GP100 0514 2 PDF

INSTRUCTION MANUAL Date Project No.
Page
Dept. 230 2005-02-10 SL04046-3 1 (3)
TABLE OF CONTENTS
Manual No. 11145 (5 pcs), CD-ROM (2 pcs)
Certificate for
crane issued by: ABS
Certificate for
foundation issued by: ABS
IMO No. L9315654
Name of ship
Newbuilding No. H5276
Shipyard DSME
Owners Sonavgol
Project No. SL04046-3
Mfg. No. 62506179 - Right crane, 62506180- Left Crane
Type of crane GP 100-0514-2
Collecting list -
Crane specification -
Order specification 490 4603-803 -804/A
SAFETY DOCUMENTS
Document names written with bold letters are documents with safety aspects.
INSTRUCTION NO. REV NAME OF INSTRUCTION
GENERAL 1 1.005 E e PREFACE

1.009 E a GENERAL INSTRUCTIONS, CLEANLINESS IN HYDRAULIC SYSTEMS
1.102 E c CONVERSION FACTORS
1.518.3 ED a HYDRAULIC AND ELECTRIC SYMBOLS
TECHN. DESCRIP. 2 SL04046-3 TECHNICAL DATA

2.007.56 E b TECHNICAL DESCRIPTION
189 4059 A GENERAL ARRANGEMENT
FUNCTION 3 3.110.70 E a HYDRAULIC FUNCTION

3.142.10 E b CRANE CONTROL SYSTEM
OPERATION 4 PM40 0803-E00 b OPERATING INSTRUCTION

PM40 1822-E00 b SAFETY PRECAUTIONS CHECKLIST FOR CRANE TYPE GP/HH
4.620.13 E - PARKING THE CRANE, SEA STOWING
MAINTENANCE 5 5.005.25 E f MAINTENANCE CHART

5.019 E - INSPECTION OF STRESSED COMPONENTS AND STRUCTURES
PM51 1216-E00 b LUBRICATING CHART, GP- AND HH-CRANES
5.302.15 E e CRANE HOUSING / HYDRAULIC OIL TANK
5.421.16 E d LUBRICANTS FOR DECK MACHINERY
SERVICE 6
6.0 6.000 E b HOW TO ORDER SPARE PARTS

6.000.1 E b STATEMENT REGARDING DELIVERY OF SPARE PARTS TO SWIVELS, LIFTING B
6.000.2 E - RETURN FORM
6.003.1 E l GLOBAL SERVICE
6.004.1 E av MacGREGOR GLOBAL SERVICES
The Original Manufacturer of HÄGGLUNDS Cranes

INSTRUCTION MANUAL Date Project No. Page
Dept. 230 2005-02-10 SL04046-3 2 (3)
TABLE OF CONTENTS
INSTRUCTION NO. REV NAME OF INSTRUCTION
6.0 6.008.2 E - INTRODUCTION
6.1 6.100 E b MEASURES BEFORE STARTING, DURING AND AFTER COMPLETED SERVICE/M
6.120.16 E b SLEWING GEARSET
6.120.62 E f HYDRAULIC MOTORS, HOISTING AND SLEWING
6.120.72 E f HOISTING WINCH
6.142.5 E a RECOMMENDATION FOR INSPECTION AND REPLACEMENT OF HYDRAULIC HO
6.2 6.214 E h TIGHTENING TORQUES, SCREWS AND BOLTS

6.216.69 E c ROPE REEVING DIAGRAM FOR CRANES TYPE GP AND HH
6.222.1 E a HANDLING, INSTALLATION AND MAINTENANCE OF STEEL WIRE ROPES
625/1473 E a WEAR ON WIRE SHEAVES
625/1560 E b LIFTING BLOCK
6.3 6.305.11 E - ELECTRICAL EQUIPMENT, GENERAL MAINTENANCE

6.990.41 E c EMERGENCY LOWERING.., OPERATION OF CRANE USING A HAND PUMP
EXTRA EQUIPMENT 7
APPENDICES 8
SPARE PARTS 9 SEE SEPARATE TABLE OF CONTENTS

