected regularly by
the responsible officer onboard.
3. The safety chains on the open-air crane top and
work platforms inside the crane, must be used
for attendant’s safety during stay and work.
c. Firefighting equipment:
A fire extinguisher shall be made available by
owner in the operator’s cabin.

GENERAL 1.000.4 E rev.: c 2009-05-18
Danger, Warning, Caution and Notice

Signs
Principles of Risk Classification

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

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

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

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

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

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

signs are in good condition and readable to any
person admitted to the crane area.

GENERAL 1.000.4 E rev.: c 2009-05-18
Alert / Warning signs
All signs used in MacGREGOR cargo handling cranes are presented below. Each sign in your specific crane has a
number on it, which can be found in the list and in the illustrations below.
PM40 7101-E00 REPORT TO SUPERINTENDENT OR OPERATOR’S ROOM FOR PERMIT TO ENTER

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

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

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

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

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

PM40 7106-E00 RISK OF GETTING CAUGHT BETWEEN DRUM AND BRACKET - WATCH OUT!
This sign warns the visitor about the risk of getting jammed during drum rotation.
Adequate caution must be regarded.
WARNING SIGN
Attached to brackets and walls of work platforms inside crane

GENERAL 1.000.4 E rev.: c 2009-05-18
PM40 7108-E00 RISK OF GETTING CAUGHT BETWEEN WIRES DURING CRANE OPERATION - WATCH
OUT!
This sign warns about the risk of moving wires that may catch and jam personnel.
The authorized visitor must be aware of the risk and be cautious to avoid being seriously hurt.
WARNING SIGN
This sign is attached to the steel bracket side at the open-air crane top entry.
PM40 7109-E00 RISK OF FALLING DOWN - USE SAFETY BELT!
During any visit to the crane top (e.g. for service jobs), the authorizing officer and the person
entering to the area must fully understand the risks involved.
WARNING SIGN
The safety belt must be worn during any visit to the crane top.
This sign is attached to the steel bracket side at the open-air crane top entry.
PM40 7111-E00 ROTATING FAN - KEEP HANDS OFF!
The rotating fans are protected by grids and the risk is for anyone who sticks fingers or hand
inside. This can be avoided by sign information.
CAUTION SIGN
Attached to fan houses on the open-air crane top and to wall surfaces near the top roof of the
crane.
PM40 7112-E00 RIDING ON CARGO FORBIDDEN
For the attention of the crane operator, to observe that the crane is a Cargo Handling device.
DANGER SIGN The crane operator is obliged to stop operation and to alert any person riding to keep off. The
operator’s alarm bell, in the crane operator’s cabin, may be used, preferably.
Attached on the wall side of the crane operator’s cabin.

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

GENERAL 1.000.4 E rev.: c 2009-05-18
PM40 7115-E00SLIPPERY SURFACES - WATCH OUT!

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

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

PM40 7123-E00 RISK OF GETTING CAUGHT BETWEEN WIRE AND WIRE SHEAVES - WATCH OUT!
This sign warns of the risk of moving wires that may catch and jam personnel.
The authorized visitor must be aware of the risk and be cautious to avoid being seriously hurt.
WARNING SIGN
This sign is attached to the steel bracket side of the open-air crane top entry.

GENERAL 1.000.4 E rev.: c 2009-05-18
PM40 7124-E00 RISK OF BODILY INJURY. EMERGENCY OPERATION, AUTHORIZED PERSONNEL ONLY
OPERATE WITH UTMOST CARE, SEE INSTRUCTION
Emergency operation of luffing and slewing, in the event of complete power failure or main
DANGER SIGN pump unit failure, is extremely difficult and dangerous.
This operation must be undertaken with great care and only by skilled personnel. Instructions
must be observed at all times.
Attached to the wall side of the crane operator’s cabin.
PM40 7125-E00 DANGER - KEEP OUT OF WORKING AREA!
The working area of the crane, over deck as well as over the deck-sides, is dangerous for
personnel, equipment or property. Items lifted or articles dropped may cause death, injury or
DANGER SIGN severe damage.
The crane operator must stop operation and alert personnel.
The operator’s alarm bell must also be used for attention.
Attached on both sides of the crane jib.
PM40 7127-E00 220V INSIDE. DO NOT OPEN! AUTHORIZED PERSONNEL ONLY
This high voltage equipment is covered and does not expose risk unless cover is removed.
The electrical equipment inside cover is powered even if the main switch has shut off other
DANGER SIGN electrical supply.
Access is restricted to qualified and authorized personnel only.
Attached outside and inside the cabin.

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

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

PM40 7132-E00 HOT OIL AND SURFACES - WATCH OUT!
Surfaces of equipment in which there is hot oil can be extremely hot when the crane is in
operation. When service personnel are working on such equipment (e.g. checking and setting
NOTICE SIGN valves) they must be aware of the danger.
Attached to surfaces inside the crane housing, close to pumps, valves, pipes, and manifold
blocks. Also in the foundation, close to oil tank and pipes.

GENERAL 1.000.4 E rev.: c 2009-05-18
PM40 7134-E00RISK OF GETTING CAUGHT BETWEEN WIRE AND DRUM. WATCH OUT!
When the winch is started and during operation, there is a risk of getting caught and jammed by
moving wire. A safe distance from wires and drums must be maintained and adequate caution
WARNING SIGN must be exercised.
Attached to the crane wall surfaces close to winches.

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

PM40 7136-E00 RISK OF GETTING CAUGHT BETWEEN WIRES DURING CRANE OPERATION - WATCH
OUT!
This sign warns about the risk of moving wires, that may catch and jam personnel.
Authorized visitors must be aware of the risk and be very cautious to avoid serious injury.
WARNING SIGN
This sign is attached to the steel bracket at the open-air crane top entry.
PM40 7140-E00 HIGH VOLTAGE, SEPARATE FEED, EVEN WHEN MAIN SWITCH (Q1) IS SWITCHED OFF.
AUTHORIZED PERSONNEL ONLY.
High voltage equipment, couplings and boxes are covered and do not expose risk unless co-vers
DANGER SIGN or hoses are removed.
Boxes with this sign are powered even if main switch has shut off other electrical power. Access
is restricted to qualified and authorized personnel only.
Attached to electric cabinet CT1.
PM40 7142-E00 HIGH VOLTAGE INSIDE. DO NOT OPEN! AUTHORIZED PERSONNEL ONLY
This high voltage equipment is covered and does not expose risk unless cover is removed.
The electrical equipment inside cover is powered even if the main switch has shut off other
DANGER SIGN electrical supply.
Access is restricted to qualified and authorized personnel only.
Attached to the cover of slipring device in the foundation.

GENERAL 1.000.4 E rev.: c 2009-05-18
Fig. 1. PM40 7101-E00 Fig. 2. PM40 7102-E00
Fig. 3. PM40 7103-E00 Fig. 4. PM40 7104-E00
Fig. 5. PM40 7105-E00 Fig. 6. PM40 7106-E00
Fig. 7. PM40 7108-E00 Fig. 8. PM40 7109-E00

GENERAL 1.000.4 E rev.: c 2009-05-18
Fig. 9. PM40 7111-E00 Fig. 10. PM40 7112-E00
Fig. 11. PM40 7113-E00 Fig. 12. PM40 7114-E00
Fig. 13. PM40 7115-E00 Fig. 14. PM40 7116-E00
Fig. 15. PM40 7117-E00 Fig. 16. PM40 7118-E00

GENERAL 1.000.4 E rev.: c 2009-05-18
Fig. 17. PM40 7119-E00. Fig. 18. PM40 7122-E00
Fig. 19. PM40 7123-E00 Fig. 20. PM40 7124-E00
Fig. 21. PM40 7125-E00 Fig. 22. PM40 7127-E00
Fig. 23. PM40 7129-E00 Fig. 24. PM40 7130-E00

GENERAL 1.000.4 E rev.: c 2009-05-18
Fig. 25. PM40 7131-E00 Fig. 26. PM40 7132-E00
Fig. 27. PM40 7134-E00 Fig. 28. PM40 7135-E00
Fig. 29. PM40 7136-E00 Fig. 30. PM40 7140-E00
Fig. 31. PM40 7142-E00

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

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

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

sections cover the following subjects:
General
Contents list; Safety; Conversion tables; Hydraulic
and electric symbols.
Technical description
Technical data; description of crane design.
Function
Electric and hydraulic functions of the crane.
Operation
Operating instructions; crane operator’s checklist.
Maintenance
Lubricating chart and maintenance instructions.
Service
General service instructions for the hydraulic system,
mechanical, control system and electrical equipment.
Extra equipment
Extra equipment, if any; e.g. cargo handling equip-
ment.
Appendices
Other information, which cannot be referred to any of
the above mentioned sections.

GENERAL 1.005 E rev.: e 2003-09-09
THIS PAGE IS INTENTIONALLY LEFT BLANK

GENERAL 1.009 E rev.: a 1996-05-20
General Instructions
Cleanliness in Hydraulic Systems
General
The fundamental and foremost rule in all work with Use a brush for cleaning, wipe off with a non-
hydraulic systems and components is absolute linting rag, repeat the cleaning if necessary. Fin-
cleanliness. ish by spraying the area of operations - hose con-
nections etc. - with the solvent.
Many components, e.g. valves and pumps, have 4. Mount protective covers immediately after remov-
very narrow tolerances, therefore microscopic im- ing a component, a pipe or a hose. Components,
purities, invisible to the human eye, may have dis- shall also be fitted with covers and plugs in order
astrous effect on the function of a hydraulic sys- to prevent ingress of dirt.
tem. These covers must be kept in clean and closed
packages. After use, covers are to be cleaned in
The hydraulic system installation contains a cleaner the workshop.
with a cartridge designed to stop impurities pro- 5. Observe minute cleanliness when handling all
duced within the hydraulic system during operation. types of quick-release connectors. Spray both
Every care must be taken to prevent external im- connectors with solvent before making up a con-
purities from entering the system when servicing or nection. Clean all covers before reinstallation.
repairing it.
Storing and filling up of hydraulic oil
This also applies for components that have been
1. Store barrels, hoses and pump as clean as pos-
removed and or to be reinstalled. Sooner or later, a
sible and best of all in a warm room. The oil vis-
component that has been replaced will be inspected
cosity will then be considerably lower, which
in a test equipment somewhere. It is important that
make the filling through filter easier.
the component stays in the same condition as it was
2. Barrels, hoses and pump must be carefully han-
when it was removed, as it may otherwise be
dled and cleaned when necessary.
impossible to decide the real cause of a malfunction.
3. Store barrels horizontally, so plugs (or cocks) are
It may also be possible that a component sent in
below the liquid level and impurities (e.g., damped
for inspection is not defective at all, and will be
air) does not penetrate the barrels.
returned.
4. Observe minute cleanliness when filling up oil -
carelessness is one of the greatest sources when
Rules when working on the hydraulic system impurities penetrates the hydraulic system.
The following fast rules shall be observed during 5. Fill up hydraulic oil. See separate instruction.
working on the hydraulic system: 6. Never use the last drop in the barrel, as it often
consists of water and other impurities depend-
1. Carry out a rough general clean-up. ent on how many times the barrel has been
2. Protect the area where work shall be done. Use opened.
a sheet of plastic material or similar.
3. Clean well with white spirit or a similar solvent.
Remember that it is not enough to clean only the
parts immediately concerned, but also their sur-
roundings from where accumulated dirt may be
transferred in to the repair area. Do not forget to
clean the tools to be used.

GENERAL 1.009 E rev.: a 1996-05-20

GENERAL 1.102 E rev.: c 1999-09-14
Conversion Factors
Length Pressure
1 mm = 0,0393701 in (tum) 1 atm = 14,6959 lbf/in2 (psi)
1 m = 3,28084 ft (fot) 1 atm = 1,01325 bar
1 in = 25,4 mm 1 atm = 1,03323 at
1 ft (fot) = 304,8 mm 1 bar = 0,986923 atm
1 at = 14,2233 lbf/in2 (psi)
Volume 1 at = 0,980665 bar
10 lbf/in2 = 0,689476 bar
1 dm3 = 1 litre = 0,219969 gallon (UK)
10 lbf/in2 = 0,70307 at
1 dm3 = 1 litre = 0,264172 gallon (US)
1 bar = 1,01972 at
1 gallon (UK)= 4,54609 dm3
1 bar = 14,5038 lbf/in2 (psi)
1 gallon (US)= 3,78541 dm3 2
1 kp/cm = 14,2233 lbf/in2
1 bar = 100 kPa = 0,1 MPa
Mass 1 Pa = 1 N/m2
1 kg = 2,20463 lb 1 Pa = 10,2 · 10-6 kp/cm 2
1 lb = 0,45359 kg 1 Pa = 0,145 · 10 -6 lbf/in2
1 ton (metric) = 1000 kg 1 Pa = 7,5 · 10-3 mm Hg
1 ton (UK) = 1 longton (US) 1 kp/cm2 = 98,07 ·103 Pa
1 ton (UK) = 1016,05 kg
Power
Force 1 kW = 1,35962 hk
1 kp = 2,20462 lbf 1 kW = 1,34102 hp (UK, US)
1 kp = 9,80665 N 1 hk = 0,986320 hp (UK, US)
1 lbf = 4,44822 N 1 hp (UK, US) = 1,01387 hk
1 lbf = 0,453592 kp 1 hk = 0,735499 kW
1N = 0,101972 kp 1 hp (UK, US) = 0,745700 kW
1N = 0,224809 lbf
Temperature
Moment of force 0°C = 32°F
1 kpm= 9,80665 Nm 0°C = 273,15 K
1 kpm= 7,23301 lbf · ft 0°F = -17,7778°C
1 Nm = 0,737562 lbf · ft 0°F = 255,3722 K
1 lbf · ft = 0,135582 daNm 0K = -273,15°C
1 lbf · ft = 1,35582 Nm 0K = -459,67°F
1 lbf · ft = 0,13825 kpm
1 daNm = 1,01972 kpm 1
°C = (°F - 32) °F = 1,8 (K - 273,15) + 32
1 daNm = 7,37562 lbf · ft 1,8
1
°F = °C · 1,8 + 32 K= (°F - 32) + 273,15
1,8
Moment of inertia
°C = K - 273,15
1 kg · m 2 = 3417,17 lb · in2
1 lb · in 2 = 0,00029264 kg · m2 K = °C + 273,15

1.102 E rev.: c 1999-09-14

GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
Hydraulic and Electric Symbols
Hydraulische und elektrische Bildzeichen
This section covers a part of the symbols and port markings commonly
used in MacGREGOR (SWE) AB, Service Division hydraulic and electric
circuits, divided into three parts:
Diese Sammlung umfaßt einen Teil der allgemeinen Bild- und

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

Hydraulic symbols and valve assemblies
Hydraulische Bildzeichen und Ventil-

Baugruppen
1. Hydraulic Symbols
Hydraulische Bildzeichen
Working oil line.

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

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

Temperaturunabhängige Drosselung.
Flexible hose.
Schlauch, biegsame Leitung.

Pipe junction.
Leitungsverbindung.
Crossed pipes, no connection.

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

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

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

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

Pumpe, variables Deplacement, 2 Stromrichtungen.

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

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

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

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

Filter mit Anzeiger.
Filter with by-pass valve.

Filter mit Rückschlagventil.

Air breather.
Luftreiniger.
Pressure electric switch, normally open.

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

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

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

pressure difference.
Rückschlagventil, federvorbelastet mit gewisser
Schließungsdruckdifferenz.

Quick coupling or gauge connection.

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

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

Zylinder, doppelt wirkend mit konstanter Dämpfung
auf einer Seite.
Pressure gauge.
Manometer.
Thermometer.
Thermometer.

Oli cooler.
Ölkühler.
Accumulator.
Druckspeicher.
Shut-off valve.
Absperrventil.
Valve, basic symbol.

Schieber, Grundzeichen.
Electrically controlled valve.

Schieber, elektromagnetisch gesteuert.
Pressure controlled valve.

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

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

Schieber, vorgesteuert, externer Steuerdruck.
Lever controlled valve.

Schieber, knüppelgesteuert.

Mechanically controlled valve.

Schieber, mechanisch gesteuert.
Valve with spring return.

Schieber mit Feder-Rückführung.
Valve with detent.

Schieber mit Lagehalter.
4/2 direction valve

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

Electrically controlled four-way, three-position valve,
spring centred.
4/3-Wegeventil
4-Wegeschieber mit 3 Arbeitsstellungen, feder-
zentriert.
Proportional valve.
Proportionalventil.
Servo valve.
Servoventil.

Balance valve (GP- and HH-cranes)

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

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

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

Druckbegrenzungsventil, regelbar.

Pressure limiting valve with remote opening or clos-

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

Druckreduzierventil.
Pressure reducing valve with T-port.

Druckreduzierventil mit T-Anschluß.

2. Valve Assemblies
Ventil-Baugruppen
Filter unit with by-pass valve.

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

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

Filtereinheit mit Druckbegrenzungsventil.

Filter unit with pressure limiting valve.

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

tion.
Filtereinheit mit Shuntventil und Zustandsanzeige.

Pump for hoisting winch.

Pumpe für Lastwinde.



Pump for luffing winch.

Pumpe für Einziehwinde.

Pump for luffing winch.

Pumpe für Einziehwinde.
Pump for luffing or slewing.

Pumpe für Einziehwinde oder Schwenkantrieb.

Pump for slewing or luffing.

Pumpe für Schwenkantrieb oder Einziehwinde.
Pump for slewing.

Pumpe für Schwenkantrieb.

Hoisting winch with 84-series motor and motor valve.

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

valve.
Lastwinde mit Motor Typ 63/64 und Motor-Umschalt-
ventil.

Hoisting winch with variable high speed hydraulic mo-

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

Einziehwinde mit Motor Typ 63/64 und Motor-
Umschaltventil.

Unloading and flushing valve, slewing.

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

Entlastungs- und Spülventil, Lastwinde und Schwenk-
antrieb.
Flushing valve.
Spülventil.

Valve unit for stabilizing winch.

Ventileinheit für Stabilisierungswinde.
Unloading unit for feed pump.

Entlastungsventil für Speisepumpe.

Valve unit, cylinder luffing.

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

Ventileinheit, Zylinder-Einziehung.

3. Electric Symbols
Elektrische Schaltzeichen
Conductor junction, permanent.

Leitungsverbindung, fest.
Conductor junction, separable.

Leitungsverbindung, trennbar.
Crossed conductor, no connection.

Kreuzende Leitungen, ohne Verbindung.
Slip ring with brush.

Schleifring mit Bürste.
Fuse, supply side indicated.

Sicherung, Zuführungsseite markiert.
Magnetic relay, contactor.

Steuergerät, elektromagnetische Erregerwicklung.
Make contact.
Arbeitskontakt.
Break contact.
Schaltkontakt.

Main contact.
Hauptkontakt.
Contact, manually operated.

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

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

Kontakt mit Ausschalt-Verzögerung.
Contact with delayed closing.

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

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

Kontakt, thermisch gesteuert.

Pressostat.
Pressostat. P
Level switch.
Ölstandswächter.
Temperature switch, thermostat.

Temperaturwächter, Thermostat.
Touch free contact.

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

Massenverbindung (Rumpf).

Rectifier.
Gleichrichter.
Transformer with two windings.

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

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

Dreipoliges thermisches Relais (Überstrom-Aus-
lösung).
Frequency converter.
Frequenzumformer.

Diode.
Diode.
ÊÊ
Light emitting diode.
Leuchtdiode.
Pilot lamp.
Meldeleuchte.
Light.
Beleuchtung.
Flood light.
Scheinwerfer.
Alarm signal.
Alarmsignal.
Alarmsiren.
Alarmhupe.
Single-phase outlet.
Steckdose, einphasig.

Position encoder.
Drehfeldgeber.
Puls/speed encoder
Geschwindigkeitsgeber
Flexible lead connector.

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

Potentiometer mit Schleifer und einer Festanzapfung.
Heater.
Heizkörper.
Motor.
Motor. M

Condenser.
Kondensator.
Heater, cabin.
Heizkörper in der Fahrerkabine.
Air condition.
Klimaanlageapparat.
VL . . . .
Solenoid valve.
Magnetventil.
Oil tank heater.

Ölbehälterheizer.

Controller, hoisting.
Steuerknüppel, Lastwinde.
Controller, luffing and slewing.

Steuerknüppel, Einziehwinde und Schwenkantrieb.


TECHNICAL DATA
(2.001 E) Project No.: 2/07103.01HOC rev: - 2009-01-09
TECHNICAL DATA
GENERAL
Type of crane GLB 3026-2/2426gr
Work order 2/07103.01HOC
Serial number 62508699 - CRANE No. 1

62508700 - CRANE No. 2
62508701 - CRANE No. 3
62508702 - CRANE No. 4
Weight, 39 ton
Type of frequency 3 ~ 60 Hz
Supply voltage 440 V
Control voltage 220 V
MECHANICAL DATA
Jib radius max 26 m
Jib radius min 4.0 m
Lifting height H 12 m
Lifting height K 28 m
BASIC DATA
Hoisting Hoisting Jib radius Jib radius Hoisting Hoisting Luffing time Slewing speed
capacity capacity Minimum Maximum speed speed Max – min radius
Part SWL low high
(ton) (ton) (m) (m) (m/min) (m/min) (sec) (rev/min)
30 15 4.0 26 18 36 55 1.0
24 12 4.0 26 18 36 55 1.0

TECHNICAL DATA
ELECTRICAL DATA
MAIN ELECTRICAL MOTOR No 390 5126-801
Type of frequency 3 ~ 60 Hz
Rated power, cont. 127 kW
Speed, S1 1790 rev/min
Rated power, S6 15% int. 203 kW
Speed, S6 15 % int. 1780 rev/min
Rated voltage 440 V
Starting current 530 A
GEAR BOX DATA

GEAR BOX No 390 6453-801
Gear ratio i = 0.65
Speed 2740 rev/min
VANE PUMP No 390 2422-801
Displacement 58.3 cm3/rev.
HYDRAULIC DATA - HOISTING CIRCUIT

PUMP No. 289 1460-801 (2x)
Displacement 90 cm3/rev.
MOTOR, HOISTING No. 189 2418-801 (1x)
Torque theoretical 25.4 Nm/Mpa

TECHNICAL DATA
HYDRAULIC DATA - LUFFING CIRCUIT

PUMP No 289 1460-801 (1x)
MOTOR No. 188 1221-801 (1x)
Torque theoretical 17.0 Nm/MPa
HYDRAULIC DATA - SLEWING CIRCUIT

PUMP No 289 1461-801 (1x)
MOTOR No 188 1223-801 (2x)
Torque theoretical 8.9 Nm/MPa
FEEDING CIRCUIT
Vane pump 390 2422-801
Displacement 58.3 cm3/rev
WIRE ROPE
Wire rope, hoisting winch Ø 30 mm × 256 m
No 391 1689-805
Wire rope, luffing winch Ø 28 mm × 170.5 m

No 391 1690-805
OIL VOLUME / OIL FILLING

Oil tank 450 litres
Slewing gear box, module 14 9.0 litres
Hoisting winch 11.0 litres
Luffing winch 6.5 litres

TECHNICAL DATA
Limit Switches in Hoisting and Luffing Winch Systems

Basic limit switches - see instruction 6.320.367
Ton Min. jib Max. jib

outreach outreach
(m) (m)
24 4 26
30 4 26
Basic limit switches luffing winch

Cams Cam Jib Speed Max jib Force Speed Min jib Angle Values of limits
degrees parking reduce, outreach limitation reduce, outreach encoder for luffing wire
pos. luffing out (m) for parking luffing in . (mm)
(degree) Approx.(m) position Approx (m) (m)
(m)
A B spr B D C spr C AT BT
degrees
BL1 30 -7,00 109
BL2 100 24,5
BL3 100 26 405
BL4 30 7
BL5 30 4
BL6 100 26,2
**)
**) Second layer
Dimension AT and AL to be measured from the drum flange on empty drum side.
Dimension BT and BL to be measured from the drum flange on full drum side, second layer.
Limit switches - hoisting winch

Cams Cam Empty drum limit, Speed reduce, Speed Full drum Angle Values of
degrees stop position. At least empty drum reduce, full limit, encoder. limits for
three locking turns or Approx. (m) drum stop position hoisting
tank top. (m) Approx. (m) (m) wire (mm)
K spr
K H spr H degrees AL BL
BH1 30 28 123
BH2 40 25,5
BH3 40 9,5
BH4 30 12 1113
**)
**) Second layer

TECHNICAL DATA
Angle Cal dist centr – jib
(mm)
MV
761

TECHNICAL DATA

TECHNICAL DESCRIPTION 2.007.91 E rev.: - 2008-08-08
Technical Description
Jib top
Protective plate
Lifting block
Main electric motor
Pump unit
Crane operator's cab

Oil tank
Slack wire device
Luffing winch
Crane jib
Hoisting winch
Slewing gear
Fig. 1. Crane type GLB.