PARTS MANUAL Date Project No. Page
Dept. 230 2005-02-10 SL04046-3 3 (3)
TABLE OF CONTENTS
GROUP DESCRIPTION PART NUMBER FIG
9 E625-0017
9.0 HOW TO ORDER SPARE PARTS b 6.000 E
9.1 WINCH MOUNTING 289 2002-803 A/ 625-1260.098

WINCH 289 2001-803 A/ 625-1260.097A
WINCH MOUNTING 289 2002-804 A/ 625-1260.112
WINCH 289 2001-804 A/ 625-1260.113B
GEAR, COMPLETE 875 14108-014 -/ 625-1261.030
FLANGE, COMPLETE 875 14107-001 -/ 625-1261.002A
DISC BRAKE, COMPLETE 875 14101-011 -/ 625-1261.005A
LIMIT SWITCH, COMPLETE 875 14106-011 -/ 625-1261.009A
HYDRAULIC MOTOR 188 1769-801 -/ 625-2205.016
SLEWING GEAR 288 0820-801 A/ 625-3255.004A
HYDRAULIC MOTOR 188 1227-801 -/ 625-2205.017
9.2 PUMP DRIVE 289 0543-801 A/ 625-4935.067

PUMP 188 1097-801 A/ 625-4945.012
9.3 JIB TOP 288 0136-801 A/ 625-6244.001B

CYLINDER ASSEMBLY 289 3177-801 A/ 625-5882.022A
HOOK BLOCK 388 7531-801 B/ 625-7013.005D
JIB BEARING ASSEMBLY 288 0837-801 A/ 625-6170.023A
CRANE ASSEMBLY, RIGHT 189 4220-801 B/B 189 4220
CRANE ASSEMBLY, LEFT 189 4221-801 B/B 189 4221
SLEWING ASSEMBLY 289 1010-801 A/ 289 1010
SLEWING BEARING 388 9099-801 B/ 388 9099
LOAD WIRE ROPE W. THIMBLE; SEE TECHNICAL DATA 390 3424-814 X/ -
9.4 DIRECTION VALVE 188 1342-801 -/ 625-7322.008

BALANCE VALVE 388 6376-801 B/ 625-7330.001
MOTOR VALVE 388 6358-801 B/ 625-7331
BALANCE VALVE 289 0839-801 -/ 625-7330.006
LIMIT VALVE 388 6361-801 A/ 625-7334
FILTER 287 9463-801 B/ 625-7335
LIMIT VALVE 388 7388-801 -/ 625-7620.001
HYDRAULIC HOSES 625-7970G
HYDRAULIC CYLINDER 289 3176-801 -/ 625-7990.043
HYDRAULIC CIRCUIT DIAGRAM 189 4122 -/- 189 4122
HYDR.INST.HOUSE JIB L 189 2909-801 A/A 189 2909
HYDR. INST. HOUSE JIB, R 189 2079-801 A/A 189 2079
LIMIT ARRANGEMENT 189 4277-801 -/- 189 4277
LIMIT ARRANGEMENT 189 4278-801 -/- 189 4278
9.5 EL. CENTRAL/STARTER 324 0870-801 B/B 625-8630.026

ELECTRICAL SYSTEM 324 0867 A/ 324 0867

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.
The Original Manufacturer of HÄGGLUNDS Cranes 1 (1)

PAGE 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 or-
astrous effect on the function of a hydraulic sys- der 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 nection. Clean all covers before reinstallation.
or 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
2. Barrels, hoses and pump must be carefully han-
was 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.,
for inspection is not defective at all, and will be
damped 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 1.102 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
1 kp/cm² = 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/cm²
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

GENERAL/ALLGEMEINES 1.518.3 ED rev.: a 2002-12-10
Hydraulic and Electric Symbols
Hydraulische und elektrische Bildzeichen
This section covers a part of the symbols and port markings commonly
used in MacGREGOR Cranes hydraulic and electric circuits, divided into
three parts:
Diese Sammlung umfaßt einen Teil der allgemeinen Bild- und

Anschlußzeichen, die in MacGREGOR Cranes 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.
2 (29) The Original Manufacturer of HÄGGLUNDS Cranes

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).

Diode.
Diode.
ää
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.

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

Steuerknüppel, Einziehwinde und Schwenkantrieb.

TECHNICAL DATA
(2.001.4 E) Project No. SL04046-3 2005-02-01
GENERAL
TYPE OF CRANE GP 100-0514-2
WO SL04046-3
SERIAL NUMBER 62506179 - Right crane

62506180 - Left Crane
WEIGHT 10,5 tonnes
TYPE OF FREQUENCY 3 ~ 60 Hz
SUPPLY VOLTAGE 440 V
CONTROL VOLTAGE 220 V
STARTING CURRENT 435 A
MECHANICAL DATA
SWL 5 tonnes
JIB RADIUS MAX 14,0 m
JIB RADIUS MIN 2,8 m
LIFTING HEIGHT HOOK TRAVEL 46.0 m
HOISTING CAPACITY, NORMAL OPERATION MAX 5 tonnes
HOISTING SPEED 15 m/min
LUFFING TIME FROM MAX TO MIN JIB RADIUS 30 sec.
SLEWING SPEED MAX 1.5 rev/min
STEEL ROPE WITH THIMBLE Ø 13 mm L = 110 m

No 390 3424-814
ELECTRICAL DATA
EL. MOTOR 288 1629-801
TYPE OF FREQUENCY 3 ~ 60 Hz
RATED POWER, CONT. 33,0 kW
RATED POWER, S6 40 % INT. 46 kW
SPEED 1765 rev/min
RATED VOLTAGE 440 V

TECHNICAL DATA
(2.001.4 E) Project No. SL04046-3 2005-02-01
HYDRAULIC DATA
Hoisting
PUMP TYPE 188 1097-801
DISPLACEMENT 45.0 cm³/rev
MAX. SPEED 2240 rpm
HYDRAULIC MOTOR 188 1769-801
LUFFING CIRCUIT
HYDRAULIC CYLINDER 289 3176-801
SLEWING CIRCUIT
HYDRAULIC MOTOR 188 1227-801
OIL TANK
OIL VOLUME; OIL FILLING 450 litres
PLANETARY GEAR BOX
OIL VOLUME; OIL FILLING 4.2 litres
HOISTING WINCH
OIL VOLUME; OIL FILLING 1,0 litres

TECHNICAL DESCRIPTION 2.007.56 E rev.: b 2003-10-09
Technical Description
Hoisting wire rope
Hook block
Hoisting winch Limit switch box
Pennant
(only HH type) Operator's control
Crane jib panel
Luffing cylinder
Luffing limits
(optional)
Oil tank
Slewing gear
Slewing limits
(optional)
Heating fan
Pump
Cardan shaft
Main electric motor
Fig. 1. Crane types GP and HH.

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

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

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

tank for the hydraulic oil.

Fig. 2. Crane system. Main components.
Jib cylinder Surface treatment

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

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

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

tests are carried out.

FUNCTION 3.110.70 E rev.: a 1999-01-07
Hydraulic Function
General
The following description refers to the Three hydraulic work circuits, ie, main hoisting
MacGREGOR service crane type GP/HH. circuit, luffing circuit and slewing circuit make up
the complete crane operating system.
Minor variations in the hydraulic system may occur
in individual cranes of the same type. All three hydraulic working circuits have a common
main pump. The main pump is located inside the
A complete hydraulic circuit diagram relating hydraulic reservoir which is integrated with the
specifically to your crane will be found in the cranehouse.
instruction manual, “Spare Parts”, Group 9.4.
Hoisting Luffing Slewing
Pump
Fig. 1. Identifying hydraulic circuits

FUNCTION 3.110.70 E rev.: a 1999-01-07
The system has also a common main directional Hoisting winch circuit
valve with three sections, one for each circuit, and
one common base shunt section with main pressure
Introduction
limitation.
Figure 2 shows a hoisting winch circuit diagram with
the following main components:
The main directional valve is a pressure
compensated valve, which gives load independant
Pump (common) 001
speed control. The speed is only depending on the
Hydraulic motor 102
control lever position. The load sensing function in
Brake unit 103
the valve (LS-signal) controls the system pressure
Main motor valve 104
to the level just above the highest required
Main directional valve (common) 002
momentary pressure.
The high-speed motor has a fixed displacement in

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

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

2... Luffing circuit/Luffing cylinder
3... Slewing circuit
Legend
MMHO Hydraulic motor, main hoisting circuit
CLU Hydraulic cylinder, luffing circuit
MSL Hydraulic motor, slewing circuit