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

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

Crane operator’s cabin Deck lights

The crane operator’s cabin, with a tilted front window Two deck lights are installed in front under the cabin
located on the service door, affords an allround view and are controlled from cabin and bridge. Optional extra
of the entire work area. The cabincontains crane deck lights can be fitted upon request.
operator's seat, ready access to the two control
levers, one controlling the hoisting winch, and the Crane control system CC3000
other, the luffing and slewing movements.
Control of the hydraulic equipment is servo assisted
with the electronic crane control system CC3000.
The cabin also contains control panels with various
Speed regulation is infinitely variable and involves no
switches, pushbuttons, and signal lamps. Electric
loss of energy. The regulating system employs spring-
windscreen wiper, heater and ventilator are provided
loaded units which automatically return to neutral
as standard. Air conditioning is available as an
position when the hydraulic pressure drops.The main
optional feature.
movements of the crane, hoisting, luffing and slewing
- can be operated simultaneously without any speed
Emergency exit is via the cabin's side window.
reduction as well as independent of each other.
Jib
Hydraulic hoses
The jib is made of two box girders, joined by transverse
The hydraulic hoses are high-pressure tested and
tubular steel struts. The foot of the jib mounts on two
carefully cleaned and inspected before assembly.
trunnion journals at the sides of the crane house skirt.
A halogen floodlight is mounted on the jib.
Cargo handling gear
Electrical equipment The swivel, hook, shackles, rings, and chains all have
Certain electric cables outside of the crane house, ample safety margins for the maximum load to be
e.g. on the jib, are carried in steel conduit. All cables handled by the crane. The non-rotatory, langs lay wire
and electrical accessories are specifically designed ropes are galvanised and oiled.
for marine use.
Surface treatment
The slip-ring unit linking the crane network with the
All surfaces of the crane are carefully prepared by
shipboard network is placed under the platform inside
sandblasting before being given a coat of Primer. As
the crane house.
standard the crane is painted with an anticorrosive
system basically based on two-component epoxy
The electric cabinet is placed on the inside wall of the
paint and an acrylic finishing coat.
crane house. The cabinet contains contactors, relays,
motor switch and various other components of the
electric installation. The main power switch (Q1) is
placed on the CT1-cabinet.
Lighting
Lighting is installed in both crane house and cabin.
Can also be installed in foundation and pedestal if
required.


FUNCTION 3.110.96 E rev.: a 2008-08-08
Hydraulic Function
General Component identification
The following description refers to the standard The main components are identified by four-digit
hydraulic system of MacGREGOR hydraulic deck numbers in the diagram and on the actual components
cranes, GLB version. in the crane. The first digit of each number signifies
the circuit to which the component belongs:
Minor variations in the hydraulic system may occur
in individual cranes of the same type, and the objective 1... Hoisting circuit
of this description is only to provide a general 2... Luffing circuit
orientation concerning the arrangement of the 3... Slewing circuit
hydraulic system. 4... Feed and control pressure circuit
5... Additional programming equipment *)
A complete hydraulic circuit diagram relating 6... Twin crane hydraulic equipment
specifically to your crane will be found in the 7... Other additional hydraulic equipment *)
instruction manual, section “Spare Parts”, Group 9.4.
*) Equipment installed at request of customer
Three separate hydraulic work circuits, ie, the
hoisting, luffing, and slewing circuits, plus feed and Legend
control pressure circuits, make up the complete crane
operating system. MHO Hydraulic motor, hoisting circuit
MLU Hydraulic motor, luffing circuit
Each of the work circuits may have one or more MSL Hydraulic motor, slewing circuit
pumps located in the pump unit, in Figure 1 marked PHO Pump, hoisting circuit
PHO, PLU, PSL. Pump PF for the feed and control PLU Pump, luffing circuit
pressure system is also located in the pump unit. PSL Pump, slewing circuit
PF Pump, feed circuit
Identifying circuits in the hydraulic

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

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

special symbol in the circuit diagram. The meaning
of the symbols is explained in section “General” in
the Manual. The symbol for the reservoir is shown in PF
several places in the diagram for greater simplicity of
drawing; but there is naturally only one reservoir in
FEED AND CONTROL CIRCUIT
actual fact.
Fig. 1. Identifying hydraulic circuits.

FUNCTION 3.110.96 E rev.: a 2008-08-08
Feed and control circuits
Feed pressure circuit

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

The function of this circuit is to supply fluid to the
brakes and pump servos, ie, to control winch speed,
slewing speed and working direction. The system
operates at the same pressure as the feed pressure
and is measured at test point 1.
Note!
For exact pressure settings, see pressure list in the
hydraulic diagram.
1 Feed pressure inlet
16 Feed pressure outlet
Pump case drain
Fig. 2. Feed and control circuit.

FUNCTION 3.110.96 E rev.: a 2008-08-08
Lowering
Hoisting winch circuit
Introduction Low speed High speed

Figure 6 shows a hoisting winch circuit diagram, with
the following main components:
Pumps 1111, 1112 Hoisting Control lever
Hydraulic motors 1141

Brakes 1211, (1212) Fig. 3. Control lever in neutral, hoisting
The brake is mounted inside the winch gearbox.
Function
With the control lever in neutral, Figure 3 or 7, and
the pump running, the hoisting circuit performs no
actual work. A continuous supply of fluid from the
Lowering
feed circuit, flushes the circuit.
Low-speed range, brake release Low speed High speed

When the control lever is moved to the left for low-
speed operation of the winch, Figure 4, valve 1221
and 1226 in the actuated mode, "b", (1226 slightly Control lever Hoisting
delayed in relation to 1221) and connects full control
pressure to the brake valve 1226 which releases the Fig. 4. Control lever, hoisting, brake release position
brake, and also to valve 1128-1 which shifts from its
unloading mode.
With no load on the cargo hook and the control lever

in brake release position, Figure 4, the hoisting winch
should produce a slow hoisting movement, so called
plussing. See instruction under section 6.1 "High
pressure pumps". Lowering
Low speed High speed
Control lever Hoisting
Fig. 5. Control lever, hoisting, low-speed hoisting

FUNCTION 3.110.96 E rev.: a 2008-08-08
Motor
flushing
Pressure
Feed
to
pressure,
valves
inlet
and
brakes
Pump case flushing Feed pressure, Pump case drain

outlet
Fig. 6. Hoisting winch circuit.

FUNCTION 3.110.96 E rev.: a 2008-08-08
High speed range, brake release Safety functions

When the control lever is moved to the right, Figure The hoisting winch circuit embodies four safety
8, valves 1221 (a) and 1226 (b) are actuated, (1226 features:
slightly delayed in relation to 1221). Control pressure
is connected to the brake valve 1226 which releases - Main pressure limiting valves 1111-2; 1111-3,
the brake, and also to valve 1128-1 which shifts from 1112-2, 1112-3.
its unloading mode. - Pressure cut-off valves 1111-10, 1112-10.
- Pressure switch 1311 (overload valve) stops the
The brakes are released and the motor assumes the crane in the event of overloading at low speed.
high-speed position (min. displacement). The motor Shifts to low-speed when running in the high-speed
rotates at double speed, and the lifting capacity of mode.
the winch is reduced to approximately 50 - 60 % of - Pressure switch 1381 stops the crane in the event
its maximum rate. of insufficient feed pressure.
With no load on the cargo hook and the control lever Note! It is not allowed to adjust sealed safety valves
in brake release position, Figure 8, the hoisting winch without contacting MacGREGOR Cranes, Service
should produce a slow hoisting movement. Department.
Lowering
High-speed range overload
If the load on the cargo hook is too heavy for handling
in the high-speed range, the pressure switch 1311
will cause valve 1221 to shift to low-speed range. (Full
displacement)
Hoisting Control lever
Hoisting and lowering, high speed or low speed
Fig. 7. Control lever in neutral, hoisting.
Pulling the control lever backwards from the brake
release position will start the winch to lift the load,
Lowering
Figure 5 low speed and Figure 9 high speed. The
servo valves 1111-9 and 1112-9 affect the servo and
thus the pump displacement. The pumps 1111 and
1112 thereby produce a flow of fluid that is
proportional to deflection of the control lever.
If, instead, the control lever is moved forward, the Hoisting Control lever
load will be lowered, ie, the function is the same as
for hoisting, except for the direction of flow. Fig. 8. Control lever, hoisting, brake release position.
High speed lowering (optional) Lowering

If the crane is designed for high speed lowering the
motor will automatically assume hgih-speed position
when the control lever is moved forward for lowering,
even if the control lever is to the left, for low speed.
Valve 1221 (a) will be actuated.
Hoisting Control lever
Fig. 9. Control lever, hoisting, high-speed hoisting.

FUNCTION 3.110.96 E rev.: a 2008-08-08
LUFFING CIRCUIT
Control pressue to
valves and brake
Feed pressure, inlet
Feed pressure, outlet Pump case drain
Pump case flushing
Fig. 10. Luffing circuit.

FUNCTION 3.110.96 E rev.: a 2008-08-08
Luffing winch circuit
Introduction
Figure 10 shows a luffing winch circuit diagram, with Note! It is not allowed to adjust sealed safety valves
the following main components: without contacting MacGREGOR Cranes, Service
Department.
Variable displacement pump 2111
Hydraulic motor 2141
Brake 2211
The luffing and slewing movements are generally

Luffing-out (lowering jib)
operated by a common control lever, Figure 11.
Brake release
Moving the control lever from neutral, eg, rearward
to raise the jib, causes the valves 2221 and 2226
(2226 slightly delayed in relation to 2221) to shift
position and control pressure is admitted to the brake
Luffing-in (raising jib)
2211 and to valve 2127 which shifts position from the
unloading mode.
Fig. 11. Control lever, luffing/slewing.

With the control lever in the brake release position,
the luffing winch should produce a slow movement of
the crane jib.
Raising and lowering the jib

Moving the control lever further backward starts
operation of the luffing winch. The servo valve 2111-
9 affects the servo and thus the pump displacement.
The pump 2111 thereby produces a flow of fluid at a
rate that is proportional to lever deflection.
To lower the jib, move the lever forward from neutral.

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

- Pressure switch 2481; stops the crane in the event
of insufficient feed pressure.
- Pressure cut-off valve 2111-10.

FUNCTION 3.110.96 E rev.: a 2008-08-08
SLEWING CIRCUIT
Control pressure to
valves and brake
Feed pressure, inlet

Feed pressure, outlet
Pump case flushing
Pump case drain
Fig. 12. Slewing circuit.

FUNCTION 3.110.96 E rev.: a 2008-08-08
Slewing circuit
Introduction
Figure 13 shows a slewing circuit diagram for the
crane, with the following main components: Slewing left Slewing right
(Anti-clockwise) (Clockwise)
Variable displacement pump 3111
Hydraulic motors 3141, 3142, 3143
Flush unloading unit 3127
Brakes 3211, 3212, 3213
Fig. 13. Control lever, luffing/slewing.
The luffing and slewing movements are generally
operated by a common control lever, Figure 13.
Brake release
Moving the control lever, eg, to the left for slewing
left (anti-clockwise), will affect valve 3221. The brakes
will be released and the unloading valve 3127-1 will
be blocked.
Slewing left and right

By moving the control lever further to the side, the
crane will start to slew in the direction chosen. The
servo valve 3111-9 affects the servo and thus the
pump displacement. The pump 3111 thereby
produces a flow of fluid at a rate that is proportional
to lever deflection.
To slew to the right (clockwise), move the lever to

the right instead. The function is the same as for
slewing left, except for the direction of the fluid flow.
Safety functions
The slewing circuit embodies two safety features:
- Main pressure limiting valves 3111-2, 3111-3.

- Pressure cut-off valve 3111-10.

FUNCTION 3.110.96 E rev.: a 2008-08-08

FUNCTION 3.131.29 E rev.: a 2009-02-13
Starting and Stopping, Electric Safety Functions

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

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

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

FUNCTION 3.131.29 E rev.: a 2009-02-13
Other electric functions

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

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

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

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

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

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

der the bottom plate. The cabin lighting is operated by
a switch and the jib light is operated by a pushbutton
in the cabin.

FUNCTION 3.142.35 E rev.: a 2009-02-04
Crane Control System CC3000
General
The following description refers to the microcomputer For detailed information about the control system a
based crane control system CC3000 for complete electric circuit diagram, relating specifically
MacGREGOR Cranes hydraulic deck cranes, single to your crane, will be found in the instruction manual,
crane versions. section "Spare Parts", Group 9.5. Also for detailed
information about the hydraulic system a complete
Minor variations in the use of control system input hydraulic circuit diagram can be found in section
and output signals due to differences in hydraulic and "Spare Parts", Group 9.4.
electric system may occur. The objective of this
description is only to provide a general orientation
concerning the principles of the control system.
Control lever Unloading/displacement

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

Brake valve
Slewing gear
SLEWING
MC Hydraulic Hydr.
"SL" pump motor
Unloading valve Limit switch box
Fig. 1. Crane control system with interfaces to control levers and hydraulic system.

FUNCTION 3.142.35 E rev.: a 2009-02-04
Crane control system - interfaces and

principle of operation
Control levers (joysticks) Hydraulic pumps

The right control lever controls the hoisting winch and The hydraulic pumps are variable displacement
the left control lever controls the luffing and slewing pumps (e.g., the flow is steplessly variable from zero
movements. The control lever linear potentiometers to max. rated flow). The pump oil flow is controlled by
are fed with 0V, +6V and +12V. The output level is a 24V pulse width modulated (PWM) current signal.
approx. +6V with the control lever in neutral. The out- The direction of the oil flow is dependent on which
put signal is controlled by the lever and is decreased one of the two solenoid valves is activated.
to approx. +1.5V and increased to approx. +10.5V,
depending on the lever movement. The speed of the winch, the pump displacement, the
current through the solenoid coil and the lever
The control lever for hoisting also gives 24V signals movement are proportional to each other.
for selection of low speed/high speed and hoisting/
lowering. The control lever for luffing/slewing also Hydraulic motors
gives 24V signals for selecting luffing in/luffing out and
The hydraulic motors may be reversed by changing
slewing left/slewing right.
the direction of the hydraulic pump oil flow. Each mo-
tor also having a low and a high speed range selected
Crane control system cabinet by the operator's control lever.
The Crane control system consists mainly of four
micro processor cards. One Communication Card Overload protection
(CC) is used for internal communication between the
To prevent the crane from being overloaded, i.e. lifting
cards and a parameter memory card. Three Motion
a too heavy load, the hydraulic system is equipped
Control cards (MC) are controlling all input and out-
with an electro-hydraulic overload system. Pressure
put signals for each crane movement hoisting, luffing
sensing switches, which normally enable the opera-
and slewing. Each MC card feeds a potentiometer in
tion, stop the hoisting movement if a too heavy load
the control lever for the crane movement in control.
is lifted at the current jib outreach. The pressure switch
Potentiometer and control lever direction signals go
gives a signal to the control system overload logic,
to a microprocessor with a software control program
which senses the overload input signal and switches
that handles brake release logic, overload logic and
over from high speed to low speed or from low speed
rampforming. The output from the microprocessor is
to stop.
fed to a voltage to current amplifier on the card.
The rampformer gives smooth acceleration and re- Limit switch box, hoisting
tardation to the crane movements. The limit switch box controls speed reduction and stop
function for full or empty drum. It also contains a
The brake release logic circuit releases and applies speed-encoder used for plussing control.
the brake in the correct sequence with the displace-
ment/unloading signals when the hydraulic motor is Limit switch box, luffing
started and stopped.
The limit switch box controls speed reduction and stop
function for all max. and min. outreach, and stop
The voltage to current amplifier feeds the hydraulic
parking, if fitted.
pump solenoids.

FUNCTION 3.142.35 E rev.: a 2009-02-04
Limit switches, slackwire Micro Processor Cards - CC and MC

The limit switch for hoisting slackwire stops the
lowering movement, and the limit switch luffing slack-
Hardware
wire stops the luffing out movement when a wire is
The control system consists mainly of one CC card
slack.
and three MC cards. All MC cards are identical and
100% interchangeable.
Limit switches, slewing
If fitted, the limit switches for slewing control the speed Each MC card is a complete stand-alone
reduction and stop function for each direction at maxi- microprocessor system with processor, several types
mum slewing range. of memories and communication channels, analogue
and digital inputs as well as analogue and digital out-
put current drivers. Each card can fully handle all in-
put and output signals needed for one hydraulic circuit,
i.e. one crane movement. A separate safety system
consists of a secondary micro processor whose pur-
pose is to monitor the behavior of the primary pro-
cessor in critical situations such as hazardous opera-
tion at low feed pressure and overload pressure as
well as ensuring the stopping of the crane movement
due to activated limit switches.
Software
All cards, CC and MC are programmed with the same
crane control software. Each card senses which rack-
position and therefore which function/crane movement
it is controlling.
All cards identify themselves by showing a two-

character abbreviation of the function/movement
name on the front panel display: Sc - supervisor, Ho -
hoisting, Lu - luffing, SL - slewing.
Fig. 2. Crane control system CC3000.
The leftmost card, the CC "Sc", is only used for
supervisory functions such as communication with
other cards and distribution of control system para-
Crane control system cabinet
meters from the parameter memory card.
The Crane control system CC3000 is protected
against humidity by a casing with protection class IP54 New versions of the crane control software can be
(dust and splash water proof). loaded/programmed into the cards by using a stan-
dard notebook PC.
19" subrack with electronic cards
All electronic cards are mounted in a standard 19" Parameter memory card
aluminium subrack. A backplane card is used for All parameter values are stored in the parameter
connecting power, 24V to the CC and MC cards. It memory card. The information is stored in electronic
also provides communication lines between CC and memories on the card. Stored parameter values are
MC cards and between CC card and the parameter not dependent on power supply or battery. There is,
memory card.

FUNCTION 3.142.35 E rev.: a 2009-02-04
however, a battery on the card used for a calendar, input from the operator's handle, are also detected.
giving all cards date and time information. The card is When any type of malfunction is detected, the card
located inside the rack and is mounted on the flashes with its error LED, no. 28. All card error LEDs
backplane card that also holds all the card connectors. are wired together to an error lamp in the operator's
The lifetime of the battery is 10 years. cabin, the "control system error" lamp. To get the
corresponding error message number, push the
Select/Info push-button on the card with the flashing
Anti-condensation heating
LED.
To avoid condensation on the electronic cards, the
temperature inside the enclosure is kept a few degrees
If there are several errors, they are shown one at a
above the temperature outside. Heating elements are
time for each push on the Select/Info push-button.
therefore mounted behind the row of plinths. They are
When there are no more error messages to read, the
powered with 24V AC when the control system is
display shows two hyphens "- -". The error LED is
switched off or when the crane is not operational.
now either on or off.
- If it is on, the error is still present but has been

Signal overview CC3000 acknowledged.
Coloured LEDs - If it is off, the errors are no longer present.

Signals to and from each card are indicated by green,
yellow and red LEDs (Light-Emitting Diodes) on the When a new error is detected the error LED starts
front panel of each card. flashing again to indicate that a new error exists.
Green are used for normal input and outputs. Yellow Error message sign
indicates that the crane motion concerned is driven The corresponding error message text can be found
with slower speed. Red indicates that the motion is on the ERROR MESSAGES sign in the cabinet, see
stopped. section "Service", Group 6.3.
Signal overview sign

All signals indicated with LEDs are listed on the SIG-
NAL OVERVIEW sign inside the cabinet, see section
"Service", Group 6.3.
Error messages
Built-in diagnostics system

The CC3000 control system has its own built-in
diagnostics system. The system is capable of
detecting several types of malfunctions.
The system checks itself and external input and out-

put signals. Internal problems such as loss of
communications are continuously checked. Loose
connections to pumps and valves are detected when
the output is activated. Signal levels that do not
correspond to normal levels, i. e. the potentiometer

FUNCTION 3.155.3 E rev.: - 2001-08-23
Thermostatic Controlled Ventilation Fan
General
The ventilation fan is thermostatic controlled and

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

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

Fan
Fig. 1. Crane house Fig. 3. Thermostat

FUNCTION 3.155.3 E rev.: - 2001-08-23

OPERATION PM40 1863-E00 rev.: c 2009-03-05
CREW CHECK LIST

BEFORE TAKING CRANE INTO OPERATION
Note! When the crane is rigged ready for opera- Unclamp jibs and loose gear
tion, all keys for all lockable switches must be stored Unclamp jib and loose gear from its parking
in a safe place by the officer responsible on board. position.
Read sections Operation and Maintenance in the

instruction manual and make sure that maintenance
is performed according to Maintenance Chart.
Make sure nobody enters the crane without
permission from responsible officer on board.
Make sure that there is nobody in the crane house
who might be caught in the machinery or strangled
by the wire ropes.
The following checks and procedures must be

performed before taking crane into operation:
Oil level and operating temperature Wires and sheaves
- Verify hydraulic oil level. Verify that wires run correctly in the sheaves and
- Check oil level in all gear cases. that the wire ends are securely clamped.
- Verify that the ambient temperature is not below
-15 oC. If the crane operates in temperatures
below -15oC a heater has to be installed in the oil
tank.
Note! If the crane is equipped with an oil heater
and the ambient temperature is below -10°C
proceed as follows:
- Start the electric heater by setting switch S50
positioned on the CT1 cabinet to "winter" or "1".
Set main switch (Q1) to "1" 24 hours before
operation. See also "Controls and Indicators",
section 4.
- Let the crane idle for 1 hour before operation to
heat the hydraulic oil.
CT2
S50
CT1
Oil heater
Q1

DURING OPERATION IF CRANE STOPS

List/trim Check the following:
Verify that ship does not list more than 5 degrees a. Crane overheated
and does not trim more than 2 degrees.
1. The crane stops automatically (overheating
protector) when the oil temperature exceeds +85°C.
2. Pilot light "HIGH OIL TEMPERATURE" illuminates.
3. Press pushbutton, position "1" (Start), to start main
Max. 5°
motor and oil cooler fan. Crane control system
CC2000/CC3000 is still blocked and pilot light, "DO
NOT OPERATE" lights.
4. Pilot light "HIGH OIL TEMPERATURE" goes out
when the crane's working oil temperature is back
below +85°C.
The crane control system CC2000/CC3000 returns
to normal and pilot light "DO NOT OPERATE" goes
out.
5. The crane is ready for operation.
b. Oil level
1. Check oil level in oil tank.
2. Fill oil if necessary. (See Lubricating Chart).
AFTER OPERATION c. Current setting list
Park the crane 1. Check current setting list inside the electric
Park the crane according to separate instruction in cabinet door CT1.
section 4 in the instruction manual. 2. Change current setting, if necessary.