FUNCTION 3.110.70 E rev.: a 1999-01-07
Fig. 2. Hoisting winch circuit diagram

FUNCTION 3.110.70 E rev.: a 1999-01-07
Function Safety system

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

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

Safety system
valves 002-6B and 002-7B.
Fig. 3. Control lever movements

FUNCTION 3.110.70 E rev.: a 1999-01-07
002
Fig. 4. Luffing circuit diagram

FUNCTION 3.110.70 E rev.: a 1999-01-07
Slewing circuit
Introduction
Fig. 5 shows a slewing circuit diagram with the
following main components:
Hydraulic motor 302

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

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

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

similar way as for slewing left.
Safety system
valves 002-6C and 002-7C.

FUNCTION 3.110.70 E rev.: a 1999-01-07
002
Fig. 5. Slewing circuit diagram

FUNCTION 3.142.10 E rev.: b 1998-02-19
Crane Control System
The control system is based upon three control Hydraulic motor

levers (main direction valve) operated from the The hydraulic motors may be reversed by changing
outside crane housing/oil tank. The right lever the direction of the oil flow. They deliver constant
controls the hoisting winch, the middle controls the torque over their entire speed range.
luffing and the left lever controls the slewing
movement. All movements except for the luffing The hydraulic hoist motor has a fixed displace-
movement are driven by hydraulic motors. The ment.
luffing movement is driven by a hydraulic cylinder.
Limit switch box, hoisting

The brake releases and closes in the correct
sequence when the hydraulic motor is started and Controls stop for full drum.
stopped.
Hydraulic pumps (Common)

The pump is a fixed displacement pump.
The speed of the winch is depending on the lever
movement.
Fig. 1. Crane system. Main components

OPERATING INSTRUCTION PM40 0803-E00 rev.: b 1999-05-04
OPERATING INSTRUCTION
Notify responsible officer onboard before taking crane into operation.
Make sure that there is nobody in the crane working area who might be injured.
START - STOP
BEFORE STARTING START START (REMOTE)
Set main switch, placed on Star- Press "Start" button on Starter Press "Start" button (green) on
ter box, in position "1". Indicator box. Remote Start/Stop box, placed
lamps "Main Supply" and "Anti- Indicator lamp "Crane Running" on the crane foundation.
condensation Heater" illuminate. illuminates.
Main switch should be switched Indicator lamp "Anticondens-
on approx. 10 hours before the ation Heater" goes out.
crane is taken in operation.
AFTER STOPPING
Set main switch in position "0".
EMERGENCY STOP STOP STOP (REMOTE)

Turn Emergency stop cock to stop Press "Stop" button on Starter Press "Stop" button (red) on
crane movements. box. Indicator lamp "Crane Remote Start/Stop box, placed
Running" goes out. on the crane foundation.

OPERATING INSTRUCTION PM40 0803-E00 rev.: b 1999-05-04
CRANE OPERATION
If more than one crane movement are activated at the same time the speed of the crane will be reduced.
Notice! The movements of the crane are activated directly by the movements of the control levers.
Notice! Always check that the wire runs correctly on the drum.
Operator's Control Panel
1. Control lever Hoisting 2. Control lever Luffing 3. Control lever Slewing

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

OPERATION PM40 1822-E00 rev.: b 2004-09-17
Safety Precautions Checklist for Crane type GP/HH
List Wires and sheaves

Verify that ship does not Max. 5° Verify that wires run
list more than 5 degrees. correctly in the sheaves
and that the wire ends
are securely clamped.
Oil level
Prior to cargo handling Verify hydraulic oil level.
Max
Unclamp jib and loosen the hook from its parking
position.
Min

OPERATION 4.620.13 E rev.:- 1999-06-03
Parking the Crane, Sea Stowing
Sea stowing Prior to cargo handling