AFTER SEA STOWING

Check that the heating elements in electronic
cabinet CT2 are working, i.e. get warm.
Heating elements
Also see instruction "Crane control system CC2000",
section 3.
Check that the heating elements in electronic
cabinet CT2 are working, i.e. get warm.
Heating elements
Also see instruction "Crane control system CC3000",
section 3.


OPERATION PM40 5500-E00 rev.: b 1996-08-08
OPERATING INSTRUCTION
Handling of dangerous cargo

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

and health in dock work.
The crane is not designed for transport of passengers.

OPERATION PM40 5500-E00 rev.: b 1996-08-08

OPERATION PM40 6462-E00 rev.: - 2008-10-31
OPERATING INSTRUCTION
START - STOP
MacGREGOR cranes are designed for operation in harbour or sheltered water environments where there is no
significant movement of the ship due to wave action.
WARNING!
Only ship's crew is allowed to operate key switches. Keys must be stored in a safe place by responsible officer.
Notify responsible officer on board before taking crane into operation.

Make sure that there is nobody in the crane house who might be caught in the machinery or strangled by the
wire ropes.
When using grab or magnet, handling log or palletized cargo the lifting capacity must be reduced to 80% of
SWL if there is no "GRAB" switch in cabin.
BEFORE STARTING START
- Start the electric oil heater by
using switch S50 positioned on WARNING
the CT1 cabinet. LIGHT
- Let the crane idle for 24 hours
before operation to heat the
hydraulic oil.
START
Read instructions carefully before Press pushbutton, position 1

taking crane into operation. (START) to start the crane. The
crane will start within 20 seconds
Verify that the ambient tempera- and is operational when the red
ture is not below -15oC. If the warning light goes out.
crane operates in temperatures Do not operate on red light.
below -15oC a heater has to be
installed in the oil tank. Note! Joysticks for hoisting or
luffing/slewing motions must be
Note! If the crane is equipped with in neutral position when starting
an oil heater and the ambient Check that control levers are in the crane. If the joysticks have
temperature is below -10°C neutral. If not, notify responsible been moved in any direction when
proceed as follows: officer. pressing the start button the mo-
tion is blocked. Move the joy-
sticks to neutral position then
EMERGENCY STOP operation is possible.
STOP
STOP
If the crane gets out of control... - LET GO both control levers; they
will return automatically to their
neutral positions. Press pushbutton, position 0
- Press Emergency Stop button! (STOP).

CRANE OPERATION
CONTROL LEVER, CONTROL LEVER, CONTROL LEVER,

SLEWING / LUFFING HOISTING / LOWERING HOISTING / LOWERING
Luffing out Lowering Lowering
Neutral Low speed High speed

Slew Slew Low speed High speed
left right
Hoisting
Lowering
Luffing in Hoisting
With the slewing/luffing control

lever in neutral, the brakes are
engaged.
Moving the lever a short distance
from neutral releases the brakes. Hoisting
Moving the lever left or right starts With the hoisting winch control
the crane to slew in the direction lever in neutral, the winch brake
chosen. is engaged and holds the load. To be able to hold the load at
Moving the lever forwards or constant height, move the hoisting
backwards starts operation of the Moving the hoisting winch lever winch control lever to one of the
luffing winch. to one of the grid slots for high or positions shown above. The brake
Note! When operating luffing the low hoisting speed releases the will then be realeased and the
hoisting brake is released and the winch brake; the winch starts load will be held at constant height.
hoisting winch starts hoisting at hoisting at creep speed. This The position of the lever is
creep speed. speed is depending on the load. depending on the load on the hook.
LIST / TRIM DRAGGING LOADS SHORT BREAKS IN

OPERATION
1,5 m
Verify that ship does not list more Dragging loads is not permitted! ... or if a technical malfunction
than 5 degrees and does not trim has developed:
more than 2 degrees. Do not drag loads - lift them.
- Raise swivel to approx. 1.5 m
below jib head, if possible.
- Return control levers to neu-
tral.
- Press STOP button.

OPERATION PM40 6879-E00 rev.: a 2009-06-05
Controls and Indicators

CT3 CT3
Luffing out 31 Lowering

32
Low High
Slew Slew
left right
speed speed
Luffing in
Hoisting
Fig. 1. Controls and indicators in the crane cabin.
Warning!
Only ship's crew is allowed to operate key switches.
WARNING!
Store Keys Safely
When the crane is rigged ready for operation, all keys
H3 CHECK OIL FILTER
for all lockable switches must be stored in a safe place
by the responsible officer on board. Pilot light. Illuminates when the oil pressure over the
oil filter is more than 5 bar.The oil filter is saturated and
ought to be changed or hydraulic system is to be
H1 DO NOT OPERATE checked.
Pilot light. Illuminates during starting sequence of the
crane (feed pump motor, main electric motor and
supply to electronics). H4 CONTROL SYSTEM ERROR
Pilot light. Illuminates when an error is detected by the
crane control system in the electronic cabinet CT2.
H2 LOW OIL LEVEL
Pilot light. Illuminates as a pre-warning for low oil level
H5 HIGH OIL TEMP
in crane and the siren or bell, which is mounted under
the crane cabin will sound. Refill oil tank. The pilot light Pilot light. Illuminates when the crane stops and the oil
and the siren/bell can be switched off by selecting the temperature in the hydraulic system exceeds 85°C.
key float switch S19 in position ”SIREN OFF”. Note! Check that the hydraulic system functions.

H6 OVERLOAD
Pilot light. Illuminates at overload. S19 FLOAT SWITCH
Key switch with three positions. 0/1/2.

Normal oil level is between MIN and MAX. If the oil
S13 START/STOP level drops the indicator lamp ”LOW OIL LEVEL”
illuminates and the alarm will sound. Select position
Pushbutton with two positions, 1/0: "1" or "2". Check why oil level has dropped!
1 - On
Position "1" starts the complete crane. During the 0 - Normal position
starting sequence the ”DO NOT OPERATE” pilot 1 - Siren off
light illuminates. The siren off position is used in an emergency. The
0 - Off siren will be silent and the indicator lamp ”LOW OIL
Position "0" stops the complete crane. The power LEVEL” goes out. The operation of the crane may
supply to the main electric motor and electronics be continued for a short time.
will be broken, and the feed pump motor stops 2 - By-pass
when running in summer position. When the feed The by pass position is in extreme emergency to
pump is running in winter position, the feed pump lower a load which is hanging in the hook. The
continues to run after stopping the crane. ”LOW OIL LEVEL” lamp continues to illuminate
and the crane siren sounds.
F14 RESET WIPER
Pushbutton. Resets the wiper motor (automatic fuse), See also separate instruction "Oil level float switch
when the wiper motor has stopped due to a too high and overheating protector".
current.
S15 EMERGENCY STOP S20 PARKING OF JIB

Pushbutton. Stops the complete crane in case of
emergency. The pushbutton has to be reset, otherwise This two-position key switch is normally in position
the crane cannot be re-started. "0".
When luffing out is stopped due to the maximum
outreach limit switch, further lowering of the jib is
S16 DECK LIGHT possible (for parking purposes of jib) only if the key
Pushbutton. Activates an impuls relay that activates switch is held in position "1".
the deck light when the pushbutton is pressed. Can
also be switched on and off from bridge.
S22 WIPER
S17 SIREN
Switch. 0/1 (On/Off). Starts and stops the window
Pushbutton. The siren sounds when the pushbutton is
wiper.
activated.
S18 JIB LIGHT

S23 CAB LIGHT
Pushbutton. On/Off. Activates an impuls relay that
activates the jib light.
Switch. 0/1 (On/Off).

Control lever movement
S24 CAB HEATER
Switch. 0/1 (On/Off). Starts and stops the cabin heater.
Start - acceleration Retardation - stop
Speed
S26 CARGO / GRAB HANDLING
max.
Key switch with two positions, Cargo/Grab.

Cargo position - Full SWL Time
Grab position - Reduced SWL due to grab handling.
2 sec. 2 sec.
Acceleration Retardation
S31 CONTROL LEVER, HOISTING/LOWERING
Note! Joystick for hoisting/lowering motion must be in Fig. 2. Hoisting/lowering.
neutral position when starting the crane. If the joystick
has been moved in any direction when pressing the
start button the motion is blocked. Move the joystick to
neutral position then operation is possible. S32 CONTROL LEVER, LUFFING/SLEWING
Note! Joystick for luffing/slewing motion must be in
When control lever is in neutral position the brake is neutral position when starting the crane. If the joystick
engaged and holds the load. has been moved in any direction when pressing the
Moving control lever in low speed or high speed posi- start button the motion is blocked. Move the joystick to
tion releases the winch brake. neutral position then operation is possible.
Moving control lever in hoisting or lowering direction
means continued speed increase from zero to max. With the control lever in neutral position the brakes are
speed. engaged.
To give a smooth acceleration and retardation to the Moving the control lever short distance from neutral
winch movement the control system is fitted with a releases the brake for luffing winch or/and slewing
ramp former with a special ramp time. machinery.
The ramp time is the time it takes to increase the winch Moving the control lever furthermore in luffing or slewing
speed from standstill to maximum speed, when the direction means continued speed increase from zero
control lever is moved rapidly from zero to maximum to max. speed.
speed position. In the same way it also takes the To give a smooth acceleration and retardation to the
corresponding ramp time to decrease the winch speed luffing winch movement and the slewing movement
from maximum speed to standstill, if the control lever the control system is fitted with a ramp former with a
will be dropped. special ramp time.
The ramp time for the hoisting system is 2 sec. See The ramp time is the same as it takes the luffing winch
Fig. 2. speed or the slewing machinery to increase from stand-
still to maximum speed when the control lever is moved
Pushbutton *. rapidly from zero to maximum speed position.
In the same way it also takes the corresponding ramp
time to decrease the winch speed from max. to stand-
still if the control lever will be dropped.
The ramp time for luffing is 2 sec. and for slewing 4
sec. See Fig. 3 and 4.
Pushbutton *.
* Pushbuttons on top of the control lever to be used only when operating extra equipment e. g. power swivel, grab.


S51 EMERGENCY STOP
Pushbutton. Stops the complete crane in case of

emergency. The pushbutton has to be reset, otherwise
the crane cannot be re-started.
Speed
S71 EMERGENCY STOP
max.
Pushbutton. Positioned in the bottom of the foundation
(deck level) near the access door.
Time
2 sec. 2 sec.
Q1 MAIN SWITCH
Acceleration Retardation Cuts off the main power to electric cabinet CT1.
Fig. 3. Luffing. DANGER! Separate feed in electric cabinet CT1!

Powered even when main switch is switched off.

S50
Speed
max.
Time
4 sec. 4 sec.
Acceleration Retardation
Fig. 4. Slewing.
Hour
meter
Electric Cabinet CT1
S50 FEED PUMP MOTOR

Q1
224 0254
Switch with two positions: Summer and Winter.
Summer S51 Emergency stop

When outside temperature is more than +5°C set switch
in summer position. Set main switch in position "ON" (1).
Fig. 5. Electric cabinet CT1/CT2.
Winter
When outside temperature is less than +5°C set switch
in winter position. Set main switch in position "ON" (1)
some 24 hours before operation.

OPERATION PM41 0001-E rev.: - 1994-06-16
EMERGENCY ESCAPE INSTRUCTIONS

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

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

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

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

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

reverse it after each lowering operation.

OPERATION PM41 0001-E rev.: - 1994-06-16

EMERGENCY ESCAPE INSTRUCTIONS

Rope Ladder / Fixed Ladders
Leaving Crane Operator's Cabin Using Leaving Crane Operator's Cabin Using
Rope Ladder Emergency Ladders
1. Exit through the window to the escape ladder on 1. Exit through the window to the emergency ladder
the outside of the cabin. on the outside of the cabin.
2. Release the rope ladder by removing the strops
and pull the rope ladder out of the console and let
it fall down towards the deck.
1
Emergency
ladder
Rotating
ladder
Strops
Hand rail
2
Foot rail
Fixed ladder
Deck level


OPERATION 4.620.26 E rev.: a 2008-08-20
Parking the Crane, Sea Stowing

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

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

OPERATION 4.620.26 E rev.: a 2008-08-20
Sea stowing with cargo hook/block Prior to cargo handling

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

crane in operation
Fig. 3. Locking arrangement on parking support.
Rope
Fig. 4. Block secured to deck by using a rope.

OPERATION 4.620.26 E rev.: a 2008-08-20
Crane jib parked on next crane

housing or foundation (If no electrical
interlocking.)
Example:
Before operating crane No. 1 carefully check that crane
No. 2's jib has been removed from its parking support,
see Fig. 5.
Crane No. 2 Crane No. 1
Fig. 5. Jib parked on crane housing.
Example:
Jibs parked in their jib supports on the foundation Before operating the crane carefully check that the
towards each other. Hook secured to deck, see crane jib has been removed from its parking
Fig. 6. support.
Crane No. 2 Crane No. 3
Fig. 6. Jib parked on foundation, hook secured to deck.

OPERATION 4.620.26 E rev.: a 2008-08-20
Parking suggestions of extra equipment
Example: Important!
The grab should be lowered to the deck when the Power cable and stabilizing cable should be parked
crane is parked, this to avoid load on the wires. on jib top during sea voyage. Parking on hook block
is for temporary use only.
Turnbuckle
Support Support
SIDE VIEW TOP VIEW
Fig. 7. Grab lowered to deck, fixed with suitable tightening equipment.
Example: Example:
Fix block
with wire
ropes
Deck Deck
Angle bar Angle bar
Fig. 8. Power swivel with lifting block secured to deck. Fig. 9. Power swivel secured to deck.

OPERATION 4.630 E rev.: - 1994-02-04
Handling Hatches by Deck Crane
Handling hatches
When pulling hatch covers by means of deck Always check that the pulley blocks are correctly
cranes, it is very important that the pulley blocks are positioned, so that the hoisting ropes cannot deviate
so placed that the hoisting wire can be maintained more than 5°, at the most, from the crane house
very nearly vertical during operation. The crane jib centre line.
should be set at an angle where it will not require
any subsequent shifting in order to achieve the N.B. The capacity of the wire pulling the hatch cover
required lifting height. may limit the force which can be applied by the
crane.
The included angle between the hoisting wire and
the vertical centre line of the crane house must not
exceed 5°.
Fig. 1. Fig. 2.

OPERATION 4.630 E rev.: - 1994-02-04

MAINTENANCE 5.005.55 E rev.: e 2009-04-17
Maintenance Chart
Lubricate crane according to LUBRICATING Loose gear

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

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

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

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

- Function test, see instruction in section 6.3.

Slewing bearing screws - Check that wire rope clamps on wire drums are
- Inspect visually the slewing bearing screws from safely secured.
deck and inside pedestal. If any screw shows any
tendency to slacken, tighten all screws with a torque Wire sheaves
wrench or a hydraulic tensioner according to - Inspect for wear
drawing "Slewing bearing, yard mounting" and - Check that shafts are safely secured.
"Slewing bearing, mounting", section 9.3.
Climb protection, jib top

Wire rope sockets (thimbles)
- Inspect climb protection for wear and damage
- Check that wire rope thimbles are safely secured - Check play between wire sheave and climb
- Check for wear and damage. protection. See instruction in section 6.2.
Ventilation filter unit (optional) Slack wire device

- Make sure the coarse filter is clean. - Inspect rollers for wear or damage.
- Clean or replace if necessary. See separate
instruction.
Pressure roller (hoisting winch)
- Check roller and springs for wear and damage
- Check function.
After 200 operating hours
Electrical equipment including slip-ring unit
- Inspect according to “Electrical Equipment, General
Slewing gear case
Maintenance” in section 6.3.
- The first oil change. (Running-in period 200 hours.)
See instruction in section 6.1.
Heating elements, cabinet CT2
- Check that the elements in cabinet CT2 is working
Winches, hoisting and luffing
i.e. get warm.
- The first oil change (Running-in period 200 hours).
See instruction in section 6.1.
Crane house, foundation and jib welding joints
- Inspect for any sign of crack
See "Inspection of Stressed Components and
Structures", section 5.
Every 500 operating hours or every six
months
Hydraulic system
- Check the following pressures:
Oil cooler - Feed pressure inlet, at guage connection 1
- Inspect oil cooler externally. Clean when required. - Control pressure, at guage connection 2
- Pressure cut-off (overload) valve/valves 1311,
Wire ropes, wire rope clamps 1312 etc., at connection 3.1

Pressures should be according to the Hydraulic
- Inspect for wear. See instruction "Handling, Installation,
Component Specification, part of Hydraulic Circuit
and Maintenance of Steel Wire Ropes" in section 6.2
diagram in section 9.4.
- Wire ropes are inspected according to stipulations
- Adjust if required.
issued by Classification Associations and National
Bodies.

Oil analysis (oil tank) Air breather, hydraulic oil tank

- Sample oil and analyse every six months. - Check and replace air breather on top of the tank.
Pump servo Hydraulic accumulators

- Check plussing - Check pressure, re-charge as required. See
- If necessary adjust. instruction “Hydraulic Accumulators”, section 6.1.
Slewing gear, pinion Cable winch (optional)

- Check backlash. - V-belt, check tension
- Measurement to be taken according to instruction - Slipring unit, check
"Measuring Procedure for Wear in Slewing - Brake discs, check
Bearings for Rope Luffing Cranes" in section 6.2 - Brush holders, check.
- Check seals. See instruction in section 7.
Filter service indicator Service door

- Replace filter cartridge. See instruction "Filters", - Open service door, see instruction in section 6,
section 5. and check hinges for damage and corrosion.
Slip-ring unit
- Check brush holders, wire brushes and slip-rings
Every 2000 operating hours or every two
according to instruction in section 6.3.
years
External access ways

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

every year - Check for leaks
- Check braking torque
- Check according to instruction "Winch" in section 6.1.
Slewing gear case
- Change oil. See instruction in section 6.1.
Winches
- Oil analysis. See instruction "Winch" section 6.1
- Change oil. See instruction in section 6.1.

Multiple-disc brake, slewing gearset

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

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

- Drain oil and clean the reservoir. See instruction, in
section 7.
Every four years
Slewing bearing studs/screws

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

- Check hydraulic hoses for damage. See instruction
in section 6.1.
Every ten years
- Replace all hydraulic hoses. See instruction in

section 6.1.

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

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

A thorough visual inspection is fairly easy to carry ways contact MacGREGOR Cranes, Service De-
out as cracks will generally show by cracking or partment for advice.
flaking of the paint followed by a brownish discol-
oration by rust.
(Inspect welds and surrounding material.)
Example:
Fig. 1. Crane structure. Fig. 2. Parking support.

MAINTENANCE 5.018 E rev.: b 2004-05-24

LUBRICATING CHART PM51 1709-E00 rev.: c 2009-04-17
Item Part of crane (see page 2 for location) a b c d e f

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

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

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

Oil quantity required: "Technical data", Section 2.
Maintenance intervals: "Maintenance chart", Section 5.
Location of nipples etc: "Lubricating and maintenance", Section 5.
Lubricants: "Lubricants for deck machinery", Section 5.

LUBRICATING CHART PM51 1709-E00 rev.: c 2009-04-17
Red lamp on right control panel in operator’s cab Jib top with lifting block for single crane
CHECK
OIL FILTER
6. Wire ropes
3. Wire sheave
CAUTION!
Renew all filter cartridges 5. Swivel
when this lamp is lit.
Example: Wire sheaves crane top and wire rope

thimble, manual greased.
1, 4 Example: Wire sheaves jib top and wire rope
1
thimble, central greased.
1, 4 1
1. Wire sheaves
Filter service
indicator
12
Filter
4135 7. Electric motor
8. Door hinges
12. Oil filters
Oil filling
12
Filter
4136
10. Oil tank

11. Air breather cap
16, 17. Luffing winch
16, 17. Hoisting winch 13. Slewing gear case
15. Slewing bearing 9. Jib bearings
14. Slewing bearing teeth

MAINTENANCE 5.150.4 E rev.: - 2003-02-19
Lubricating and Maintenance

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

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

Door hinges
Grease nipple;
Service door

Electric motor
Grease nipple;
Upper bearing
Grease nipple;
Lower bearing

Slewing bearing
Grease nipple; Grease;

Slewing bearing Slewing bearing teeth

Jib bearing
Grease nipple;
Inside crane house

Wire sheaves Jib and Wire rope socket
Grease nipples; Jib top, Central lubricating

Wire sheaves Crane house
Grease nipple

Wire rope socket Crane top
The wire rope sockets can also be located on jib top

or lifting block.
Grease nipple

Slewing gear case
Oil change Air breather
Check oil level
Oil drain plug

Lifting equipment
Grease nipple, Lifting block
Grease nipple, Swivel

Oil tank
Check air breather

Check oil level (dipstick)
Drain oil tank

Oil filter
Filter unit, outlet Filter unit, inlet

Oil filling Electrical indicator, visual indicator

Oil filter change

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

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

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

5 old filter
6 the spanner.
cartridge.
Install the new
O-ring Mount the drain-plug and the O-ring on the
7 filter cap and tighten it using the spanner.
between the
filter cap and
the filter head.
Install the new
filter cartridge.

Wire ropes
Relubricating of steel wire ropes, see instruction

6.222.1 E.
Grease

Winch with high speed motors
Grease nipple
Oil filler inlet

Oil dipstick
Oil outlet

Cable winch (optional)
Oil change; Spur gear

Grease nipples; Electric motor
Oil drain plug;

Spur gear
Oil change; Turbo coupling

Power swivel (optional)
Check oil level (dipstick)
Grease nipples, ball bearing
Drain oil tank (seen from below)

MAINTENANCE 5.301.13 E rev.: a 2009-04-20
Filters
Introduction
For cleaning hydraulic oil, the hydraulic system is The other indicator is visual (see Fig. 1) and should
equipped with two filters. The two filters are marked be read when the oil temperature is approximately
4135 and 4136. 45°C. Upon reaching a certain degree of clogging, a
red indication can be seen on the top of the filter
Filter indicators indicator. Replace both filter cartridges in the system
when the red indication shows.
The filter indicators operate only when the crane
starts.
Replacement filter cartridges
Filter 4135 has two filter indicators. One indicator is You must replace both cartridges (see Fig. 3) in the
electric and operates a warning lamp placed on the crane at the same time. Flush all other parts of the
control panel in the cabin (see Fig. 4a and 4b). filters with white spirit when you replace the cartridges.
Use new seals. Reassemble the filters.
4101 4102
Electric indicator
Visual
indicator
Oil filling
Filter Filter
4135 4136
Fig. 1. Filter inlet. Fig. 2. Filter outlet.
Fig. 4a. Control panel.
Filter cartridge
Fig. 3. Filter cartridge. Fig. 4b. Control panel.