Make sure the hook and the crane jib is loosened
Prior to sea voyage, the jib/jib extension should be before raising the jib from the parking support. Also
put on its parking support. If the hook is to be stowed make sure that the crane jib is luffed-in to its working
to deck, fibre strops with low ultimate load or manual area, i.e. within max. outreach.
"stretching screw" are to be used, see Fig. 2.
Notice! Releasing the hook from sea stowing position
Important! has to be done manually (as the hook will start
The wire ropes must not be tightened. The wire ropes, "hoisting" when the brake is released).
sheaves, and winches are subject to heavy stress
during sea voyage.
Fig. 1.
Recommendation for parking the hook
To be observed!
Rope connection
Notice! Hand-tighten only to the extent Stretching screw turnbuckle

that the tightening gear is not slack
Deck
Fig. 2.
1 (1)
MAINTENANCE 5.005.25 E rev.: f 2004-06-03
Maintenance Chart
Lubricate crane according to LUBRICATING slacken, tighten all screws with a torque wrench.
CHART. See drwg. "Slewing assembly", section 9.3.
Every time before taking crane into After 200 operating hours (running in
operation period)
Crane housing/Hydraulic oil tank
- Check oil level Slewing gear case
- The first oil change.
Oil filter
- Check oil pressure. See "Lubricating Chart", Winch
section 5. - The first oil change.
Slewing gear case

- Check oil level. See instruction "Slewing
Gearset", section 6.1. The oil quantity is marked Every six months or every 500 working
on the name plate and in "Technical Data", hours
section 2.
- Check visually all sides. Check for leakage, Wire ropes, wire rope clamps
particularly on the bottom shaft seal ring. - Inspect for wear. See instruction "Handling and
Checking Steel Wire Ropes" under section 6.2.
Winch - Wire ropes are inspected according to
- Check oil level. See instruction "Winch", section stipulations issued by Classification Associations
6.1. The oil quantity is marked on the name plate and National Bodies.
and in "Technical Data", section 2.
Bottom plate
Loose gear - Check for leakage.
- Check that block, beam, hook, swivel and shackle
are intact. Wire sheaves
Check according to instruction "Lifting block", - Inspect for wear
section 6.2.
Loose gear
- Check that hook and swivel are intact.
Every two months or every 200
operating hours Electrical equipment
- Inspect according to “Electrical Equipment,
Slewing rim screws General Maintenance” under section 6.3,
Service.
- Inspect visually the slewing rim screws from the
deck. If any screw shows any tendency to

Crane house, foundation and jib welding joints Every two years or every 2000 hours of
- Inspect for any sign of crack. See "Inspection of operation
Stressed Components and Structures", section 5.
Crane housing/Hydraulic oil tank; oil change
and cleaning
Hydraulic system
- Measure the pressures according to the hydraulic - Drain oil and clean the reservoir. (See “Hydraulic
circuit diagram’s adjoining list, section 9.4. Oil Tank”, section 5.)
- Reset as required. - Top up with fresh oil according to “Lubricants for
Deck Machinery”, section 5.
- Change oil filter cartridge.
Oil analysis
- Change air filter.
- Sample oil and analyse every six months.
- If no oil analysis is done the oil must be changed
every two years or every 2000 hours of operation. Multiple disc brake, winch
See separate instruction section 5. - Check for leakage.
- Check discs.
Slewing rim Check according to instruction "Hoisting Winch"
under section 6.1.
- Check seals.
Multiple disc brake, slewing gearset

Slewing gear, pinion
- Check for leakage.
- Check backlash.
- Check discs.
Check according to instruction "Slewing Gearset"
under section 6.1.
Hydraulic hoses and couplings outside crane

Every 1000 operating hours or at least house
every year
- Inspect for damage and leakage.
Slewing gear case
- Change oil. Gear box.
- Change oil. Disc-room.
- Check motor spline shaft for deformations or
Every four years
wear.
See instruction "Slewing Gearset", section 6.1. Slewing rim studs/screws
- Tighten all studs/screws with a torque wrench.
Tightening torque, see separate drawing,
Winch
"Slewing assembly", section 9.3
- Oil analysis.
- Consult MacGREGOR Cranes before replacing
- Change oil. Gear box.
studs/screws with any other specifications than
- Change oil. Room between motor and gear.
recommended.
See instruction "Hoisting Winch", section 6.1.
Air filter
- Check and change air filter.

Every five years
Hydraulic hoses and couplings inside crane

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

- Replace all hydraulic hoses.