MAINTENANCE 5.301.13 E rev.: a 2009-04-20

MAINTENANCE 5.315 E rev.: a 2003-04-04
Sampling of Oil to Verify the Cleanliness in Hydraulic System
General Procedure for Oil Sampling

- Oil temperature in the system should be 40-50oC.
This service information describes sampling oil from - Special oil sampling bottles should be used and
a hydraulic crane system. can be purchased from oil companies.
- Connect a pressure gauge hose to gauge outlet
This procedure is general and there can be some 3.1 (hoisting circuit), (see Fig. 1).
differences depending of crane type. - Start the crane and run the hosting winch in maxi-
mum speed hoisting.
Type of oil to be used in the system can be found - Bleed out 0.5 litre of oil in a bucket. This oil to be
in Section 5. disposed.
- Fill the oil sample bottle.
When to Sample Oil - Send the oil sample to an oil company for
analysis.
To verify the oil condition, an oil sample should be
The oil company will be able to recommend if the
taken every six months and sent for analysis. This
oil can be further used.
analysis is done by the oil companies and can be
Feedback on the oil analysis can also be obtained
of different levels. When the result is received, a
from MacGREGOR Cranes.
recommendation is normally given if the oil is ap-
proved or has to be changed.
Procedure if Oil Sample is Showing Too High
Contamination
For maximum practical contamination in the sys-
tem, see Table 1. If the oil analysis shows too high contamination, the
oil and the filters should be changed. The crane
should be driven for approx. 1 hr and a new oil sam-
ple should be taken and sent for analysis.
Pump Hose
Gauge outlet 3.1

Bottle
Fig. 1. Sampling Hydraulic Oil.

MAINTENANCE 5.315 E rev.: a 2003-04-04
Cleanliness Level Correlation Table
Particles/millilitre
ISO ≥ 5 Micro- ≥ 15 Micro- ACFTD NAS Disavowed
Code meters meters Gravimetric 1638 "SAE" Level
Level, mg/L (1964) (1963)
26/23 640.000 80.000 1000
25/23 320.000 80.000
23/20 80.000 10.000 100
Not
21/18 20.000 2.500 12
OK
20/18 10.000 2.500
20/17 10.000 1.300 11
20/16 10.000 640 10
19/16 5.000 640 10
18/15 2.500 320 9 6
17/14 1.300 160 8 5
16/13 640 80 1 7 4
15/12 320 40 6 3
14/12 160 40
14/11 160 20 5 2
OK 13/10 80 10 0.1 4 1
12/9 40 5 3 0
11/8 20 2.5 2
10/8 10 2.5
10/7 10 1.3 1
10/6 10 .64 0.01
Table 1. Cleanliness Level Correlation Table.

Hydraulic Oil Tank
The hydraulic oil tank is placed on the wall inside the Oil level MIN
crane house. If the oil level drops to MIN, the oil and temperature
guard activates the lamp LOW OIL LEVEL on the
Checking oil level control panel in the operator's cab. At the same time
the siren sounds.
Check oil level by use of the dipstick. Check that oil
level is between min. and max on the dipstick.
Verify that the guard is working properly by starting the
crane. Loosen the nut that holds the guard and lift it up
slowly.
1
Oil filling
1. Outlet filter
2. Inlet filter
3. Air filter with dipstick
4. Oil level and temperature guard
2 5. Thermometer
6. Vedge valve (oil drain)
3
7. Quick coupling
8. Heater
4
Fig. 1. Hydraulic oil tank.

Filling oil
Oil is filled at an ”aero-quip” type quick-release coupling,
placed on the filter unit, see Fig. 2. When filling oil the
hydraulic system must be at rest and the electric
power switched off.
Fill oil to just under the MAX mark on the dipstick. Use
oil according to the ”Lubricating Chart”.
NOTE! Oil must not be filled directly into the tank.
Cleaning the oil tank

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

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

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

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

clean.
Fill oil to just under the MAX mark on the dipstick. Use
oil according to the ”Lubricating chart”.

MAINTENANCE 5.421.40 E rev.: d 2008-05-14
Lubricants for Deck Machinery

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

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

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

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

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

Viscosity 32 cSt/40oC approx. (ISO VG 32 HV).
Viscosity index (VI) min. 150.
Solidification point -45oC or better.
Example: SHELL Tellus T 32.

MAINTENANCE 5.421.40 E rev.: d 2008-05-14
B. GREASES
Plain bearings and wire rope sockets

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

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

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

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

lubricants for extreme temperatures.

How to order
spare parts 6.0
SERVICE
Hydraulic system 6.1
Mechanical
equipment 6.2
Address:
MacGREGOR Cranes
Cargotec Sweden AB
SE-891 85 ÖRNSKÖLDSVIK, Sweden
E 2009-03-02
Telephone: 46 - 660 - 29 40 00
Telefax: 46 - 660 - 139 77 Electrical
(Spare Parts, Technical Services & 6.3
Technical Documentation Services) equipment
www.macgregor-group.com/cranes
SERVICE 6.000 E rev.: d 2009-03-03
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 Cranes
Cargotec Sweden AB
SE-891 85 ÖRNSKÖLDSVIK, Sweden
Telephone: 46 - 660 - 29 40 00
Telefax: 46 - 660 - 139 77

6.000 E rev.: d 2009-03-03 page 2 (2)
SE-891 85 ÖRNSKÖLDSVIK, 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/

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 Section D

AND HEALTH IN DOCK WORK, section A, B and
D. Section D stipulates the Test loading is needed.
Section A Due to the difficulties for the shipowner to perform

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

be considered sufficient to subject that part, Quality Manager
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 B
Paragraph B.1.2 stipulates that every item of loose

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

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

SERVICE 6.000.1 E rev.: c 2007-01-08

SERVICE 6.000.2 E rev.: d 2009-03-05
RETURN FORM
How to return parts from deck crane manufacturing,
installation or guarantee exchange
Delivery address: MacGREGOR Cranes

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

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

SERVICE 6.000.2 E rev.: d 2009-03-05
RETURN FORM
To be packed inside return box or parcel
Date:
Sent by:
Newbuilding no.:
Ship’s name:
IMO no.:
Crane place on board:

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

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

SERVICE & PARTS 6.004.1 E rev.: bb 2009-03-03
MacGREGOR Global Services
BELGIUM CHINA DENMARK

Antwerpen, (S) (P) Hong Kong, (P) Copenhagen, (S) (P)
MacGREGOR (NLD) B.V. MacGREGOR (SGP) Pte Ltd. MacGREGOR (DNK) A/S
Luithagen-Haven 2E Unit 3119, 31/F, Tower 1, Smedeholm 11,
B-2030 ANTWERPEN Millennium City 1, DK-2730 HERLEV
Phone: (+32) 3-546 46 40 388 Kwun Tong Road, Kowloon Phone: (+45) 44-53 84 84
Telefax: (+32) 3-542 4772 HONG KONG Telefax: (+45) 44-53 84 10
Phone: (+852) 2394 1008
Telefax: (+852) 2787 7652 FINLAND
BRAZIL Telefax: (+852) 2787 9878 (cranes)
Rio de Janeiro, (S) Turku, (P)
MacGREGOR Brasil Ltda MacGREGOR (FIN) OY
Shanghai, (S) (P)
Avenida Rio Branco 31 Hallimestarinkatu 6
MacGREGOR (SHA)
salas 1913 & 1914 FI-20780 KAARINA
Trading Co. Ltd. Phone: (+358) 2-412 11
Edif. Julio Lima Room 1701, Cross Tower
CEP 20090-003 Centro RIO DE Telefax: (+358) 2-4121 517
318 Fu Zhou Road
JANEIRO R.J. 200001 SHANGHAI
Phone: (+55) 21-2516 1790 Phone: (+86) 21-6391 2798
FRANCE
Telefax: (+55) 21-2516 1743 Telefax: (+86) 21-6391 2276 Marseille, (P)
MacGREGOR (FRA) S.A.
CANADA CROATIA Porte 4, Cap Janet
Vancouver, (S) 13314 MARSEILLE Cedex 15
Rijeka, (S) (P)
Nagesco Ltd. Phone: (+33) 491-09 52 52
MacGREGOR (HRV) d.o.o.
961A West 1st Street Telefax: (+33) 491-095 240
Vrh Martinscice 93B
NORTH VANCOUVER, B.C., V7P 1A5 HR-51221 KOSTRENA-RIJEKA
Phone: (+1) 604-985 61 73 Phone: (+385) 51-289 717 / 718
GERMANY
Telefax: (+1) 604-980 44 76 Telefax: (+385) 51-287 154 Hamburg, (S) (P) (LCE)
MacGREGOR (DEU) GmbH
CHILE CYPRUS Normannenweg 24
Santiago (Valparaiso), (S) D-20537 HAMBURG
Limassol, (P)
EXIMTEC Ltda. Phone: (+49) 40-25 44 40
MacGREGOR (CYPRUS) Ltd.
Neveria 4444 - Piso 9 Telefax: (+49) 40-25 44 44 44
Titos Building, Office 201
Las Condes
58 Gladstone Street Hamburg LCE
SANTIAGO
Phone: (+56) 2-207 65 90
CY 3041 LIMASSOL MacGREGOR Logistic Centre
Phone: (+357) 25 763 670 c/o Kühne & Nagel (AG & Co.) KG
Telefax: (+56) 2-207 65 91
Telefax: (+357) 25 763 671 Altenwerder Hauptstraße 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 Cranes Address Telephone Telefax

Cargotec Sweden AB SE-891 85 ÖRNSKÖLDSVIK (+46) 660-29 40 00 (+46) 660-139 77
www.macgregor-group.com/cranes Sweden

GREECE KOREA SINGAPORE

Piraeus, (S) (P) Busan, (S) (P) Singapore, (S) (P) (LC)
MacGREGOR (GRC) Ltd. MacGREGOR (KOR) Ltd. MacGREGOR (SGP) Pte. Ltd.
4-6 Efplias Street 173-5, Songjeong-dong 9 Kian Teck Drive
GR-185 37 PIRAEUS Haeundae-gu 628826 SINGAPORE
Phone: (+30) 210-42 83 838 612-040 BUSAN Phone: (+65) 626 52 322
Telefax: (+30) 210-42 83 839 Phone: (+82) 51-704 0844 Telefax: (+65) 626 41 261
Telefax: (+82) 51-704 0414
INDIA SPAIN
Bombay, (S) NETHERLANDS Bilbao, (P)
Renascent Enterprises Rotterdam, (S) (P) MacGREGOR (ESP) S.A.
Flat 8, Building D/6-9 MacGREGOR (NLD) B.V. Edificio Inbisa
Radha Nagar, Barave Road Albert Plesmanweg 95-97 Amaya, 2 - 1o, Leioa
KALYAN (WEST), Pin - 421 301 3088 GC ROTTERDAM ES-48940 VIZCAYA
Phone: (+91) 251 232 30 65 Phone: (+31) 10-283 2121 Phone: (+34) 94-480 7339
Telefax: (+91) 251 232 06 43 Telefax: (+31) 10-42 93 219 Telefax: (+34) 94-431 6945
Bombay, (S) NORWAY Alicante, (S)

Kalmar India Private Limited Oslo, (P) Stanley van der Pers
903-905, Plot No. 66, Greate MacGREGOR (NOR) A/S c/o Vanpershydro S.L.
Eastern Summit Building "B" Wing Skur 39, Vippetangen Apartado de Correos No. 7
9th Floor, sector-a5, CBD Belapur NOR-0150 OSLO ES-03170 ROJALES - ALICANTE
400 614 NAVI MUMBAI Phone: (+47) 23-10 34 00 Phone/telefax: (+34) 9667 13665
Phone: (+91) 22 2758 2222 Telefax: (+47) 23-10 34 01 Mobile: (+34) 620 953 722
Telefax: (+91) 22 2758 2227
Bergen, (S) SWEDEN
ITALY MacGREGOR (NOR) A/S Örnsköldsvik, (S) (P)
Genoa, (S) (P) Bleivassvegen 105 MacGREGOR Cranes
MacGREGOR (ITA) S.p.A. N-5363 ÅGOTNES Cargotec Sweden AB
Via Al Molo Giano Phone: (+47) 55-56-31 33 00 Sjögatan 4 G
I-16128 GENOA/PORTO Telefax: (+47) 55-56-31 33 23 SE-891 85 ÖRNSKÖLDSVIK
Phone: (+39) 010-254 631 Phone: (+46) 660-29 40 00
Telefax: (+39) 010-2461 194 POLAND Telefax: (+46) 660-139 77
Gdynia, (P) www.macgregor-group.com/cranes
JAPAN MacGREGOR (POL) Sp. z. o.o.
Tokyo, (S) (P) ul. Luzycka 8 Gothenburg, (S) (P)
MacGREGOR-Kayaba Ltd. - PL-81-537 GDYNIA Cargotec Sweden AB
Head Office Phone: (+48) 58-7855 110 MacGREGOR Service
9/F, Suzue Baydium Bldg. Telefax: (+48) 58-7855 111 Warehouse, Atlashuset,
1-15-1, Kaigan, Minato-Ku Banehagsliden 2
105 - 0022 TOKYO SE-414 58 GOTHENBURG
Phone: (+81) 3-5403 1966 Phone: (+46) 31 850 700
Telefax: (+81) 3-5403 1953 Telefax: (+46) 31 424 946



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






SERVICE 6.005.7 E rev.: - 2003-02-12
Introduction
Before proceeding to trouble-shooting, the crane ope-

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

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

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

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

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

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

- Was the operating speed first reduced, or did Electric circuit diagram
the movement run irregularly?
- What manoeuvre immediately preceded the
failure?
Fig. 3.

SERVICE 6.005.7 E rev.: - 2003-02-12
As a first check always try to operate the crane and Analysis of information collected
at the same time check the status of the trouble- By methodical trouble-shooting, it is often possible
shooting panel in the CT2 cabinet, according to error to find, at an early stage, the defect producing the
list and signal overview list, (see instruction under faulty operation, thereby avoiding unnecessary waste
section 6.3). of time.
Also measure the feed pressure at gauge outlets 1 and

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

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

SERVICE 6.100 E rev.: b 1998-10-22
Measures Before Starting, During and After Completed

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

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

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

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

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

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

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

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

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

after completed work.

SERVICE 6.100 E rev.: b 1998-10-22

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

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

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

Internal leakage because of wear. Contact MacGREGOR Cranes.
valving, or hydraulic motor.
N.B.
When the hydraulic system is overheated thermostat BT2 (+85oC) opens
and crane stops.
To cool the system press the "Start" button to start main electric motor in
idling while the control system is switched off. The control system will then
start automatically when thermostat BT2 closes.

SERVICE 6.117 E rev.: b 1999-12-21
Trouble Shooting, Pumps
Pumps, general
Fault Probable cause Remedy
A. Pump not supplying any fluid. Servo error. Contact MacGREGOR Cranes
Worn or cracked parts in the Measure leakage, contact

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

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

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

instruction manual.

SERVICE 6.117 E rev.: b 1999-12-21

SERVICE 6.120.15 E rev.: d 2005-10-04
Slewing Gearset
Oil filling Air filter - Fill gear oil as required (see lubricating instructions
Expansion tank for appropriate type; the approximate quantity
Plug a needed is given on the nameplate).
Expansion pipe
- Fill brake disc chamber with hydraulic oil; e.g. 0,1
litre ATF-oil, type A.
Disc brake
Brake surface sealed with Loctite type 573.
- Before assembling the drive motor, grease shaft
Oil level sight
glass 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
Screws holding function of the brake and the correct control of the
gearset to crane
house floor motor.
Oil outlet
Maintenance
Lubrication
Fig. 1. Slewing gearset. The slewing gearset is splash lubricated. The output
shaft roller bearing is ”for-life” lubricated with ball
Assembly of slewing gearset bearing grease.
- Install slewing gearset in crane without using force. Oil level check
- Use hand pump to release disc brake hydraulically. Inspect oil level when the gear is at rest with the brake
Input drive sleeve must turn easily. engaged.
- Check slewing gear backlash (pinion-to-rim gear).
See description under Checking and adjusting
Oil changes
slewing rim backlash.
- The gear backlash may be adjusted by rotating the Whenever practicable, let the oil drain off while still
gearset one or more screw hole divisions. hot; remove also the filler plug(s).
- Tighten the screws to torque recommended, secure
with Loctite 242 (or a similar compound). Applying For oil change open both pipes. Remove air filter with
a suitable sealing compound, such as Loctite 640, oil expansion tank at marked pos. a, see Fig 1.
on the mating surfaces of the flanged connection,
is recommended. At low ambient temperatures, flush out the gearcase
- Remove threaded plug from top of expansion pipe with a quantity of fresh oil to remove abraded matter
(for transport sealing only). and contamination products.
- 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.

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 If coarser abraded matter (above 25 µ) or flake off
the filling drained off at intervals as described in the material from the gear teeth is found, the gearset must
Maintenance Chart. To obtain a representative be dismantled, irrespective of the actual amount of
sample, drain the gearcase during operation and with foreign matter present, beginning at the input end of
the oil at operating temperature. the gearset.
Oil discoloration
Hydraulic-Release Multiple-Disc Brake
A darkish or black colour of the used oil suggests that
temperatures in excess of 100o C did occur in opera- Technical description
tion, causing accelerated aging of the oil and impaired The brake comprises the following major components:
lubricating properties. In this case the oil should be - Brake piston
changed at shorter intervals. - Brake cylinder
- Disc carrier
If the oil sample displays a cloudy aspect, it may be - Internal discs
that water has managed to seep into the oil. The oil - External discs
must then be changed a t o n c e, and the gearcase - Sealings
flushed out very thoroughly several times with fresh - Thrust spring
oil.
The brake housing is mounted on top of the gearcase,
The gearcase should preferably be dismantled for with long assembly screws through the motor adap-
inspection beginning at the input side, and the ter housing and both parts of the brake housing.
components examined for signs of corrosion.
The sleeve disc carrier, with the internal discs, is fixed
Foreign solid matter on the driven shaft with a shaft key or by splines.
- As a first simple test, drop some of the used oil

The disc assemblies are pressed together by a set
onto the filter fleece specified. Coarse foreign mat-
of thrust springs and the brake is disengaged by
ter, if present, will then show up on inspection,
hydraulic power.
preferablythrough a magnifying glass.
- A better test may be made by diluting an oil sample
with n-heptane, passing it through a diaphragm Maintenance
filter, washing and drying it, and weighing it to The brake is self-adjusting.
determine the mass difference.
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 Test of brake torque may be performed according to
mass of the oil in the gearcase. These impurities must following:
be, exclusively, very fine abraded matter (max 25 µ). - Drive hydraulic motors against closed brakes.
If the contamination keeps within these limits, Brakes shall be able to withstand motor torque
continued operation of the gearset is permitted after without slipping.
the oil has been changed. Note! Test procedure shall be performed only for a
short period, a few seconds.

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 Leakage oil
of discs
Disc carrier
Internal discs
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 - Slew the crane 90 degrees and check.
worn. - Proceed to check the backlash at four 90-degree
- If discs are coloured dark yellow to blue, the discs position in the rim.
have been overheated. Replace discs and springs. - Put the dial gauge on the tooth of the pinion. By
- Inspect sealings for wear. If sealings are defect manual turning at the input, the pinion can be moved
replace brake cylinder and piston with sealings to in both directions up to contact with the teeth. Now,
new ones. the tooth flank clearance can be exactly measured
on the dial gauge.
b. Brake heats - Check the backlash at one spot
Check the hydraulic pressure to make sure that it is - Slew the crane 90°. Check again
sufficient in order to disengage the brake completely. - Proceed to check the backlash at four 90-degree
positions in the rim
- Compare the four backlash values.
Checking and setting slewing rim Backlash values: See drawing "Slewing
backlash assembly".
An oversize backlash between the pinion and the The backlash shall be set at the position of the slewing
slewing rim will cause irregularities in the slewing rim with the lowest backlash value.
movement of the crane. Read this instruction carefully
prior to checking or resetting! Setting backlash
The backlash may be set by turning the entire gearset
Checking backlash one or more screw hole divisions.
The backlash should be checked by a dial gauge or
a feeler. When slewing the crane, the backlash may Proceed as follows:
vary from one position to another due to some slight - Slew the crane into the position with the lowest
excentricity of the slewing rim. It is therefore backlash value.
recommended to check the backlash at four positions - Remove all screws holding the gearset to crane
of the slewing rim. house floor.
- Release the disc brake hydraulically by means of a
Proceed as follows: manual pump.
- Check the backlash at one spot.

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 Upper part
the hoses connected or by space limitations. To over-
come this problem, release the upper part of the Screws
gearset by just removing the holding screws, see Fig.
3 ”Slewing gearset”.
Screws holding
Make sure that the upper part can be turned freely. gearset to crane
house floor
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

Fig. 3. Slewing gearset.
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.

SERVICE 6.120.64 E rev.: n 2009-04-07
Hydraulic Motors
Hoisting, Luffing, and Slewing Circuits
Hydraulic motor 188 1221-801 Oil filling

Drain connection
Before the first operation the hydraulic motor housing

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

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

Drain connection

Displacement Vg: 160-79 cm3/rev.

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

Drain connection


Oil filling
Drain connection

SERVICE 6.120.64 E rev.: n 2009-04-07

Drain connection


Oil filling
Drain connection

Drain connection


Oil filling
Drain connection

Drain connection


Oil filling
Drain connection

SERVICE 6.120.64 E rev.: n 2009-04-07
Hydraulic motor 188 1774-801 Oil filling / Drain

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

connections.
Oil filling / Drain

connection
Hydraulic motor 189 2418-801

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

Oil filling
Drain connection
Oil filling
Drain connection

Displacement Vg: 160.4 cm3/rev.

Oil filling
Drain connection

SERVICE 6.120.64 E rev.: n 2009-04-07

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

Oil filling
Drain connection

Drain connection


Oil filling
Drain connection


Oil filling
Drain connection

SERVICE 6.120.64 E rev.: n 2009-04-07
Before the first operation the hydraulic motor housing Oil filling
Drain connection
Displacement Vg: 160-72.5 cm3/rev.

Oil filling
Drain connection

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

Oil filling
Drain connection

SERVICE 6.120.64 E rev.: n 2009-04-07

Drain connection
Displacement: 200 cm3/rev.

Oil filling
Drain connection

Drain connection


Oil filling
Drain connection

Drain connection

Oil filling
Drain connection

SERVICE 6.120.64 E rev.: n 2009-04-07

Drain connection


Oil filling
Drain connection

Drain connection

Displacement: 200-100 cm3/rev.

Oil filling
Drain connection

Drain connection


Oil filling
Drain connection

SERVICE 6.120.64 E rev.: n 2009-04-07

Drain connection


Oil filling
Drain connection

SERVICE 6.120.107 E rev.: - 2008-03-28
Winches, Hoisting/Luffing
Winch and gearbox Journal Luffing winch

bearing
General
The luffing winch (upper) is driven by one high speed

hydraulic motor with fixed displacement, via a planetary
gearbox.
The hoisting winch (lower) is/are driven by one or two Oil filler inlet
Oil dipstick
high speed hydraulic motor(s) with variable displace-
ment, via a planetary gearbox.
Oil filler inlet for wet Oil outlet
The planetary gearbox has splash lubrication and is running motor and shaft.
filled with gear oil.
A brake is integrated in each winch gear set. When the
winch is running, the brake is automatically released Journal Hoisting winch
by hydraulic pressure. bearing
Assembly of winches
- Mount the winch together with winch support. The
clamping screws of the winch support must easily
be connectable.
- Tighten the screws according to torque
recommended. Secure with Loctite 242 or a
similar compound.
Oil filler inlet Oil outlet
- Connect brake line and release disc brake
Oil dipstick
hydraulically. The drive sleeve in the drive unit
must turn easy.
- Remove plug off the drive sleeve of the drive unit. Fig. 1. Hoisting and luffing winches with oil filler inlet,
For protection against corrrosion the drive sleeve dipstick and outlet.
is provided with gear oil from the gear. The plug
prevents a filling with oil of the motor flange before - Oil type: See instruction "Lubricants for Deck
mountage of the motor. Machinery", section 5.
- Before test-running, fill the motor flange completely - Check rope winch with running motor as to function.
with oil. Check above all the control and function of the
- Center motor in the motor flange. Fix motor with holding brake and the drive motor.
screws. Motor shaft must be grease-free. - After test-running check oil level once more with
- Remove plug off the vent pipe and mount the air oil dipstick. During the test-running, the oil level in
filter. the gear and motor flange is adjusting itself and
- Check oil level with oil dipsstick. Refill oil if fills the space around the motor shaft slowly with
necessary. gear oil. Therefore the oil level may be reduced.
- The rope winch is normally filled with oil. If the - If necessary, refill oil.
winch is supplied without oil, this is indicated on a - The journal bearing is filled with grease. Before
corresponding label. taking into operation grease again until grease
- Oil volume: See name plate on winch or instruction emerges at the sealing profile.
"Technical Data", section 2. - Insert rope and fix it. Secure screws accordingly.

SERVICE 6.120.107 E rev.: - 2008-03-28
Oil changes Oil discoloration

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

Foreign solid matter
See "Lubricating chart", section 5.
As a first simple test, drop some of the used oil onto
Type of oil and grease:
the filter fleece specified. Coarse foreign matter, if
See "Lubricants for deck machinery", section 5.
present, will then show up on inspection, preferably
Oil volume:
through a magnifying glass.
See "Technical data", section 2.
A better test may be made by diluting an oil sample
with n-heptane, passing it through a diaphragm
Sampling oil filter, washing and drying it, and weighing it to
Withdraw a sample of gearbox oil for inspection at determine the mass difference.
intervals as described in the "Maintenance Chart".
To obtain a representative sample, drain the gear Overall assessment
case during operation and with the oil at operating The maximum permissible amount of foreign matter
temperature. carried by the oil is some 0.15 per cent of the total
mass of the oil in the gear case. These impurities
Procedure for oil sampling: must be, exclusively, very fine abraded matter (max
- The oil temperature in the gearbox should be 25 m). If the contamination keeps within these
above +40 0C. limits, continued operation of the gear set is permitted
- Special oil sampling bottles should be used that after the oil has been changed.
can be obtained from oil companies. If coarser abraded matter (above 25 m) or flake off
- The oil sample should be taken from the oil drain material from the gear teeth is found, the gear set must
on the winch, see Fig. 1. be dismantled, irrespective of the actual amount of
- Drain 1-2 litres of oil into a bucket. This oil should foreign matter present, beginning at the input end of the
be disposed of. gear set.
- Fill the oil sample bottle.
- Send the oil sample to an oil company for analy-
sis.
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 Cranes.

SERVICE 6.120.107 E rev.: - 2008-03-28
Hydraulic-Release Multiple-Disc Brake
Technical description Trouble-shooting

The brake comprises the following major components. Braking torque insufficient
See also Fig. 2.
Test of brakes may be performed as follows:
- Brake piston
- Brake cylinder - Drive winch hydraulic motors against closed
brakes. The motors shall not be able to rotate.
- Disc carrier
Note! Test procedure shall be performed only for
- Inner discs
a short period; a few seconds.
- Outer discs
- Inspect brake discs and replace if excessively
- Hydr. part for disc brake
worn. If brake discs are coloured dark yellow to
- Pressure spring
blue, the discs have been overheated. Replace
The brake housing is mounted on top of the gearbox, discs and springs.
with long assembly screws through the motor adapter - Inspect brake for leakage. If leakage appears in
housing and both parts of the brake housing. oil pressure unit, the complete unit must be
The disc assemblies are pressed together by a set of replaced.
thrust springs and the brake is disengaged by hydrau- Note! Sealings are not available as spare parts.
lic power.
Brake heats
Maintenance Check the hydraulic pressure to make sure that it is
The brake is self-adjusting. sufficient in order to disengage the brake completely.
Motor side
Hydr. part for
disc brake Pressure spring
Connect
pressure oil
Leakage oil
Arrangement of
Outer disc Inner discs Disc carrier
the brake discs
Gear side
Fig. 2. Disc brake

SERVICE 6.120.107 E rev.: - 2008-03-28
Hoisting winch additional equipment

(optional)
Adjustment of pressure roller
After replacement of wire the pressure roller must be re-

adjusted.
- Tighten adjusting nut carefully until the pressure

roller touches the hoisting wire on the drum.
- Tighten adjusting nut 12 turns to get correct
spring force.
- Secure with the locking nut.
Adjusting nut
Pressure roller
Locking nut
Fig. 6. Hoisting winch with pressure roller.

SERVICE 6.121.3 E rev.: a 1999-03-16
Trouble-Shooting Chart, Hydraulic High Speed Motors
Fault Probable cause Action
The motor does not run. Mechanical stop in the drive. Check system pressure. If the pres-
sure has risen to the relief valve set-
ting, remove the load from the drive.
The motor does not deliver enough Investigate the pressure level in the
torque because the pressure differ- system and correct the setting of the
ence across the motor is not great pressure limiting valve if necessary.
enough for the load.
Insufficient or no oil being supplied Check the hydraulic system. Check

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

Investigate the drain oil.
External oil leakage on the motor. The radial lip seal is worn. Replace the radial lip seal.

SERVICE 6.121.3 E rev.: a 1999-03-16
Insufficient braking torque. The brake discs are worn out. Dismantle the brake and replace
the worn discs.
The brake does not open. Insufficient brake opening pres- See Hydraulic Circuit - gauge con-
sure. nection 2.
Seals or piston damage. Replace seals. Replace the piston.

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

1221.

SERVICE 6.127.50 E rev.: a 2008-11-13
High Pressure Pumps
General
All pumps are of the straight axial piston type with variable The hydraulic circuit diagrams in this instruction
displacement controlled by a servo valve mounted on the refers to the standard hydraulic system of
pump housing. MacGREGOR hydraulic deck cranes.
The pumps are equipped with one set screw for adjustment Minor variations in the hydraulic system may
of “plussing“. “Plussing“ of the pumps is done to compensate occur in individual cranes of the same type.
for internal leakage in pumps and motors to prevent load
drops. See Fig. 1. A complete hydraulic circuit diagram relating
specifically to your crane will be found in the
instruction manual, section “Spare Parts”, Group
9.4.
Set screw for

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

screw is limited according to the measure X, specified
Table 1. in Table 1. An X-measure outside this interval is not
allowed. The difference in X-measure from zero to
X (mm) maximum plussing (0.75 mm) corresponds to one
complete turn CW (clockwise) of the set screw.
14.75 Max. dimension (position at zero plussing)
14.0 Min. dimension (position at max. plussing) After adjustment tighten the locking nut with 25 Nm.
Fig. 1. Hoisting and luffing pump.

SERVICE 6.127.50 E rev.: a 2008-11-13
Function checking /
Adjusting of “plussing“
Hoisting winch
- No load in hook. - Adjust the plussing pressure on the hoisting pump by
- Stop the crane. turning the set screw. Turn the set screw CW or CCW
- Install a pressure gauge 0-400 bar at connection 3.1 (clockwise or counter-clockwise) to increase or
on pump 1111. See Fig. 6. decrease the plussing pressure. See *) in note (page
- Lock the brake in closed position by closing ball valve 1) and in Fig. 1. Pressure should be set according to
1663. the hydraulic circuit diagram in section 9.4.
- Start the crane. The oil temperature should be 40°C. - Control the pressure at connection 3.1.
- Actuate directional valve 1221 manually with a small - After adjustment tighten the locking nut. See *) in
screwdriver or similar during checking and note (page 1) and in Fig. 1. After tightening of the
adjustment, see Fig. 2. locking nut, make sure the hydraulic pressure has
- Check the plussing pressure on the pressure gauge not been changed.
at connection 3.1 according to hydraulic circuit - If there is more than one hoisting pump, the upper
diagram. See Fig. 6. pump should be adjusted.
- If the plussing pressure is incorrect according to the - Stop the crane.
hydraulic circuit diagram an adjustment must be - Open valve 1663, see Fig. 2.
made.
- Stop the crane.

- Loosen the locking nut with a hook wrench.
- Start the crane.
- Actuate directional valve 1221 manually with a small
screwdriver or similar during checking and
adjustment, see Fig. 2.
Directional valve 1221
Directional
valve 1226
Actuate
C-00013
Ball valve 1663
Fig. 2. Valves on hoisting winch.

SERVICE 6.127.50 E rev.: a 2008-11-13
Luffing winch
- No load in hook. - Adjust the plussing pressure on the luffing pump by
- Park the crane or move the hook block close to the turning the set screw. Turn the set screw CW or CCW
jib top. (clockwise or counter-clockwise) to increase or
- Stop the crane. decrease the plussing pressure. See *) in note (page
- Install a pressure gauge 0-400 bar at connection 5.1 1) and in Fig. 1. Pressure should be set according to
on pump 2111. See Fig. 7. the hydraulic circuit diagram in section 9.4.
- Lock the brake in closed position by closing valve - Control the hydraulic pressure at connection 5.1.
2661, see Fig. 3. - After adjustment, tighten the locking nut. See *) in
- Start the crane. The oil temperature should be 40°C. note (page 1) and in Fig. 1. After tightening of the
- Actuate directional valve 2221 manually with a small locking nut, make sure the hydraulic pressure has not
screwdriver or similar during checking and been changed.
adjustment. See Fig. 3. - If there is more than one luffing pump, the upper pump
- Check the plussing pressure at connection 5.1 should be adjusted.
according to hydraulic circuit diagram. See Fig. 7. - Stop the crane.
- If the plussing pressure is incorrect according to the - Open valve 2661, see Fig. 3.
hydraulic circuit diagram an adjustment must be
made.
- Stop the crane.

- Loosen the locking nut with a hook wrench.
- Start the crane.
- Actuate directional valve 2221 manually with a small
screwdriver or similar during checking and
adjustment. See Fig. 3.

Actuate

C-00012
Ball valve 2661
Fig. 3. Valves on luffing winch.

SERVICE 6.127.50 E rev.: a 2008-11-13
Slewing machinery
Set screw for

adjustment of
zero setting
Servo valve
XX*)
Locking nut
Electric connectors
*) Note! The allowed adjustment range of the set screw
is limited according to the measure XX, specified in
Table 2. Table 2. An XX-measure outside this interval is not
allowed. The difference in XX-measure from min. to max.
XX (mm) dimension (0.70 mm) corresponds to one complete turn
CW (clockwise) of the set screw.
14.4 Min. dimension
15.1 Max. dimension After adjustment tighten the locking nut with 25 Nm.
Fig. 4. Slewing pump.
Zero setting of slewing pump Zero setting

- No load in hook. - If the crane does move, right or left, an adjustment
- Start the crane. The oil temperature should be 40°C. must be made using the set screw for zero setting,
- Actuate directional valve 3221 manually with a see Fig. 4.
small screwdriver or similar during checking and - Loosen the locking nut with a hook wrench.
adjustment. See Fig. 5. - Actuate directional valve 3221 manually with a small
- Ensure that there is no slewing movement, otherwise screwdriver or similar during checking and
the zero setting must be adjusted. adjustment. See Fig. 5.

SERVICE 6.127.50 E rev.: a 2008-11-13
- Adjust the zero setting on the slewing pump by Installation of a new servo or a complete
turning the set screw. Turn the set screw CW or CCW new pump
(clockwise or counter-clockwise). See *) in note and
in Fig. 4. When a new servo unit or a complete pump is
Note! Do not turn the set screw more than ± 1/2 turn. installed, a function check of the "plussing" and zero
- After adjustment tighten the locking nut. After setting has to be carried out. Proceed according to
tightening of the locking nut make sure the zero “Function checking/Adjusting of “plussing”.
setting has not been changed.
- Stop the crane.
Hydraulic oil tank
Ball valve 3661
Actuate
C-00015
Fig. 5. Valves for slewing.

SERVICE 6.127.50 E rev.: a 2008-11-13
Valve
Outlet 3.1
Fig. 6. Part of hoisting circuit.

SERVICE 6.127.50 E rev.: a 2008-11-13
Valve
Outlet 5.1
Fig. 7. Part of luffing circuit.

SERVICE 6.127.50 E rev.: a 2008-11-13
Valve
Outlet 6.2
Outlet 6.1
Fig. 8. Part of slewing circuit.

SERVICE 6.132.18 E rev.: - 2003-02-20
Replacement of Feed Pump

Crane Type GLB
Introduction
The feed pump is placed on the pump unit. Before Notice! Before restarting the crane open valve
replacing the feed pump proceed according to 4335, otherwise the feed pump will be damaged.
below.
Close valve 4335 before removing suction hose in

order to limit oil leakage.
Pump unit
Suction hose
Valve 4335
Oil tank
Pump 4113
Pump
Valve
Fig. 1.
1 (1)
SERVICE 6.142.5 E rev.: a 2002-01-09
Recommendation for Inspection and

Replacement of Hydraulic Hoses
Hydraulic hoses and couplings assembled

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

SERVICE 6.142.5 E rev.: a 2002-01-09

SERVICE 6.189 E rev.: f 2007-04-11
Hydraulic Piston Accumulators
Function Charging hydraulic accumulators with nitrogen (N2)

A hydraulic accumulator functions as a source of pres- All crane motors must be immobilized.
surized fluid. Conversely, when the pressure falls off,
the accumulator supplies oil to the hydraulic system. 1. Dismount valve guard and unscrew the
protective cap from gas valve.
Note! - Do not bleed hydraulic accumulators! 2. New design, see Fig. 1. Connect the three-way
valve to the gas valve of the accumulator. The
bleed valve should be tightly closed.
Charging equipment
2a. Old design, see Fig. 2. Connect the three-way
To charge hydraulic accumulators, art. nos. see
valve to the gas valve of the accumulator. The
below, MacGREGOR (SWE) AB supply a charging
filling screw of the three-way valve shall be
valve and associated equipment, Fig. 2, comprising:
backed out completely, and the bleed valve
- a three-way valve
tightly closed.
- a 0-25 bar pressure gauge
3. Connect the charging valve, see Fig. 3 to the
- a 0-60 bar pressure gauge
reducing valve at the nitrogen cylinder.
- a 1-metre hose with a W24 connector for nitro-
4. Back out the adjusting screw of the reducing
gen cylinder
valve on the nitrogen cylinder until the valve
- two reduction connectors, W24/32M and W24/14D.
spring is unloaded.
5. Open the nitrogen cylinder valve.
Charging pressure for 388 0362-801: 15 ±1 bar at 20°C.
6. Adjust the reducing valve to the correct charg-
ing pressure.
New design
Valve guard
Protective
Gas valve cap
Protective cap Gas valve Open/close
Valve guard hexagonal nut
Open/close
hexagonal nut
Fig. 1. New design. Piston accumulators.

SERVICE 6.189 E rev.: f 2007-04-11
7. New design, see Fig. 1. Open the hexagonal nut 10. Close the nitrogen cylinder valve.
on the gas valve counter-clockwise to stop, by 11. Open the bleed screw of the three-way valve to
using a 19 mm fork wrench. discharge the pressure in the filling hose.
7a. Old design, see Fig. 2. Screw in the filling screw 12. Adjust the reducing valve to zero.
of the three-way valve but not so tightly that the 13. Unscrew the charging equipment from the nitro-
gas valve of the accumulator is damaged. gen cylinder and from the accumulator.
8. Fill nitrogen. 14. Check tigthness of accumulator gas valve, us-
9. New design, see Fig. 1. Check the nitrogen ing soap water.
pressure when the temperature and the pressure Note! - The protective cap shall be fitted with an
of the gas become stable. When the correct O-ring which must fit correctly into its groove.
charging pressure has been obtained, close the 15. Screw on protective cap of the gas valve.
gas valve by turning the hexagonal nut clockwise 16. After charging the accumulator, fit a lable carry-
by use of the 19 mm fork wrench. ing the charging date and signed by the operator.
9a. Old design, see Fig. 2. Check the nitrogen
pressure when the temperature and the pressure Note! For charging, it is not necessary to install a
of the gas have become stable. When the correct reducing valve on the nitrogen cylinder.
charging pressure has been obtained, again
back out the filling screw of the three-way valve.
Old design
Valve guard Valve guard
Protective cap Gas valve Gas valve Protective

cap
Fig. 2. Old design. Piston accumulators.

SERVICE 6.189 E rev.: f 2007-04-11
Filling screw, to be
used for old design
Pressure gauge
Bleed valve connection
Connector for hose

Connector for accumulator coupling
gas valve
Hose
W24 connector for

nitrogen cylinder
Fig. 3. Charging equipment.

SERVICE 6.189 E rev.: f 2007-04-11

SERVICE 6.209.15 E rev.: - 2004-04-28
Inspection of Climb Protection, Jib and Crane House Top
- Check climb protection for wear and damage.

- Check distance between outer edge of wire she-
ave and climb protection.
Distance between outer edge of wire sheave and
climb protection should not exceed 1/3 of wire rope
diameter, max. 10 mm and 8 mm respectively, see
Fig. 1 and Fig. 2.
Max. 10 mm Max. 8 mm
Fig. 1. Jib top, example. Fig. 2. Crane house top, example.

SERVICE 6.214 E rev.: i 2007-03-02
Tightening Torques
Studs/Screws and Bolts
Introduction
This instruction applies to studs, screws and bolts Note!

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

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

5 4.9 7.0 8.3 5 5.7 8.1 9.7
6 8.4 12.0 14.6 6 9.8 14.0 17.0
7 13.8 19.8 23.2 7 16.1 23.0 27.0
8 20.6 28.4 34.4 8 24.0 33.0 40.0
10 40.4 55.9 67.9 10 47.0 65.0 79.0
12 69.7 98 117 12 81.0 114 136
1/2" 80.8 114 136 1/2" 94.0 132 158
14 110 156 187 14 128 181 217
5/8" 159 224 269 5/8" 185 260 312
16 169 238 286 16 197 277 333
3/4" 280 393 471 3/4" 325 457 548
18 237 332 398 18 275 386 463
20 331 465 558 20 385 541 649
22 445 626 752 22 518 728 874
24 572 804 963 24 665 935 1120
1" 670 942 1131 1" 779 1095 1315
27 826 1161 1393 27 961 1350 1620
30 1127 1582 1901 30 1310 1840 2210
1 1/4" 1308 1840 2208 1 1/4" 1521 2140 2567
33 1522 2133 2563 33 1770 2480 2980
36 1961 2761 3311 36 2280 3210 3850
39 2520 3543 4248 39 2930 4120 4940
42 3130 4395 5280 42 3640 5110 6140

SERVICE 6.214 E rev.: i 2007-03-02
As a rule, always change screws with specified tight- Stainless bolts and hydraulic pipe couplings
ening torque on cranes in operation if the joint has to greased with Gleitmo paste
be opened for some reasons.
Thread Tightening torque in Nm
If any joint has been opened apply Intertuf after tight- d 10 Nm ≈ 1 kpm
ening the joint to avoid rust damage. Austenite (A)
50 70 80
6 3.3 7 9.3
8 7.8 17 22
SAE flange for high pressure hose couplings
10 15 33 44
Tightening torque in Nm 12 27 57 76
Flange Screw 10 Nm ≈ 1 kpm 14 43 91 121
6000 psi Class H 10.9 and 12.9 16 65 140 187
18 91 195 260
3/4" M10 54
20 127 273 364
1" M12 94
22 171 367 490
1 1/4" M14 150
24 220 472 629
1 1/2" M16 230
27 318 682 909
2" UNC 3/4 377
30 434 930 1240
33 585 1250 1670
36 755 1620 2160
39 969 2080 2770

SERVICE 6.214 E rev.: i 2007-03-02
Strength of screws and bolts
Strength class Min. ultimate strength Min. tensile strength Corresponding strength
N/mm2 (kp/mm2) N/mm2 (kp/mm2) class of nuts
4.6 400 (40) 240 (24) 4

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

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

Forged

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

assembling.
Type of Thread Tightening Type of Thread Tiightening

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

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

Grease
O-ring sealed Sealing

SERVICE 6.215.21 E rev.: b 2007-06-08
Service Door (Opening and Closing)

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

SERVICE 6.215.21 E rev.: b 2007-06-08
B. Procedure for closing
1. Put on safety belt.

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

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

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

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

questions.

SERVICE 6.216.82 E rev.: b 2004-01-19
Rope Reeving Diagram for Cranes Type GLB-2
Important! Important!
It is of utmost importance to grease the wire thimble The wire rope thimble must be safely secured by
according to instructions "Lubricating Chart" and bending the lock washers, see Fig. 2 on page 2.
"Lubricants for Deck Machinery".
Number of reeving parts: Note! Before rigging slacken the pressure roller on
Luffing: 5 parts the hoisting winch. See Fig. 4.
Hoisting: 6 parts
Fig. 1. Rope reeving and securing wire rope thimbles.

SERVICE 6.216.82 E rev.: b 2004-01-19
Luffing wire rope
Hoisting wire rope
Fig. 2. How to secure the lock washer for the wire Fig. 3. Rope reeving for Slack wire safety switch,
rope thimble. hoisting and luffing. Slack wire condition.

SERVICE 6.216.82 E rev.: b 2004-01-19
Adjustment of pressure roller on the

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

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

the washer/bearing.
Locking nut

SERVICE 6.222.1 E rev.: a 1998-04-17
Handling, Installation and Maintenance

of Steel Wire Ropes

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

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

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

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

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

dry place indoors. The ropes must not be allowed
to rest on the floor. They can be placed on pallets.

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

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

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

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

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

on a turntable or the coil is rolled along the ground
like a hoop. In the latter case ensure that the sur-
face is clean; sand or grit that sticks to the lubricant
might damage the wires when the rope travels or
sheaves.

SERVICE 6.222.1 E rev.: a 1998-04-17
Under no circumstances must the rope be pulled If one end of the ropes has a fitting attached, as it
off a coil while it is lying on the ground or looped is mostly the case with deck cranes, there is no
over the head of the reel, because this will inevita- other possibility than pulling the loose rope end
bly induce one torsion per wrap into the rope. through the whole reeving system.
The most common rope fittings for deck cranes are

shown below.
The aluminum ferrule with mechanical splice.

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

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

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

cessary as to whether the wire rope should be pulled
through the whole reeving system or whether it
should first be wound from the coil or reel onto the
drum and afterwards be reeved into the system.

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

increased by using a Chinese finger. Fewer prob-
If the rope is wound at the bottom of the drum, it lems are caused by con-
should leave the reel at the buttom and vice versa: necting wire ropes with
i.e., always reel from top to top or from bottom to welded-on pad eyes or
bottom. chain links, which are
joined by either strands or
If this procedure is not strictly followed, the rope thin wire ropes.
will either try to twist between reel and drum or it
will later try to regain its preferred position when in
practical service. In both cases structural changes
of the rope may occur. This connection provides satisfactory
load capacity, it is flexible and pre-
vents the transfer of twist from the old
rope into the new one. When using
two strands to pull the rope into place,
these will indicate the intensity of twist
in the old rope on the basis of the
number of turns they have made dur-
Installing the rope with the help of the old ing the installation procedure.
one or by a thinner rope
Another possibility is connecting the
If the new rope is pulled in by the old one or by a rope ends with Chinese fingers. These
thinner rope one must make sure that the connec- are tubes made out of braided
tion between these ropes is absolutely safe. In ad- strands, which are pulled over the
dition it must be ensured that the thinner rope can- rope ends and then secured at their
not rotate. Rotation-resistant steel wire ropes or ends with tape or seizing wire. Under
three-strand ibre ropes for instance, can be re- load the Chinese fingers will contract
commended for this purpose. When using conven- and hold the rope ends by friction.

SERVICE 6.222.1 E rev.: a 1998-04-17
When installing a lang lay rope one must take care Under no circumstances should one attempt to gen-
that the Chinese finger cannot unwind from the rope erate the tensioning load by jamming the rope, for
like the nut from a screw. It is recommended to wrap instance between two boards. Structural changes
a tape around the whole rope length to be held by would deform the rope beyond repair.
the Chinese finger to increase the friction.
Installing under load
To achieve perfect spooling of the rope on the drum

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

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

plank bearing against the reel flanges or by a brak-
ing disk attached to the reel.