MAINTENANCE 5.019 E rev.: - 1999-06-03
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.
N.B.
Cracks detected at an early stage do not generally Rust on a painted surface does not necessarily
impair the handling safety of the crane unless they mean that there is a crack in the underlying mate-
are not repaired. rial.
For safety reasons, service routines should include

Remedy
a regular inspection of the entire crane, with par-
When rust is found on top of or near a weld, grind
ticular attention paid to stressed parts.
the topmost surface layer away to expose the crack
clearly. When in doubt, use a liquid penetrant to
Inspection identify the crack.
A thorough visual inspection is fairly easy to carry
out as cracks will generally show by cracking or Before repairing of a crack in a stressed part, always
flaking of the paint followed by a brownish discol- contact MacGREGOR Cranes Service Department
oration by rust. for advice.
(Inspect welds and surrounding material.)
Fig. 1. Crane Structure.

LUBRICATING CHART PM51 1216-E00 rev.: b 2004-08-05
GP- and HH-cranes

PART OF CRANE a b c d e f g
KEY TO SYMBOLS
1 WIRE SHEAVES AND THIMBLE, JIB TOP, 3-4 NIPPLES
a DAILY OR BEFORE TAKING CRANE INTO OPERATION
2 WIRE ROPE
b EVERY 50 WORKING HOURS (ITEM 7 AND 14*). 3 LIFTING EQUIPMENT, 1-3 NIPPLE(S)
AFTER MORE THAN 48 HOURS OFF DUTY (ITEM 14*)
4 HOISTING WINCH BEARING, 1 NIPPLE
c EVERY 100 WORKING HOURS 5 AIR BREATHER
6 OIL DRAIN PLUG (IN PUMP BRACKET) 1)

d EVERY TWO MONTHS OR EVERY 200 WORKING
HOURS BEARING, SLEWING RIM, 3-8 NIPPLES, 2)
7
SEE DRWG. PARTS MANUAL SEC. 9.3
e EVERY SIX MONTHS OR EVERY 500 WORKING HOURS
8 SLEWING RIM TEETH
f EVERY YEAR OR EVERY 1000 WORKING HOURS 9 JIB BEARINGS, 2 OR 4 NIPPLES
10 OIL LEVEL TEMPERATURE GAUGE

g EVERY TWO YEARS OR EVERY 2000 WORKING HOURS
11 SLEWING GEAR CASE, OIL CHANGE
GREASE FOR BALL AND ROLLER BEARINGS
12 WINCH GEAR BOX, OIL CHANGE.
GREASE FOR WIRE ROPES 13 WINCH + SLEWING GEAR
14 LUFFING CYLINDER BEARINGS, 4 NIPPLES (INNER)

GREASE FOR OPEN SPUR GEARS
15 LUFFING CYLINDER BEARINGS, 4 NIPPLES (OUTER)
CHECK OIL LEVEL
16 PISTON SEALING, 1-3 NIPPLE(S)
CYLINDERS 17 OIL FILTER 3)
18 CARDAN SHAFT, 2 NIPPLES
OIL FILTER, CHECK/CHANGE
19 OPEN GEAR
CHECK AIR BREATHER
20 DRAIN COCK, HYDRAULIC OIL DRAIN
HYDRAULIC OIL TANK, OIL CHANGE ELECTRIC MOTOR, UPPER AND LOWER BEARING,
21
SAMPLE OIL AND ANALYSE EVERY SIX MONTHS. IF NIPPLES
NECESSARY CHANGE OIL AND CLEAN TANK
22 OIL FILLING
SLEWING GEAR CASE, OIL CHANGE 1) Open oil drain plug after oil tank is drained through drain cock.
THE FIRST OIL CHANGE AFTER 200 WORKING HOURS.
2) Relubrication should be performed under slewing motion. If that is
WINCH, OIL CHANGE not possible relubricate bearing through all grease fittings, than
THE FIRST OIL CHANGE AFTER 200 WORKING HOURS. turn bearing approx. 200 mm and relubricate again. Repeat this
procedure until overlap of greasing is achieved and the whole
WINCH + SLEWING GEAR bearing circumference is filled with new grease at the gaps and
MOTOR FLANGE/SHAFT COUPLING; OIL CHANGE.
seals. (Five rotations/greasings should be sufficient.)
3) Check pressure on the manometer every time before taking crane
MAINTENANCE INTERVALS: SEE MAINTENANCE CHART into operation. The pressure must not exceed 1.5 bar (0.15 MPa).
LUBRICANTS: SEE LUBRICANTS FOR DECK MACHINERY If necessary, change filter.
OIL VOLUMES: SEE TABLES PAGE 2
* Four times a year if the crane is off duty for a longer
period (item 14).
14 12 13 4
2
9
1
5
22
17 1 3
10 Jib equipped with
11 14 15 centralized lubrication.
16 1
8 15 19
7
20 18
6 Grease 3
21
nipples 1
CAUTION!
FILLING OF OIL TO BE MADE AT HORIZONTAL JIB AND/OR CYLINDER IN BOTTOM POSITION.

MAINTENANCE PM51 1216-E00 rev.: b 2004-08-05
Oil volumes
Crane size Oil volume Oil volume Oil volume

(litres) (litres) (litres)
Total hydraulic Oil tank Slewing gear
system
63 250 200 0.9
100 500 450 4.2
160 600 550 5.5
250 750 700 7.7
320 1050 950 7.7
400 1100 950 16.0
500 1250 1100 16.0
630 1250 1100 2 x 7.7
800 2050 1800 2 x 7.7
Table 1.
SWL Winch
(tonnes) (litres)
>0 to 3 0.7
>3 to 5 1.0
>5 to 8 1.6
>8 to10 2.5
>10 to15 2.5
>15 to 20 2.5
>20 to 25 3.5
Table 2.

MAINTENANCE 5.302.15 E rev.: e 2003-09-11
Crane Housing / Hydraulic Oil Tank
General Cleaning the crane housing/oil tank

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

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

Max
Min
Fig. 1. Crane housing / Hydraulic oil tank

MAINTENANCE 5.421.16 E rev.: d 2004-08-05
Lubricants for Deck Machinery
A. OILS B. GREASES
The oil shall be refined oil containing additives against Roller bearings. Crane jib bearing
oxidation, rust and foaming, as well as wear inhibitor Grease with EP additives.
and/or EP additives.
NOTE!
Hoisting winch gear box, slewing gear case MUST NOT contain molybdenum disulphide.
Must withstand wet conditions.
Oils with oil film reinforcing additives.
Example: SHELL Alvania EP (LF) 2 (-20 to +130 °C)
Viscosity approx. 220 cSt/40o C (ISO VG 220 HM).
Arctic climate: SHELL Albida PPS2.
Solidification point -15o C or better.
Example: SHELL OMALA 220
Ropes
Hoisting winch; motor flange Grease resistant to salt water and with antirust
Slewing gear; motor flange properties. (Very thin.)
Half the motor flange should be filled with hydraulic oil Temperature range -30 to +100°C.
to prevent wear/rust on motor shaft/coupling. Viscosity 9.8 cSt/40°C
Example: FUCHS CEDRACON
Arctic climate: FUCHS Ceplattyn
NOTE!
When replacing brake discs the new discs should be
Open spur gear units
slightly wet with ATF-oil.
Grease with good adhesion properties.
Example: SHELL MALLEUS GL95 (-15 to +150 °C)
Crane hydraulic system
SHELL MALLEUS GL65 (-30 to +150 °C)
Viscosity approx. 46 cSt/40o C (ISO VG 46 HV).
Viscosity index (VI) approx. 150.
Cylinder
Solidification point -45o C or better.
Example: SHELL TELLUS T46. (Only for cranes with cylinder luffing)
A lithium/calcium-based grease with base oil viscosity
150 - 200 cSt/40°C.
NOTE!
Please contact MacGREGOR Cranes when choosing MUST NOT contain molybdenum disulphide.
lubricants for extreme temperatures. Example: SHELL CALITHA EP T2

How to order
spare parts 6.0
SERVICE
Hydraulic system 6.1
Mechanical
equipment 6.2
Address:
MacGREGOR Cranes AB
E 2003-01-31
S-891 85 ÖRNSKÖLDSVIK, Sweden

Telephone: 46 - 660 - 29 40 00 Electrical
Telefax: 46 - 660 - 139 77 (Spare Part & Service Dept.) 6.3
Telefax: 46 - 660 - 29 42 81 (Technical Info. Dept.) equipment
www.macgregor-group.com/cranes