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

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

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

SERVICE 6.222.1 E rev.: a 1998-04-17
Relubricating steel wire ropes It is important with all different methods of

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

SERVICE 6.222.1 E rev.: a 1998-04-17
Cutting or shifting steel wire ropes
Very often wire ropes must be discarded although

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

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

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

at those sections where the rope rubs against the
adjacent winding (crossover point) and must be
deflected to the side. If the damage caused in these
sections is the main reason for discarding the rope,
several cuttings or shiftings will move the stresses
to different rope zones and possibly multiply the
service life of the rope.

SERVICE 6.222.1 E rev.: a 1998-04-17
Examples of damage to steel wire ropes
The following pages illustrate some typical exam-

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

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

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

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

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

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

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

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

size sheaves are used. Vibrations and torsional
stress loads in the rope accelerate fatigue rupture.

SERVICE 6.222.1 E rev.: a 1998-04-17

SERVICE 6.223.11 E rev.: a 2004-01-19
Replacement of Wires
One or Two Fall Rigging
General
This instruction covers almost all MacGREGOR - Run the winch by pulling in the new hoist wire, so
cranes type GLB, which are equipped with limit switch that there are the same numbers of revolutions of
boxes containing electric limit switches. The wire on the wire drum as noted earlier and that the
procedure is general and should be seen as a winch corresponds to the position marked earlier .
guidance only. - Attach the wire rope end to the wire drum with the
wire rope clamps and tighten the bolts.
- Assemble the limit switch box in its proper place,
Hoisting winch / wire
the marking on the shaft/box must correspond.
For cranes with one or two fall rigging proceed as
- Run in the rest of the wire.
follows:
NB. The wire thimble should be safely secured,
- Place the jib in the jib rest.
see Fig. 6 or 7.
- Slacken the pressure roller on hoisting winch, see
- Remove the wooden piece holding the slack wire
Fig. 9.
roller.
- Disengage the slack wire switch by blocking the
- Test the winch and check all limits, which should
spring tensioned roller, which can be done with a
now function correctly, if the new wire is the same
piece of wood, see Fig. 1.
length as the old one. If necessary, adjust the limits,
- Loosen the wire rope thimble attached to the crane
see instruction under section 6.3.
house top, see Fig. 6.
- Readjust the pressure roller, see Fig. 9.
- Run the winch by paying out the hoist wire, and at
the same time pulling on the loose wire end.
- Stop the winch just before it enters into the empty Luffing winch / wire
drum limit. - Place the jib in the jib rest.
- Mark the position of the wire drum in relation to the - Disengage the slack wire switch by blocking the
bracket, this to avoid setting of all hoisting limits spring tensioned roller, which can be done with a
again after installing the new hoist wire. piece of wood, see Fig. 1.
- Remove the cover from the limit switch box. - Loosen the wire rope thimble attached to the crane
NB. Mark the position of the shaft in relation to the house top / jib, see Fig. 6 or 7.
box. See Fig. 2. - Lower the luffing wire rope to the deck by means
- Loosen the bolt that holds the limit switch box. of a rope.
- Remove limit switch box. - Mark the position of the wire drum in relation to the
- Note how many revolutions of the wire there are bracket.
left on the drum at this position. Make a mark on - Remove the cover from the limit switch box.
the drum. NB. Mark the position of the shaft in relation to the
- Secure the wire so the wire clamps that hold the box, see Fig. 2.
end of the wire can be removed safely. - Remove the limit switch box.
- Attach a long rope (longer than the wire rope) to - Note how many revolutions of the wire there are
the wire end, and place it 4 to 5 turns around the left on the drum at this position. Make a mark on
wire drum. the drum.
- Run the winch by paying out the old (damaged) - Secure the wire so the wire clamps that hold the
wire until it is on the deck. end of the wire can be removed safely.
- Attach the new hoist wire to the same rope by using
tool 662 0754-000, see Fig. 5.

SERVICE 6.223.11 E rev.: a 2004-01-19
- Attach a long rope to the wire end (longer than the Hoisting Piece of wood
wire rope ≈ 100 x 200
wire rope) and place it 4 to 5 turns around the wire
drum.
- Run the winch by paying out the old, damaged
luffing wire, and at the same time pulling on the Luffing wire rope
loose wire end until it is on the deck.

- Attach the new luffing wire to the rope, by using
tool 662 0754-000, see Fig. 5.
- Run the winch by pulling in the wire, so that there Piece of wood
are the same numbers of revolutions of wire on ≈ 100 x 200
the wire drum as noted earlier and that the winch
corresponds to the position marked earlier as it
was when the limit switch box/gear box was
disconnected.
- Attach the wire rope end to the wire drum by the
wire rope clamps and tighten the bolts.
- Assemble the limit switch box/gear box in its proper
place.
- Run in the rest of the wire.
- Attach the wire rope end to the crane house top or
jib, see Fig. 6 or 7.
NB. The wire rope thimble should be safely se-
cured to the crane house top/jib, see Fig. 6 or 7.
- Remove the wooden piece holding the slack wire
roller.
- Test the winch and check all limits, which should
Fig. 1. Disengage of slack wire safety switch.
now function correctly, if the new wire is the same
length as the old one. If necessary, adjust the limits,
see instruction under section 6.3.
Tightening torque: In the first place look for

tightening torque on the winch spare part picture,
in the second place see instruction 6.214 E.
Fig. 2. Marking inside limit switch box.

SERVICE 6.223.11 E rev.: a 2004-01-19
Limit box Bracket Winch drum
Limit box
Winch drum
Bracket
Fig. 3. Limit switch box, hoisting winch. Fig. 4. Limit switch box, luffing winch.
Fig. 5. Tool, wire rigging sock, 662 0754-000.
Securing of wire rope thimble
Check the "Rope Reeving Diagram (6.216.xx E) that

applies to your crane.
Hoisting
Example
Luffing
Fig. 6. Securing hoisting/luffing wire thimbles to crane house top.

SERVICE 6.223.11 E rev.: a 2004-01-19
Example
Fig. 7. Securing the luffing or hoisting wire thimble to crane jib.
Fig. 8. How to secure the lock washer for the wire rope thimble.

SERVICE 6.223.11 E rev.: a 2004-01-19
Adjustment of pressure roller on the

hoisting winch
After replacement of wire the pressure roller on the

hoisting winch must be re-adjusted.
- Tighten adjusting nut carefully until the pressure

- Check that the play (approx. 2 mm) between wire
and pressure roller corresponds to Fig. 9. Adjust if
necessary by changing location (rotation) of frame
bearings, see Fig. 9.
- Tighten adjusting nut 12 turns to get correct spring
force. Adjustment shall be done at full drum Full drum
Empty drum
condition. Approx. 2 mm
- Secure with the locking nut.
Approx. 2 mm
Full drum
Empty drum
Frame bearing
Pressure roller
Adjusting nut
Adjust play by rotating Frame
the washer/bearing.
Frame bearing
Locking nut

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 wear, see Table 1, can certainly occur on every
the wire rope it is important to inspect the condition of spot where the wire rope is in contact with the wire
the wire sheaves. sheave, not only on places shown in Fig. 1.
Wear criterias Indentation

When the wear on the wire sheave exceeds 3mm, it A new wire rope and wire sheave are in contact on
will according to our experience decrease the lifetime certain spots, see Fig. 2. After some time the
of the wire rope. The wear of the wire sheave will also indentation will have the shape shown in Fig. 3. This
reduce the load capacity. Maximum wear is therefore is considered as normal wear.
25% of the wire sheave thickness (t) with a limit to
maximum 3mm, see Fig. 1.
Fig. 1. Wear on wire sheave. Fig. 2. Contact spots.
t a
max
16 4
12 3
10 2.5
8 2
6 1.5
Fig. 3. Good contact between an old wire rope and the

Table 1. wire sheave.

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.

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.

Fig. 1. Lifting block for crane with two sheaves.
2. In area of hook, hook nut and swivel.
Take great care to avoid clothing becoming trapped.
Repair and reeving should be carried out by trained

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

Fig. 2. Lifting block for crane with one sheave.
Inspection should be carried out on every possible
occasion before taking into operation.
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.

SERVICE INFORMATION
625/1560 E rev.: e 2007-01-02
NO welding should be carried out unless prior working hours, see also separate lubrication chart.
authority is obtained.
If the holes in the sideplates, eyes and swivels are Limitation of use
enlarged by more than 5%, the part should be
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, un-
less 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 cer-
tificate must be issued.
Lubrication
As a general rule sheaves, shafts and swivels

should be greased through nipples every 100

625/1579 E rev.: h 2009-02-19
Measuring Procedure for Wear in Slewing Bearings

for Rope Luffing Cranes
General
The slewing bearing is an essential part of the crane It is important to use about the same position for all
and must be well maintained. Over the years the further measurements to be able to compare the
slewing bearing will have some wear, and to be able measurements.
to know if there is a need for changing the slewing
bearing it is needed to keep a record of the wear. With the jib at maximum outreach two measurements
are to be taken, see Fig. 1.
The initial measurements should be taken when
the crane is installed at yard or within 2 months With the jib at minimum position one measurement is
from crane installation. to be taken, see Fig. 2.
If the wear measurement shows wear, grease Enclosed table can be used to record the
samples can be taken for analyze. See procedure on measurements.
page 5.
Note!
Measurements should be recorded with an accuracy
Measuring of 0.1 mm.
The measurements should be taken regularly, every If B - C = 0, or negative, the measurement is wrong.
6 months. Measurements can be sent to If B - A is greater than 7 mm the crane must not be
MacGREGOR Cranes, Örnsköldsvik, Sweden for used.
evaluation.
Maximum allowed play is:
Note! for roller bearings 1.5 mm
When measurements are to be taken the ship shall for ball bearings 3.0 mm.
have as little list/trim as possible.
Neither a load nor a cargo handling equipment should

be attached to the hook.
Procedure
First time a measurement is to be taken two reference
points on the crane's bottom plate must be marked.
These reference points shall then always be used at
any future measuring, see Fig. 3.
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

625/1579 E rev.: h 2009-02-19
Jib at maximum outreach
Measurement B
(back of crane) Empty hook
Jib direction Jib direction
Measurement A
(front of crane)
Fig. 1. Jib in outer position.
Measurement C
(back of crane)
Jib direction
Min. outreach,
empty hook
Fig. 2. Jib at minimum outreach.

625/1579 E rev.: h 2009-02-19
Note! If there is a machined surface this shall be used

as reference point. In other cases a reference point
must be marked.
Reference point
Reference point
Fig. 3. Reference points.

625/1579 E rev.: h 2009-02-19
Vessel name: Fore Note!

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

Jib at max. outreach Jib at min. outreach
A (front of crane) B (back of crane) C (back of crane) B-C
Fore
Stb
Aft
Ps
Crane No.: 2
Fore
Stb
Aft
Ps
Crane No.: 3
Fore
Stb
Aft
Ps
Crane No.: 4
Fore
Stb
Aft
Ps

625/1579 E rev.: h 2009-02-19
Procedure of grease sampling
Following information is necessary in order to give a - Clean up the seal and the surrounding areas where
correct statement and allow further advice: the sample will be taken. When cleaning the area
of the seal, prevent the cleaner from contacting the
1. Type of grease used at lubrication (manufacturer seals or from entering the raceway's system.
and type). - Push new grease into the grease nipples / bearing
2. Lubrication intervals (crane running hours or without rotation and collect the first used grease
months). which will come out at the seal.
3. Crane running hours.
4. Information where the samples are taken. Attention: Do not take fresh grease for analyzing!
The required quantity of grease for analyzing is
As a correct procedure of grease sampling is very approx. 2 cm3.
important below procedure should be followed.
The normal interval for grease sampling is 12 months.
Procedure
- The grease sample should be taken at the inner
seal of the bearing, see Fig. 4.
- One sample should be taken in the area under jib
and one sample 180° in opposite direction.
Grease sampling
area (inner seal)
Slewing bearing with balls.
Grease sampling
area (inner seal)
Slewing bearing location Slewing bearing with rollers.
Fig. 4. Grease sampling areas.

625/1579 E rev.: h 2009-02-19

SERVICE 6.303.48 E rev.: a 2008-11-13
Absolute Encoder Calibration, CC3000
General Preparation of minimum jib outreach

luffing
Absolute encoders are used for position control
purposes. Each encoder gives an accurate position Warning! Always use safety belt when measuring
feedback to the control system. the distance "MV".
The encoder calibration has to be done when the wire Caution! Position the minimum jib outreach. Do a
or the absolute encoder has been replaced. visual inspection of the distance between the front of
the crane house and the first jib stay on jib.
Absolute encoders for hoisting and luffing winches
are installed in the limit switch box or on jib bearing. - Carefully position the jib to minimum jib outreach
until the measure of "MV" is achieved.
For slewing motion the absolute encoder is mounted - Measure the distance "MV" on top of the crane
under the crane towards the slewing bearing. house, see Fig. 1, according to table in Technical
Data, section 2.
Center line of crane house
MV
(m
m)
First jib stay
Measure of
the distance MV
Center line of jib profile

(calibration point)
There must be a distance

between the front of the
crane house and the first jib stay.
Fig. 1. Crane house top.

SERVICE 6.303.48 E rev.: a 2008-11-13
- Calibration of the encoder in the CT2-cabinet, see

page 4.
- Set the limit switch for "Min Jib Outreach", see
table "Basic limit switches - luffing winch" in
Technical Data, section 2.
- Luff out a few meters and stop. Luff in until the jib AL
stops at "min jib outreach".
- Recheck the distance "MV".
Preparation of hoisting
- Start by driving the crane to "AL" (hoisting

winch), see Fig. 2, according to table "Limit
Fig. 2. Definition of "AL" hoisting winch.
switches - hoisting winch" in Technical Data,
section 2.
- Measurement to be done in front of the hoisting
winch, from the empty drum flange to the side of
the wire.
- Set the limit switch for empty drum. Hoist the
hoisting wire a few meters and stop. Lower the
wire until it stops at position empty drum, i.e. at
least three locking turns or tank top.
- Calibration of the encoder in the CT2 cabinet,
see page 4.

SERVICE 6.303.48 E rev.: a 2008-11-13
Preparation of slewing
To calibrate the absolute encoder for slewing aim

the crane jib straight ahead, i.e. 0°, see Fig. 3.
Calibration of the encoder in the CT2 cabinet, see
page 4.
0°
Fig. 3. Reference points.

SERVICE 6.303.48 E rev.: a 2008-11-13
Calibration of encoders in the CT2

cabinet
Hoisting Luffing/slewing
1. Push the "Select/Info" button on the front of the To calibrate the encoder on the other cards proceed in
MC-card which you want to calibrate, for example the same way as in items 1, 2, and 3 in above
Ho-card. The display on the Ho-card shows paragraph except for choosing the corresponding card.
"ERROR".
2. Push the "Down/Exit" button on the Ho-card front.
The display on the Ho-card shows "CAL".
3. Push the "ENCODER CALIBRATION" button in
the CT2 cabinet. The display in the Ho-card then
starts flashing, showing "ANG".
Push the "Select/Info" button on the Ho-card.
Angle encoder is calibrated in this position.
Table 1. Encoder calibration modes
Function/ Purpose Calibration position

Mode
Ho Zero position of hoisting winch Empty drum, at least three locking turns (AL).
Lu Zero position of luffing winch Full drum, min. jib outreach (MV).
SL Zero position of slewing Aim crane jib straight ahead for 0°.
ENCODER
CALIBRATION
Display
button
Select/Info
button
Up button
Down/Exit
button
Fig. 4. CT2 cabinet, CC3000.

SERVICE 6.303.49 E rev.: c 2009-06-04
Troubleshooting
Crane Control System CC3000
CT2
Contents
1. Description of input and output signals ............................................................................................. 2
2. Control system input and output signal levels................................................................................... 5
3. Troubleshooting for the control system............................................................................................ 8
4. Spare parts ....................................................................................................................................... 12

SERVICE 6.303.49 E rev.: c 2009-06-04
1 Description of input and output signals
1.1 General
The following description refers to the
microcomputer based crane control system
CC3000 for MacGREGOR hydraulic deck cranes.
Minor variations in the use of control system input

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

Crane Control system CC3000 see "Function",
section 3. For detailed information about the control
system a complete electric circuit diagram, relating
specifically to your crane, will be found in the
instruction manual, section "Spare Parts", Group
9.5. Also for detailed information about the
hydraulic system a complete hydraulic circuit
diagram will be found in section "Spare Parts", Fig. 1. CC3000 Power supply principle.
Group 9.4.
1.3 Power supply, Control system anti-
1.2 Power supply, Control system condensation heating
operation The anti-condensation heating in CT2 cabinet is
The power supply transforms the input powered with 24V DC when the control system is
380/400/440V AC to 24V DC. See Fig. 1. switched off and the crane is not in operation. A
separate power supply is used for all anti-
It consists of a three-phase power supply. The condensation heating in the crane. A separate
output 24V DC is divided into two supplies, one for power line feeds the power supply.
the control system and its output signals (terminal
48) and one for the limit switches, pressure 1.4 Control levers - potentiometers,
switches (terminal 42). There are fuses on each outputs to and inputs from
supply in the CT1 cabinet.
The control levers linear potentiometers are fed
The 0V level for 24V DC is grounded in power with 0V, +6V and +12V from their appropriate MC
supply unit. and CC card. The potentiometer output is approx.
+6V with the lever in neutral. The output signal is
controlled by the lever and is depending on the
direction of lever movement. The output signal is
increased to approx. +10.5V for maximum speed
hoisting, luffing in, and slewing left respectively.
The output signal is decreased to approx. +1.5V for
maximum speed lowering, luffing out, and slewing
right respectively.

SERVICE 6.303.49 E rev.: c 2009-06-04
1.5 Control levers - direction signal

inputs
winch in use, to be used for calculation of the hook
The control lever for hoisting selects two out of four
load. The signal is connected to the control system
24V direction signals, for selection of low speed/
via the backplane card.
high speed and hoisting/lowering. See Fig. 2. The
control lever for luffing/slewing gives two out of four
24V direction signals for selecting luffing in/luffing 1.7 Load cell
out and slewing left/slewing right.
If fitted, a load cell (load measuring pin) is mounted
on the hoisting winch. The signal is connected to
1.6 Pressure/force sensor input the control system via the backplane card.
If fitted a pressure sensor giving 4-20 mA is used to
measure the hydraulic oil pressure for hoisting
Fig. 2. Control lever signals, hoisting movement.

SERVICE 6.303.49 E rev.: c 2009-06-04
1.8 Overload pressure switch input 1.11 Displacement/unloading outputs
The overload pressure switch makes the MC card Each MC card has two separate outputs. They are
control program to switch over from high speed to used for selecting low speed or high speed for the
low speed operation or, if already in low speed, hoisting movement and for the unloading function
stopping the hoisting and luffing crane movement. for the luffing movement. Each output giving a fixed
The input signal from the overload pressure switch 24V output with a maximum current of 2A. The
is often only seen as a short pulse. system is capable of detecting short-circuited
output and then giving an error-message, see sign
ERROR MESSAGES.
1.9 Pump solenoid outputs
Each hydraulic pump has two solenoid valves, one 1.12 Low feed pressure input
for each direction of the oil-flow. The solenoids are
controlled with a 24V PWM (Pulse Width The low feed pressure switch indicates that the
Modulated) signal with current feedback control. If pump feed pressure is too low for safe operation.
wanted output current is not reached (due to short- Output signals to pumps, displacement/unloading
circuit, open-circuit or MC card failure) the system valves and brake relief valves are immediately
then gives an error message, see sign ERROR switched off. If the low-pressure signal comes
MESSAGES. Each MC card is capable of back within approx 0.3 s the crane operation
controlling a maximum of four pumps with a total of continues with the same output signal levels as
eight output drivers, one for each solenoid valve. before the pressure drop. However, if short
Each driver is capable of outputting a maximum pressure drops are repeated 4-5 times within a
current of 1A. To obtain the value of the current it is short period of time the crane operation is stopped
possible to get it on the display on the cards in CT2 and starts 4-5 seconds after the feed pressure has
cabinet. a stable high level again.
1.10 Brake release/direction valve 1.13 Lamp output "Control System Error
outputs in CT2"
Each MC card has an output driver for the brake The LED no 28 on the CC Card are wired to a lamp
release signal (or direction valve for cranes in crane operator's cabin. The first time an error
equipped with cylinder luffing). The system is occurs, the lamp flashes. When the error is
capable of detecting short-circuited output and then acknowledged by pushing the Select/Info push-
giving an error-message, see sign ERROR button on the appropriate MC or CC card the lamp
MESSAGES. is on if the error remains or out if the error is not
present for the moment. See chapter 3.5 for
detailed information about error messages.

SERVICE 6.303.49 E rev.: c 2009-06-04
2 Control system input and output signal levels
Power for control system input and output CT2-X10:48

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

Lu
Luffing CT2-X10:302 "Lu". 0V from MC "Lu".
CT2-X10:303
Control lever potentiometer input signal luffing CT2-X10:304 Lu 10.5V with 6V in neutral
position.
Control lever direction inputs slewing
24V when control lever actuated
Luffing In CT2-X10:307 Lu
luffing in luffing out
Luffing Out CT2-X10:308 Lu
CT2-X10:401
12V from MC "SL". 6V from MC
Outputs to control lever potentiometer slewing CT2-X10:402 SL
"SL". 0V from MC "SL".
CT2-X10:403
Control lever potentiometer input signal
CT2-X10:404 SL 10.5V with 6V in neutral
slewing
position.
Control lever direction inputs slewing
CT2-X10:407 24V when control lever actuated
Slewing Left SL
CT2-X10:408 slewing left slewing right
Slewing Right SL
Brake relief valve - outputs
Ho
Hoisting CT2-X10:230 24V, max. 2A, open circuit gives
Lu
Luffing - (direction valve if cylinder luffing) CT2-X10:330 error message.
SL
Slewing CT2-X10:430
24V, max. 2A, open and short
Hoisting displacement low speed output CT2-X10:231 Ho
circuit gives error message.
Hoisting displacement output high speed CT2-X10:232 24V, max. 2A, open and short
Ho
Current return CT2-X10:248 circuit gives error message.
Luffing unloading output CT2-X10:331 Lu 24V, max. 2A, open and short
circuit gives error message.

SERVICE 6.303.49 E rev.: c 2009-06-04
Pump PWM signals for Hoisting Pump1 24V, 0 to approx. 600 mA, error
CT2-X10:233
Hoisting output message if wanted current not
CT2-X10:234 Ho
Lowering output achieved. 1mA gives approx.
CT2-X10:235
Current return and current measure input 1mV.
Pump PWM signals for hoisting pump2 (if
24V, 0 to approx. 600 mA, error
fitted) CT2-X10:236 Ho
message if wanted current not
Hoisting output CT2-X10:237 Ho
achieved. 1mA gives approx.
Lowering output CT2-X10:238 Ho
1mV.
Current return and current measure input
Pump PWM signals for luffing pump1 24V, 0 to approx. 600 mA, error
Luffing In output CT2-X10:333 Lu message if wanted current not
Luffing Out output CT2-X10:334 Lu achieved. 1mA gives approx.
Current return and current measure input CT2-X10:335 Lu 1mV.
Pump PWM signals for luffing pump2 (if fitted) 24V, 0 to approx. 600 mA, error
Luffing In output CT2-X10:336 Lu message if wanted current not
Luffing Out output CT2-X10:337 Lu achieved. 1mA gives approx.
Current return and current measure input CT2-X10:338 Lu 1mV.
Pump PWM signals for slewing pump1 24V, 0 to approx. 600 mA, error
Slewing Left output CT2-X10:433 SL message if wanted current not
Slewing Right output CT2-X10:434 SL achieved. 1mA gives approx.
Current return and current measure input CT2-X10:435 SL 1mV.
24V, 0 to approx. 600 mA, error
Pump PWM signals for slewing pump2 (if
CT2-X10:436 SL message if wanted current not
fitted) Slewing Left output Slewing Right output
CT2-X10:437 SL achieved. 1mA gives approx.
Current return and current measure input
CT2-X10:438 SL 1mV.
Limit switch inputs hoisting 24V at normal operation, 0V at
CT2-X10:214
Hoisting Ho limit. At limit movement is
CT2-X10:215
Lowering, slack wire stopped and brake closed.
Speed-reduce limit inputs hoisting
CT2-X10:211 Ho 24V at normal operation, 0V at
Hoisting
CT2-X10:212 limit.
Lowering
Limit switch inputs luffing 24V at normal operation, 0V at
CT2-X10:314 Lu
Luffing In limit. At limit movement is
CT2-X10:315
Luffing Out, slack wire stopped and brake closed.
Speed-reduce limit inputs luffing
CT2-X10:311 Lu 24V at normal operation, 0V at
Luffing In
CT2-X10:312 limit.
Luffing Out
Limit switch inputs slewing 24V at normal operation, 0V at
CT2-X10:414 SL
Slewing left limit. At limit movement is
CT2-X10:415
Slewing right stopped and brake closed.
Speed-reduce limit inputs slewing
CT2-X10:411 24V at normal operation, 0V at
Slewing left SL
CT2-X10:412 limit.
Slewing right
CT2-X10:256
Slack wire
CT2-X10:356
CT2-X10:219 Ho
24V at normal operation, 0V at
Pressure switch input for low feed pressure CT2-X10:319 Lu
low feed pressure.
CT2-X10:419 SL
Pressure switches for overload CT2-X10:220 Ho 24V at normal operation, 0V at

SERVICE 6.303.49 E rev.: c 2009-06-04
CT2-X10:320 Lu overload.
Output "Error in control system CT2" CT2-X10:128 Sc 24V outputs wired together to
error lamp in drivers cabin.
Output for "Speed dependent" overload 24V when the hoisting speed is
CT2-X10:229 Ho
function (if fitted). less than approx. 3 rpm.
Ho 24V when the hoisting pressure
Output for "Hoisting Overload" indication lamp CT2-X10:255
Lu exceeds adjusted value.
24V input from cabin switch,
CT2-X10:217 Ho
Speed reduction, input signal ext. 1 (bit 0) to such as Grab operation, Parking
CT2-X10:317 Lu
reduce normal operation speed (utilization). Lock Slewing, Power Limiter,
CT2-X10:417 SL
Twin operation, etc.
Speed reduction, input signal ext. 2 (bit 1) to
CT2-X10:218 Ho
reduce normal operation speed (utilization). 24V input from cabin switch,
CT2-X10:318 Lu
Same as above, but could be used with same as above.
CT2-X10:418 SL
different utilization.

SERVICE 6.303.49 E rev.: c 2009-06-04
3 Troubleshooting the Crane Control system
3.1 General
This section provides information for identifying and When troubleshooting a malfunction: Locate the
correcting malfunctions, which may develop while symptom or symptoms that best describes the
operating the cargo crane. Before performing malfunction. If the appropriate symptom is not
troubleshooting, read and follow all safety listed, notify your supervisor.
instructions found in section "General", section 1, of
this manual. This chapter cannot list all Read this section in conjunction with the electrical
malfunctions that may occur, nor all inspections and hydraulic diagrams provided in Group 9.5 and
and corrective actions. If a malfunction is not listed, 9.4.
or is not corrected by the listed corrective actions,
notify your supervisor.
3.2 Troubleshooting Chart

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

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

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

supply, see chapter joysticks and electro-
4.3. hydraulic interfaces,
see chapter 4.4.

SERVICE 6.303.49 E rev.: c 2009-06-04
• Replace valve.
3.3 Checking Power supply 24V DC in
CT2 cabinet
Check pump servo valves 1111-9, 1113-9,
See chapter 1.2. for explanation of the power supply 2111-9, 2113-9, 3111-9, 3113-9
function.
• Check over-current relay F3 in cabinet CT1. • Check electric cable connections.
• Check fuse F16 in CT1 for 24V in terminal 48 in • How to obtain error codes from the CC3000
CT2 cabinet.
system.
• Check fuse F17 in CT1 for 24V in terminal 42 in
CT2 cabinet. •
Error message codes from CC3000
• Check relay K34 in cabinet CT1, see electric
circuit diagram. If the error from the CC3000 has no influence on the
• No LED and display readout on MC card performance of the crane the “control system error”
indicates missing 24V in terminal 48. lamp in the driver’s cabin will not flash.
With the crane still running, the following steps are

3.4 Checking Limit switches, Joysticks
necessary to obtain the error code(s).
and Electro-Hydraulic Interfaces
Check Limit Switches, see Control system CT2 • Open the control system cabinet and look for the
cabinet Sc-card (the leftmost card in the rack). LED 28 is
now flashing. Then look for the card with the
flashing LED “error MP” or “error SP” on top of
See chapter 3 for explanation of signal indication the cards.
LEDs. •
• No LEDs on and no display readout - indicates
missing 24V in terminal 48. Green LED 28 on Indicate error status in the
the Sc-card whole system (All cards)
• Check for Red LEDs - indicating stop limits.
Red LED “Error Indicate error status from MP
• Check for Yellow LEDs - indicating speed
MP” in the local card
reduces.
• Check electric cable connections for limit Red LED “Error Indicate error status from SP
switches. SP” in the local card
• For checking and adjustment of limit switches see
instruction for “Limit Switches in Hoisting …” in • Push the “Select/Info” button once on the card
"Service", section 6.3. with error LED flashing. An error code (e.g.
E51_11) is shown on the display on the card.
Check control lever (joystick) • Hold on pressing “Select/Info” button, the
description of this error will be rolling on the
display. Release the button, the description
See chapter 1.4 for explanation of the control lever disappears and the error code is shown.
functions.
• Continue to press “Select/Info” or “Down/Exit”
• Check for missing Green input signal LEDs - from button once to see the next error and so on.
joystick.
• Pressing “Up” button once to show the previous
• Check electric cable connections to control lever. error and so on.
• Check analogue input signal from joystick • When there are no more error messages, the
potentiometer. display shows three hyphens “---”. When all
• Check for missing Green output signal LEDs: errors have been shown on the display, the error
Exchange the MC card with other movement MC LED is either on or off.
card. Replace broken MC card with a new one. • All errors can be shown round and round if you
continue pressing “Select/Info” or “Down/Exit”
Check valves 1221, 1226, 2221, 2226, and button or “Up” button.
3221! LED flashing New error, not acknowledged
LED on Error remains, now
• Check electric cable connections. acknowledged
• Replace electric coil.
LED off No error present at the moment

SERVICE 6.303.49 E rev.: c 2009-06-04
• The display returns to normal mode (Sc, Ho, Lu, • Pressing “Up” or “Down/Exit” button to see the
Sl, Cl, Au, Ec, Tl, Tr, Li, Io) 15 seconds after one previous respective next error, following the same
of the three buttons was last pressed, or holding instruction above.
on pressing “Down/Exit” button longer than one
second. Note!
• If the system is restarted (i. e. 24V power supply Before reporting to MacGREGOR Cranes in
is switched off for a short time) all alarms Örnsköldsvik, please look for the error code in the
disappear and only reappear when the error
display of the MC or CC card and use the
recurs.
“Select/Info” button to view all error codes. It is
• How to see the remaining errors after
essential that all faults to be corrected to allow the
acknowledging (i.e. error LED is always on)?
crane to function correctly.
• Errors can show again from normal mode when
pressing “Select/Info” twice.
Hardware Hardware Hardware Hardware

324 1670-901 324 1665-901 324 1665-901 324 1665-901
Error MP SP
Encoder
Calibration
Sc-Card
Display
Select/Info button
Up
Down/Exit
Software Software Software Software

CC3K H01_00 CC3K H01_00 CC3K H01_00 CC3K H01_00
Rev B Rev B Rev B Rev B
Error Error Description 10 10 MEM card errors

code sub-
code • Replace the MEM card
01 01-10 System errors • Contact MacGREGOR Cranes,

Örnsköldsvik
• Contact MacGREGOR Cranes,
Örnsköldsvik 11 01-20 Parameter errors
02 01-61 MC or CC card errors • Contact MacGREGOR Cranes,

Örnsköldsvik
• Restart system or replace the card
24 01-03 24 supply voltage error
Örnsköldsvik • Check 24V supply
03 01-91 Safety processor errors

Örnsköldsvik

SERVICE 6.303.49 E rev.: c 2009-06-04
30 01 Joystick level, which should normally be 37 01-06 Limit error at stop cam (hoist stop cam,
1.25 to 11.75 V. lower stop cam, in stop cam, out stop
• Check connection to joystick cam, left stop cam, right stop cam)
• Check switches/cam in joystick • Check stop cam connection or switch
• Measure potentiometers in joystick 49 01-05 External analog in(AI1, AI2, AI3, AI4, AI5)
errors
02 Joystick logic error for “Lowering”,
“Luffing Out” or “Slewing Right” • Check cable, connection
movement. Check according code 30_01. • Check encoder
03 Joystick logic error for “Hoisting”, “Luffing • Replace the MC or CC card
In” or “Slewing Left” movement. Check 50 11,21, Displacement open circuit (Low speed,
according code 30_01.
31 high speed, unloading)
04 Joystick is not in zero position when • Check cable and connection
system starts. Check according code
30_01. 12,22, Displacement short circuit (Low speed,
32 high speed, unloading)
31 01 Angle encoder communication error
• Check output cable is not connected to
• Check angle encode connection 0V(ground)
• Replace the angle encoder • Replace the MC or CC card
02 Angle shaft coupling 13,23, Displacement transistor (Low speed, high
• Check angle encoder connection 33 speed, unloading)
• Replace the angle encoder • Check cable and connection
03 Angle encoder or speed encoder error • Replace the MC or CC card
• Replace the angle encoder or speed 51 11 Brake open circuit
encoder • Check according to code 50_11
• Contact MacGREGOR Cranes, 12 Brake short circuit
Örnsköldsvik
• Check according to code 50_12
33 01 Weight: load cell
13 Brake transistor
• Check load cell cable and connection
• Check according to code 50_13
• Replace the load cell
52 01-04, PWM current
• Contact MacGREGOR Cranes, 05,11-
Örnsköldsvik 14
(Pwm1 LOR, Pwm2 LOR, Pwm3 LOR,
Pwm4 LOR, Pwm0 LOR, Pwm1 HIL,
Pwm2 HIL, Pwm3 HIL, Pwm4 HIL)
35 01-02 MC or CC card temperature is too high
• Check that PWM output is not
• Power off system connected to 0V(ground)
• Contact MacGREGOR Cranes, • Check that cable is not broken
Örnsköldsvik • Replace the MC or CC card
4 Spare parts

SERVICE 6.303.49 E rev.: c 2009-06-04
4.1 MC card and CC card

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

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

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

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

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

To protect all types of electronic cards from
damages from ESD (Electro Static Discharge) it is
important to use pink anti-static plastic bags and
conductive transit boxes of the same type as used
for delivered original spare parts.

Page Date
SIGNAL OVERVIEW 1 (2) 2008-11-11
No Revision
Crane Control System CC3000 424 0738 -
LEDs - 24V Input/Output signals are indicated with coloured LEDs

.Colour Indicating LEDs on External communication
when LEDs within the COM box are external communication and
communication with Main Processor (MP).
Green Normal inputs and outputs +24V
The external communication LEDs are blinking when
Yellow 11,12 Speed reduce limits 0V transmitting data in one direction and is lit when data is
transmitted both ways. The MP LED must always be lit.
Yellow 17,18 Speed reduction switches +24V
Software
Red Limit switches, low pressure, 0V Sw before LED No means the software.
slack wire and overload
SC ± Supervisory Ho ± Hoisting
CC Card MC Card
LED Plinth LED Plinth
Signal Description Signal Description
No No No No
07 Overload test 107 07 Hoisting, input 207
08 Rigging mode 108 08 Lowering, input 208
Hardware
324 1670-901 09 Parking of jib 109 Hardware
324 1665-901
09 Low speed, input 209
10 110 10 High speed, input 210
11 111 11 Speed reduce hoisting 211
12 112 12 Speed reduce lowering 212
13 113 14 Limit switch hoisting 214
16 116 Sw14 When parking
17 117 15 Limit switch lowering 215
18 118 17 Speed reduction, ext1 217
19 119 18 Speed reduction, ext2 218
20 120 19 Low pressure switch 219
26 Run enable in 126 20 Overload switch input 220
27 Run enable out 127 26 Run enable in 226
28 Alarm (error in CT2) 128 27 Run enable out 227
29 Ready to run 129 29 Indication Speed reduce/stop 229
30 130 30 Hoisting brake, output 230
31 131 31 Low speed, output 231
32 132 32 High speed, output 232
33 133 33 Pump1 hoisting, output 233
34 134 34 Pump1 lowering, output 234
35 135 36 Pump2 hoisting, output 236
36 136 37 Pump2 lowering, output 237
37 137 39 239
39 139 40 240
40 140 43 243
49 149 45 245
51 151 49 249
53 153 51 251
56 156 52 252
57 Calibration 157 53 253
58 158 54 254
59 159 55 Indication Overload 255
60 160 56 Slack wire 256
61 161 Sw56 When parking
Power supply +24V
24 V 57 257
C1CAN1 Sc_C1 58 258
C2CAN2 Sc_C2
Software
59 259
Software
CC3K H01_00 C3CAN3 Sc_C3 CC3K H01_00
Rev B
C1 CAN1 Ho_C1
Rev B C4CAN4 Sc_C4 C2 CAN2 Ho_C2
R1RS485_1 Sc_R1 R1 RS485_1 Ho_R1
R2RS485_2 Sc_R2 MP Internal communication
R3RS485_3 Sc_r3
Internal
MP
communication
Page Date
SIGNAL OVERVIEW 2 (2) 2008-11-11
No Revision
Crane Control System CC3000 424 0738 -
LEDs - 24V Input/Output signals are indicated with coloured LEDs

.Colour Indicating LEDs on External communication
when LEDs within the COM box are external communication and
communication with Main Processor (MP).
Green normal inputs and outputs +24V
The external communication LEDs are blinking when
Yellow 11,12 speed reduce limits 0V transmitting data in one direction and is lit when data is
transmitted both ways. The MP LED must always be lit.
Yellow 17,18 Speed reduction switches +24V
Software
Red limit switches, low pressure, 0V Sw before LED No means the software.
slack wire and overload
Lu - Luffing Sl - Slewing
MC Card MC Card
Hardware LED Plinth LED Plinth
324 1665-901 Signal Description Hardware Signal Description
No No 324 1665-901
No No
07 Luffing in, input 307 07 Left, input 407
08 Luffing out, input 308 08 Right, input 408
11 Speed reduce luffing in 311 11 Speed reduce left 411
12 Speed reduce luffing out 312 12 Speed reduce right 412
14 Limit switch luffing in 314 14 Limit switch left 414
15 Limit switch luffing out 315 Sw14 When parking
17 Speed reduction, ext1 317 15 Limit switch right 415
18 Speed reduction, ext2 318 Sw15 When parking
19 Low pressure switch 319 17 Speed reduction, ext1 417
20 Overload switch input 320 18 Speed reduction, ext2 418
26 Run enable in 326 19 Low pressure switch 419
27 Run enable out 327 20 320
29 Indication Speed reduce/stop 329 26 Run enable in 326
30 Luffing brake, output 330 27 Run enable out 327
31 Unloading, output 331 29 329
32 30 Slewing brake, output 430
33 Pump1 luff in, output 333 31 431
34 Pump1 luff out, output 334 32 432
36 Pump2 luff in, output 336 33 Pump1 left, output 433
37 Pump2 luff out, output 337 34 Pump1 right, output 434
39 339 36 Pump2 left, output 436
40 340 37 Pump2 right, output 437
43 343 39 439
45 345 40 440
49 349 43 443
51 351 45 445
52 352 49 449
53 353 51 451
54 354 52 452
55 Indication Overload 355 53 453
56 Slack wire 356 54 454
57 357 55 455
58 358 56 456
59 57 457
Software
Software
CC3K H01_00 C1 CAN1 Lu_C1 CC3K H01_00
Rev B
58 458
Rev B C2 CAN2 Lu_C2 59 459
R1 RS485_1 Lu_R1 C1 CAN1 Sl_C1
MP Internal communication C2 CAN2 Sl_C2
R1 RS485_1 Sl_R1
MP Internal communication
Page Date
ERROR MESSAGES 1(2) 2008-11-11
No Revision
Crane Control System CC3000 -
424 0739
Error message codes from CC3000 have been shown on the display, the error LED is
If the error from the CC3000 has no influence on the either on or off.
performance of the crane the ”control system error”  All errors can be shown round and round if you
lamp in the driver’s cabin will not flash. continue pressing “Select/Info” or “Down/Exit” button
With the crane still running, the following steps are or “Up” button.
necessary to obtain the error code(s).
LED flashing New error, not acknowledged
 Open the control system cabinet and look for the Sc-
card (the lestmost card in the rack). LED 28 is now LED on Error remains, now acknowledged
flashing. Then look for the card with the flashing LED off No error present at the moment
LED “error MP” or “error SP” on top of the cards.
Green LED 28 on Indicate error status in the  The display returns to normal mode (Sc, Ho, Lu, Sl,
the Sc-card whole system (All cards) Cl, Au, Ec, Tl, Tr, Li, Io) fifteen seconds after one of
Red LED “Error MP” Indicate error status from MP the three buttons was last pressed, or holding on
in the local card pressing “Down/Exit” button longer than one second.
Red LED “Error SP” Indicate error status from SP  If the system is restarted (i. e. 24V power supply is
in the local card switched off for a short time) all alarms disappear
and only reappear when the error recurs.
 Push the “Select/Info” button once on the card with
error LED flashing. An error code (e.g. E51_11) is How to see the remaining errors after acknowledging
shown on the display on the card. (i.e. error LED is always on)?
 Errors can show again from normal mode when
 Hold on pressing “Select/Info” button, the description pressing “Select/Info” twice.
of this error will be rolling on the display. Release
the button, the description disappears and the error  Pressing “Up” or “Down/Exit” button to see the
code is shown. previous respective next error, following the same
instruction above.
 Continue to press “Select/Info” or “Down/Exit” button
once to see the next error and so on. Note!
Before reporting to MacGREGOR (SWE) AB in
 Pressing “Up” button once to show the previous Örnsköldsvik, please look for the error code in the
error and so on. display of the MPC-card and use the “select/info” button
 When there are no more error messages, the to view all error codes. It is essential that all faults to be
display shows three hyphens “---”. When all errors corrected to allow the crane to function correctly.
Hardware Hardware Hardware Hardware

324 1670-901 324 1665-901 324 1665-901 324 1665-901
Error MP SP
Encoder
Calibration
Sc-Card
Display
Select/Info button
Up
Down/Exit
Software Software Software Software

CC3K H01_00 CC3K H01_00 CC3K H01_00 CC3K H01_00
Rev B Rev B Rev B Rev B
Page Date
ERROR MESSAGES 2(2) 2008-11-11
No Revision
Crane Control System CC3000 -
424 0739
Error Error Description 33 01 Weight: loadcell

code sub-
code  Check loadcell cable and connection
01 01-10 System errors  Replace the loadcell
 Contact MacGREGOR(SWE) AB  Contact MacGREGOR(SWE) AB
Örnsköldsvik Örnsköldsvik
02 01-61 MC or CC card errors

35 01-02 MPC card temperature is too high
 Restart system or replace the card
 Power off system
 Contact MacGREGOR(SWE) AB
Örnsköldsvik  Contact MacGREGOR(SWE) AB
Örnsköldsvik
03 01-91 Safety processor errors
37 01-06 Limit error at stop cam (hoist stop cam, lower
 Contact MacGREGOR(SWE) AB
stop cam, in stop cam, out stop cam, left stop
Örnsköldsvik
cam, right stop cam)
10 10 MEM card errors  Check stop cam connection or switch
 Replace the MEM card
49 01-05 External analog in(AI1, AI2, AI3, AI4, AI5)
 Contact MacGREGOR(SWE) AB errors
Örnsköldsvik
 Check cable, connection
11 01-20 Parameter errors  Check encoder
 Contact MacGREGOR(SWE) AB  Replace the MC or CC card
Örnsköldsvik
50 11,21, Displacement open circuit (Low speed, high
24 01-03 24 supply voltage error 31 speed, unloading)
 Check 24V supply  Check cable and connection
30 01 Joystick level, which should normally be 1.25 12,22, Displacement short circuit (Low speed, high
to 11.75 V. 32 speed, unloading)
 Check connection to joystick  Check output cable is not connected to
 Check switches/cam in joystick 0V(ground)
 Measure potentiometers in joystick  Replace the MC or CC card
02 Joystick logic error for “Lowering”, “Luffing 13,23, Displacement transistor (Low speed, high
Out” or “Slewing Right” movement. Check 33 speed, unloading)
according code 30_01.  Check cable and connection
03 Joystick logic error for “Hoisting”, “Luffing In”  Replace the MC or CC card
or “Slewing Left” movement. Check according
code 30_01. 51 11 Brake open circuit
 Check according to code 50_11
04 Joystick is not in zero position when system
starts. Check according code 30_01. 12 Brake short circuit
31 01 Angle encoder communication error  Check according to code 50_12
 Check angle encode connection 13 Brake transistor
 Replace the angle encoder  Check according to code 50_13
02 Angle shaft coupling 52 01-04, PWM current
05,
 Check angle encoder connection 11-14
(Pwm1 LOR, Pwm2 LOR, Pwm3 LOR, Pwm4
 Replace the angle encoder LOR, Pwm0 LOR, Pwm1 HIL, Pwm2 HIL,
Pwm3 HIL, Pwm4 HIL)
03 Angle encoder or speed encoder error  Check that PWM output is not connected to
 Replace the angle encoder or speed 0V(ground)
encoder  Check that cable is not broken
 Contact MacGREGOR(SWE) AB  Replace the MC or CC card
Örnsköldsvik
SERVICE 6.305.16 E rev.: - 2008-10-30
Electrical Equipment, General Maintenance
Introduction
General maintenance of the electric equipment of the
crane is important in order to prevent unexpected
breakdowns. The following general advice may be
useful. Relevant block diagrams and detailed circuit
diagrams can be found in section 9, SPARE PARTS.
Start the crane and try out all combinations of

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

components. Any defective component must be repai-
red or replaced without delay. A detailed inspection
and overhaul at two-year intervals is recommended.
Check that all screws and nuts are securely tighte-
ned in the contactor cabinets, that all switches and
pushbuttons operate correctly, and that cable
connections are perfectly tight and all insulating parts
intact. Make sure that inspection door gaskets seal
perfectly.
Fig. 1. Electrical equipment cabinet.
Danger!
Electrical equipment can be alive unless the main
switch and the separate supply is disconnected.
- Clean contacts, insulating parts, cams, contact
Earth connection, hull rolls, and rotary potentiometers.
- Make sure that all cable connnections are clean
Verify that the protective earth connection of the crane
and securely tightened.
is made to the ship’s hull.
- Clean the control levers, and grease their sliding
Clean contact surfaces, when required.
surfaces.
- Check on the return springs and grease lightly so
Earth connection, crane that no grease transfers to the contacts.
Check crane system earth connections, and clean
contact surfaces as required.
Jib light
Make sure that connections in the junction box are
Portable control boxes (Optional) clean and well tightened.
Control panels and remote control boxes may be
subjected to abuse an abnormal wear, and should be - Remove moisture and dirt.
inspected after every use. The control boxes must - When necessary, clean contact surfaces of termi-
be stored in a compartment that is well protected nal strips and of lamp holder.
against moisture. Remove moisture that may have - Make sure that lamp holder gasket seals correctly.
collected in the boxes, and find out how it entered. - Make sure that the work light can be rotated.

SERVICE 6.305.16 E rev.: - 2008-10-30
Slip-ring unit
Danger!
Before opening the slip-ring unit, make sure that
power supplied by separate transformers is switched
off in the ship's engine room. Also check by means of
a voltmeter that the slip-ring unit is not alive.
- Verify that slip ring contact surfaces are smooth

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

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

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

functions correctly. The thermostat is placed on the
oil filter outlet line.

SERVICE 6.307.14 E rev.: - 2003-02-19
Slip-Ring Unit
Danger!
Before opening the slip-ring unit, make sure that The function of the slip-ring assembly may not be
power supplied by separate transformers is changed in any way. Especially safety devices must
switched off in the ship's engine room. Also check not be made ineffective. Other than during mainte-
by means of a voltmeter that the slip-ring unit is not nance and inspection work the housing must al-
alive. Make sure that the current can not be ways remain closed.
switched on again during the maintenance
operation. Use only insulated tools and original spare parts.
General No responsibility will be assumed for damage to

property or injury to persons caused by improper
The slip-ring unit is mounted inside the crane house use of the slip-ring assembly.
under the platform.
Work on a slip-ring assembly may only be carried

out by a qualified electrician or by persons under
the supervision of a qualified electrician and only
according to accepted electrical safety procedures.
Connection crane
Slip-ring unit
Mounting screws
Connection box
Connection ship
power Guide pins
Driver
Rubber protection
Note! Must be
tightened.
Fig. 1. Slip-ring unit.

SERVICE 6.307.14 E rev.: - 2003-02-19
Removal Maintenance
1. Park the jib in a suitable manner. Always cut current before accessing the collector
2. Disconnect the ship's power supply at all points for inspection or maintenance. Make sure that the
of feed. current can not be switched on again during the
3. Disconnect all the cables connection from crane- maintenance operation.
and ship supply.
4. Remove the driver. Note the cables' mounting At regular intervals
sequence.
- Check collector for damaged parts
5. Remove mounting screws holding the slip-ring
- Check contact pressure of brushes
unit to the platform. See Fig. 1.
- Check brush holders
6. Remove the slip-ring unit.
Any extra equipment such as extra limit switches Carbon brushes

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

fasteners regularly for the first working period.
- Check alignment. The slip-ring unit must not be
allowed to slope in relation to the driver.
- Rotate the crane to ensure that no mechanical
side forces are transferred to the unit.
- Tighten the rubber protection , see Fig. 1.

SERVICE 6.311.12 E rev.: - 2008-09-03
Oil Level Float Switch and Overheating Protector
Introduction
To prevent operation of the crane with too little oil in
the hydraulic oil tank, an oil level guard is installed in
the oil tank, see Fig. 1. The level float switch controls
an alarm lamp on the control panel and a siren. A
FLOAT SWITCH key switch is placed on the control
panel to select different modes depending on oil level
in hydraulic oil tank. See Fig. 2.
LOW OIL LEVEL lamp
FLOAT SWITCH key switch
Fig. 1. Oil level float switch. Fig. 2. Control panel in cab.

SERVICE 6.311.12 E rev.: - 2008-09-03
Normal oil level

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

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

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

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

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

SERVICE 6.311.12 E rev.: - 2008-09-03
Testing oil level float switch

The float of the level float switch is fitted with a built-
in magnet which makes a control circuit when the oil
level drops below certain levels. The function of the
float is preferably tested when performing oil changes
or tank cleaning. For the purpose of this test, the main HIGH OIL TEMP lamp
switch will have to be temporarily switched on.
Overheating protector
The crane stops automatically when the oil tempera-
ture exceeds 85°C. The overheating protector is fitted
on the inlet line of the oil cooler. An alarm lamp HIGH
OIL TEMP on the control panel lights when oil tempera-
ture is more than 85°C, see Fig. 8.
Fig. 8. Right-hand control panel.

SERVICE 6.311.12 E rev.: - 2008-09-03

SERVICE 6.320.367 E rev.: a 2008-11-13
Limit Switches in Hoisting and Luffing Winch Systems

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

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

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

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

SERVICE 6.320.367 E rev.: a 2008-11-13
Setting limit switches
Back off the lockscrews of the switch cams in the li-

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

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

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

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

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

measuring on winches
- AT and BT - luffing winch

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

on the front side of the winch.
Fig. 3. Cam.

SERVICE 6.320.367 E rev.: a 2008-11-13
AT and AL measures (wire lock side), - from the Limit switches - Luffing winch
side of the empty drum flange side to the side of the
wire, see Fig. 5 and 6. The included limit switches are shown in the below
figs. Note that switches BL2 and BL4 actuate speed
BT and BL measures - second layer, from the side reduction of the crane jib.
of the full drum flange side to the wire, see Fig. 5
and 6. Note! When adjusting the luffing limits it is important
to start with BL1 and to continue according to Fig. 8.
Values of AT, BT (luffing) and AL, BL (hoisting) can For measurement values see table "Basic limit
be found in instruction "Technical Data", section 2, switches" in Technical Data.
see tables for hosting and luffing winches.
When changing wires it is important that the proce-
dure in instruction "Replacement of Wires" in section
6.2 is followed, thus to avoid readjustments of limits.
AT - Empty drum flange side/

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

side/second layer Wire lock side
Fig. 7. Limit switch box on the luffing winch.
BL
AL
Fig. 6. Hoisting winch, hook position.

SERVICE 6.320.367 E rev.: a 2008-11-13
Basic limit switches - luffing winch

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

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

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

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

correct operation mode has to be selected by
= Force limitation for parking position. help of the key switch "Parking of jib" in cabin.
= Speed reduce. = Stop position.

SERVICE 6.320.367 E rev.: a 2008-11-13
Measurement of the minimum jib outreach,

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

(calibration point)
There must be a distance

between the front of the
crane house and the first jib stay.
Fig. 9. Crane house top.

SERVICE 6.320.367 E rev.: a 2008-11-13
Limit switches - hoisting winch

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

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

BH1 At least three locking turns or tank top.
Speed reduce
= Stop position.
Fig. 11. Hoisting winch limit switches.

SERVICE 6.320.367 E rev.: a 2008-11-13
Limit switches, high hook (optional) *)

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

then BH5
and BH6 are used.
Max. R NA = High hook is not applicable.
See Technical Data, section 2.
Fig. 13. Extra hoisting winch limit switches, high hook.

SERVICE 6.320.367 E rev.: a 2008-11-13
Jib top and hook block functions at large

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

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

and jib top will possibly meet.
Fig. 14. Large outreaches.

SERVICE 6.320.367 E rev.: a 2008-11-13
Hook way (full drum) limit BH4
Lifting height
H (m)
Block touches
jib top
jib
c/c
Jib bearing
centre Outreach (m)
Min. jib Max. jib

outreach outreach
Fig. 15. Hook way.
Hook stop
Hook stop
Fig. 16. Jib top.

SERVICE 6.320.367 E rev.: a 2008-11-13

SERVICE 6.321.13 E rev.: a 1999-11-23
Slack Wire Safety Switch Hoisting and Luffing Winches
Function Functional test, luffing

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

Wire rope
Switch
Arm
Slack wire safety switch. Normal condition. Slack wire safety switch. Slack wire condition.

SERVICE 6.321.13 E rev.: a 1999-11-23

SERVICE 6.990.56 E rev.: - 2008-10-16
Emergency Lowering in Case of Complete Power Failure

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

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

hoisting (1664), luffing (2664) and slewing (3664)
Plug *), to be
used when
emergency
slewing
Gauge 1D
T-coupling to Mp on pump,
hoisting or luffing
Port 3A-B Port 3A-F
Valve 3B Valve 3A
Connection to tank By-pass line Bushing Screw
Fig. 1. Hand pump 1A (optional).

SERVICE 6.990.56 E rev.: - 2008-10-16
Hoisting circuit, see Fig. 4 and 5

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

Pilot hose,
Directional valve 1221 disconnect and plug **)
Connection P
Oil tank
Hand pump 1A
Quick
coupling
4333
Quick
coupling1664
Directional
valve1226
Pilot hose, Wedge valve 4332
disconnect and plug **)
**) Plug to pilot hose and included in pump set.
Fig. 2. Connection of hand pump 1A, hoisting winch.

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

SERVICE 6.990.56 E rev.: - 2008-10-16
Note! Flush-unloading unit 1128

- connection P mec. affected.
3B
3A
Fig. 4. Hydraulic circuit, hoisting. Emergency coupled.

SERVICE 6.990.56 E rev.: - 2008-10-16
Fig. 5. Hydraulic circuit, hoisting. Not emergency coupled.

SERVICE 6.990.56 E rev.: - 2008-10-16
Luffing circuit, see Fig. 8 and 9
Mp (gauge
connection 5.2)
Luffing pump 2111
Gauge
connection
removed
CAUTION!
Hose must be connected to Mp-port (gauge connection
5.2) on luffing pump to avoid uncontrolled lowering.
Ms (gauge
connection 5.1)
Gauge T-connection
connection
removed
3B
3A
Included in Unloading unit 2127
emergency
equipment Connection P
By-pass line
Disconnect and plug
Pilot hose,
disconnect and plug **)
Oil tank
Wedge valve 4332 Quick

coupling
4333
Ball valve 2661 Quick coupling 2664 Hand pump1A
**) Plug to pilot hose and included in pump set.
Fig. 6. Connection of hand pump 1A, luffing winch.

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

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

SERVICE 6.990.56 E rev.: - 2008-10-16
Note! Unloading unit 2127

- connection P mec. affected.
3B
3A
Fig. 8. Hydraulic circuit, luffing. Emergency coupled.

SERVICE 6.990.56 E rev.: - 2008-10-16
Fig. 9. Hydraulic circuit, luffing. Not emergency coupled.

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

SERVICE 6.990.56 E rev.: - 2008-10-16
Fig. 11. Hydraulic circuit, slewing. Emergency coupled.

SERVICE 6.990.56 E rev.: - 2008-10-16
Fig. 12. Hydraulic circuit, slewing. Not emergency coupled.

SERVICE 7.075.8 E rev.: a 2008-12-04
MacHeavyvisor, Release 3.0
General
MacHeavyvisor is a computer program that is part MacHeavyvisor has two main purposes:
of the logging and information system delivered by
- Displaying real time information about current
MacGREGOR (SWE) AB. The program is
properties of the crane such as jib radius, load
executed on a dedicated computer installed inside
in the hook, and hoisting speed. There can also
the crane cab. MacHeavyvisor communicates with
be additional information.
crane control system (CC3000) via a data
communication cable. The MacHeavyvisor
- Logging information about crane operations,
program and the computer is automatically started
allowing future analysis.
and stopped when the electric power of the crane
system is switched on/off.
Fig. 1. Examples of the Main screen.

joysticks used when operating the crane. When an
Main screen operation is not allowed a white cross will cross-
The main screen is the default view of the over the corresponding arrow. The small white
application and also the one first visible when the “ball” on the hoisting circle (bottom right) indicates
application starts. movement of the hoisting winch.
Note! This view can vary depending on the crane's The blue boxes
different load areas and on the extra equipment If all three boxes are showing 0 there is no
delivered with the crane, for example list or trim communication with the CC3000 system.
sensors.
The upper right box indicates the current jib
In the top left corner the current date and time is radius in meter. When the value gets close to the
displayed in UTC time. In the opposite corner the limit the background in the box will start flashing
MacGREGOR logo is displayed, if the logo is yellow. If the value equals or exceeds the limit the
touched version information will be displayed. box background will flash in red.
Joysticks The top box indicates the current load in the hook
On each side of the screen there are two circles in ton. When the value gets close to the limit the
containing green arrows. These represent the two background in the box will start flashing yellow. If
the value equals or exceeds the limit the box

SERVICE 7.075.8 E rev.: a 2008-12-04
background will flash in red. In case of an overload Touch areas

situation, specifically indicated by CC3000 an audio • Top Left Corner / Admin settings
warning is also given.
• Bottom Left Corner / User level
The bottom right box indicates the current
hoisting/lowering speed in m/min. Connected to this Top Left Corner / Admin settings.
is a small white “ball” visible on the hoisting circle. This manual does not cover this menu alternative,
This “ball” will indicate the direction and speed which is protected by administrator password. The
when hoisting or lowering. Hoisting is indicated by functions are intended for MacGREGOR
clockwise rotation and lowering by counter- personnel.
clockwise rotation.
Bottom Left Corner / User level
The diagram The user level is protected by user password and is
The centre part of the screen is occupied by a set to 1111 when delivered. Functions intended for
diagram visualizing the current load in hook and jib the ship’s crew are protected by the user
radius once more in addition to the text values password.
displayed in the grey boxes. This visualization also
indicates all limits and possible movements for the Tap the bottom left corner and a password dialog
crane. The current values are indicated by a white will appear. Enter the user password and press
“ball” with a black circumference. The areas OK. Input of an incorrect password is notified by a
displayed in the diagram are defined by warning message, press OK to close.
parameters. The green area indicates normal
operation, the yellow indicates “speed reduced”
and the red border is the stop limit. A horizontal
black line indicates at what load the crane will be
limited to reduced speed operation.
Fig. 3. Message displayed when an incorrect password

Dialogs / Passwords is given.
The program is controlled via a dialog system When the correct password is entered the User
which can be accessed by touching the Settings will appear, see Fig. 4. This dialog can
background on the display. If the user stays idle change the date and time.
(not pressing the screen) for a while (1-2 minutes)
any entry will be disregarded and the dialog
window will be closed.
Software keyboard
When a dialog needs input, a keyboard will appear
on the screen on the bottom right corner, see Fig.
2.
Fig. 4. Date and Time Settings for user.
Fig. 2. The software keyboard.

7.076.2 E rev.: b 2008-10-20
USER MANUAL
COMPUTER
CC Pilot XS
1 COMPATIBILITY...............................................................................................................................................2
2 THE INSTALLATION AND SERVICE ..............................................................................................................2
3 THE CONNECTION OF PERIPHERAL DEVICES ...........................................................................................2
4 CODE DATA .....................................................................................................................................................2
5 THE SERVICE AND PROTECTION INSTRUCTIONS .....................................................................................2
6 DISPLAY UNIT..................................................................................................................................................3
6.1 BUTTONS: ....................................................................................................................................................3
6.2 LEDS: ..........................................................................................................................................................3
6.3 CONNECTORS: .............................................................................................................................................3
7 STARTUP..........................................................................................................................................................3
8 PROBLEM SOLVING .......................................................................................................................................4

8.1 THE DISPLAY IS DARK OR DIM.........................................................................................................................4
8.2 SERIAL PORT FAULTS ....................................................................................................................................4
8.3 LED IS BLINKING RED BUT PROGRAM DOESN’T START .....................................................................................4
9 TECHNICAL DATA...........................................................................................................................................4

7.076.2 E rev.: b 2008-10-20
1 Compatibility
The computer is compatible with Windows CE and Linux.
2 The installation and service

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

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

Your computer is of a high quality product, and it should be used carefully. Following instructions help you to
keep product in good condition for a long time.
• The computer shall be cleaned regularly. Wipe out the screen of the device by the soft moist fabric. Do
not use alkaline or alcohol including cleaning agents.
• Do not scratch, damage or press the surface of the display.
If computer won't work correct, please contact MacGREGOR (SWE) AB, Service Department, Örnsköldsvik,
Sweden.

7.076.2 E rev.: b 2008-10-20
6 Display unit
6
1 7
2 8
3 9
4 10
5
11
12
The computer screen has 10,4” LCD TFT display element with a touch screen.
6.1 Buttons:
1. Power button can be used to turn on/off the unit. If pressed for a long time, there will be a
forced power off.
2. Increase brightness.
3. Decrease brightness.
6.2 Leds:
4. Red LED that blinks at startup.
5. Light detector of automatic brightness adjustment.
6.3 Connectors:
6. Power.
7. Ethernet 1 (Not used).
8. Ethernet 2 (Not used).
9. USB 1.
10. USB 2.
Either USB 1 or USB 2 can be used.
11. Misc. (Used as Serial communication port).
12. CAN
7 Startup
The computer is starting up at the same time as the crane. First it loads the operating system and after that
the computer starts the program. When starting, screen is black and the red LED is blinking.

7.076.2 E rev.: b 2008-10-20
8 Problem solving
If there is some problem with the computer check the following first, then call MacGREGOR Service Department.
8.1 The display is dark or dim when crane is working
• Check the brightness adjustment of the screen.
• Check cables and connectors to the display unit.
• Push the power on button on the display unit.
8.2 Serial port faults
• Check that cables are properly connected.
8.3 LED is blinking red but program doesn’t start
• Try to switch off the unit and start again with power button.
9 Technical Data
This computer system is especially developed for use of heavy machinery, which guarantees system durability
and flexible expandability to the different applications.
Kernel Power
Processor Intel XScale, 533 MHz Voltage 10 - 36 VDC
Compact Flash 32 MB -> commercially available Current < 500 mA at 24 VDC (6,5’’)
Kernel Flash 32/ 64 MB Environment
RAM -> 256 MB SDRAM IP-class IP65
Graphic controller Silicon motion, 8 MB RAM Temperature range -25 °C - + 65 °C (operating)
Interfaces -30 °C - + 70 °C (storage)
2 x CAN 2.0B, ISO 11898 – 24V,1 Mbit EMC conformity In accordance with 89/336/EEC:
2 x Ethernet 10/100 Base-T EN 50081-2: 1993
2 x USB 2.0 Software
RS232 OPTION. 115000 baud, replaces Operating system: Windows CE
Keyboard & Mouse Via USB Internal control
Display Status LED In front panel
10,4’’ SVGA 800x600 TFT Photo diode Automatic backlight control
Backlight CCFL ~400 nit Internal temperature protection against overheating
Touch screen Resistive in abnormal ambient conditions.
Mechanical
Enclosure Aluminum Dimensions
Mounting Stand Screen size: 10,4’’
Connectors DIN M12 Depth: 40 mm
Height: 217 mm
Width: 285 mm

EXTRA EQUIPMENT 7.082.1 E rev.: - 2009-01-15
Installation of Maintenance Platform on Foundation

(customer design)
MacGREGOR supplies welded brackets on foundation Maximum outreach: 1300 mm

to enable the assembly of a maintenance platform. The
platform and its support is to be designed and
manufactured by the customer.
Figures below give the technical limitations for the

design. The customer has full responsability for the
platform and the support itself.
Platform
(customer's
responsability)
Fig. 1. Foundation from above.
Welded bracket
Customer's
responsability
Fig. 2. Support assembled on foundation.
Maximum length 1300 mm
Maximum load:
150 kg*/support
Screws: Minimum UNC 7/8", 8.8 steel

Tightening torque: 588 Nm
*) Maximum total load includes people and weight of

platform.
Fig. 3. Support (customer's responsability). Fig. 4. Foundation.

EXTRA EQUIPMENT 7.082.1 E rev.: - 2009-01-15

Instruction Manual GLB3026!2!2426gr Crane1-4

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Instruction Manual GLB3026!2!2426gr Crane1-4

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INSTRUCTION MANUAL Project No.

GENERAL 1 1.000.4 E b SAFETY INSTRUCTIONS

TECHN. DESCRIP. 2 2/07103.01HOC - TECHNICAL DATA

FUNCTION 3 3.110.96 E a HYDRAULIC FUNCTION

OPERATION 4 PM40 1863-E00 b CREW CHECK LIST

MAINTENANCE 5 5.005.55 E c MAINTENANCE CHART

The Original Manufacturer of HÄGGLUNDS Cranes

MAINTENANCE 5 PM51 1709-E00 b LUBRICATING CHART, CRANE

6.0 6.000 E c HOW TO ORDER SPARE PARTS

6.3 6.303.48 E a ABSOLUTE ENCODER CALIBRATION, CC3000

EXTRA EQUIPMENT 7 7.075.8 E a MacHEAVYVISOR, RELEASE 3.0

The Original Manufacturer of HÄGGLUNDS Cranes

SPARE PARTS 9 SEE SEPARATE TABLE OF CONTENTS

The Original Manufacturer of HÄGGLUNDS Cranes

9.0 HOW TO ORDER SPARE PARTS c 6.000 E

9.1 HOISTING WINCH 189 2796-801 E/ 625-1440.047

9.2 PUMP UNIT 189 5104-801 -/- 625-4935.160

9.3 OIL TANK ASSEMBLY 189 3871-801 -/ 625-5865.046

The Original Manufacturer of HÄGGLUNDS Cranes

9.3 CAB DOOR ASSEMBLY 390 8573-801 -/ 625-6546.008

9.4 VALVE UNIT 289 1639-801 A/ 625-7207.006

9.5 POWER SUPPLY 324 0440-801 B/B 625-8562.008

9.7 MOUNTING ENCODER 390 9851-801 A/ 624-2180.014

The Original Manufacturer of HÄGGLUNDS Cranes

9.7 LIFE LINE 388 0962-801 -/ -

The Original Manufacturer of HÄGGLUNDS Cranes

Cargo Handling Equipment

Supervision, Instructions, Signs and Warnings

Preparation for Use and Operation According to Improper Use

MacGREGOR are available for full service of this cargo

The Original Manufacturer of HÄGGLUNDS Cranes 1 (14)

Functions, Installations and Equipment Safety Functions and Equipment

General Specific safety equipment is installed and delivered

2 (14) The Original Manufacturer of HÄGGLUNDS Cranes

4. If there is a multiple-disc failure caused by worn d. Mechanical functions:

The Original Manufacturer of HÄGGLUNDS Cranes 3 (14)

b. Safety belt, rescue line, safety chains:

4 (14) The Original Manufacturer of HÄGGLUNDS Cranes

Danger, Warning, Caution and Notice

Principles of Risk Classification

Those risks classified as DANGER sign are pre-

2. WARNING SIGNS are attached to equipment or

The danger does not exist unless protection instal-

3. CAUTION SIGNS are attached to equipment or

Any person should be able to avoid the danger.

4. NOTICE SIGNS are attached to equipment and

Responsible officers onboard must ensure that the

The Original Manufacturer of HÄGGLUNDS Cranes 5 (14)

Alert / Warning signs

PM40 7101-E00 REPORT TO SUPERINTENDENT OR OPERATOR’S ROOM FOR PERMIT TO ENTER

This sign is at the bottom entrance to the crane foundation.

This sign is at the bottom entrance to the crane foundation.

This sign is at the bottom entrance to the crane foundation.

This sign is at the bottom entrance to the crane (twin) platform.

Attached to the crane wall surfaces close to winches.

Attached to brackets and walls of work platforms inside crane

6 (14) The Original Manufacturer of HÄGGLUNDS Cranes

Attached on the wall side of the crane operator’s cabin.

Attached to surfaces close to pipes inside the crane house.

The Original Manufacturer of HÄGGLUNDS Cranes 7 (14)

PM40 7115-E00SLIPPERY SURFACES - WATCH OUT!

This sign is attached generally to the walls of work platforms.

Applied on the wall side of the crane operator’s cabin.