SERVICE 6.000.1 E rev.: b 2004-08-10
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 Cranes cannot
appliance should be with the provisions of section supply separate spare parts to hook blocks,
D.1: swivels, lifting beams etc. to the owner or
managers. However, it is possible to deliver such
(a) before taking in to use the first time parts to the MacGREGOR service organization,
(b) after the renewal or repair of any stress if they can guarantee that the proof load test and
bearing part; and appreciate inspection according to ILO will be
(c) at regular four-year intervals, after the date performed under their responsibility.
on which the appliance was first taken in to
use. MacGREGOR Cranes AB
Quality Department
Paragraph A.1.2 stipulates that the following
exceptions to the requirements of paragraph A.1.1
may nevertheless be allowed:
Gunnar Tjärnström
(a) where any part is renewed or repaired, it Quality Manager
should be considered sufficient to subject
that part, by separate means, to the same
stress as would have been imposed on if it
had been tested in-situ during the testing
of the complete appliance.
Section 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 6.000.2 E rev.: - 1997-10-02
RETURN FORM
How to return parts from deck crane manufacturing,
installation or guarantee exchange
Delivery address: MacGREGOR Cranes AB

Service Department 220
S-891 85 ÖRNSKÖLDSVIK
SWEDEN
Transport means, if necessary: Advised by us on request.

Tel. no 46-660-294049
Fax no 46-660-294288
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.: - 1997-10-02
RETURN FORM
To be packed inside return box or parcel
Date
Sent by
Newbuilding no
Ship’s name
Lloyd 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“.
(222/IN: 662 5000-706)

Global Service 6.003.1 E rev.: l 2004-02-25
MacGREGOR branches with

trained crane engineers
Central spare parts stock
Regional spare parts stock
Bergen Hamburg Oslo Singapore ÖRNSKÖLDSVIK

Bombay Newcastle Pusan Sydney MacGREGOR Cranes AB
S-891 85 ÖRNSKÖLDSVIK
Copenhagen New Orleans Rio de Janeiro Tokyo
Sweden
Dubai New York Rotterdam Valparaiso Tel +46 660 29 40 00
Gothenburg Norfolk Shanghai Vancouver Fax +46 660 139 77

SERVICE & PARTS 6.004.1 E rev.: av 2004-12-10
MacGREGOR Global Services
BELGIUM Shanghai, (S) (P) FRANCE

Antwerpen, (P) MacGREGOR (SHANGHAI) Marseille, (P)
MacGREGOR (NLD) B.V. Trading Co. Ltd. MacGREGOR (FRA) S.A.
Luithagen-Haven 2E Room 1701-1704, Pidemco Tower Porte 4, Cap Janet
B-2030 Antwerpen 318 Fuzhou Road 13314 MARSEILLE Cedex 15
Phone: (+32) 3-542 5112 SHANGHAI 200001 Phone: (+33) 491-09 52 52
Telefax: (+32) 3-542 4772 Phone: (+86) 21-6391 2798 Telefax: (+33) 491-09 52 40
Telefax (+86) 21-6391 2276
BRAZIL GERMANY
Rio de Janeiro, (S) CROATIA Hamburg, (S) (P) (LCE)
Offshore Reparos Navais Rijeka, (P) MacGREGOR (DEU) GmbH
Rua Delegado Waldir Guilherme 14 MacGREGOR (HRV) d.o.o. Normannenweg 24
Ilha da Conceicao Vrh Martinscice 93B D-20537 HAMBURG
CEP: 24.50-170 HR-51221 RIJEKA-KOSTRENA Phone: (+49) 40-25 44 40
Niteroi - RIO DE JANEIRO Phone: (+385) 51-289 717 / 718 Telefax: (+49) 40-25 44 44 44
Phone: (+55) 21-2717 2673 Telefax: (+385) 51-287 154
Telefax: (+55) 21-2620 0740 Hamburg LCE
CYPRUS MacGREGOR Logistic Centre
CANADA Limassol, (P) c/o Kühne & Nagel (AG & Co.) KG
Vancouver, (S) MacGREGOR (CYPRUS) Ltd. Altenwerder Hauptstraße 1
Nagesco Ltd. Titos Building, Office 201 D-21129 Hamburg
961A West 1st Street 58 Gladstone Street Phone: (+49) 40-239 39 0
NORTH VANCOUVER, B.C., CY 3041 LIMASSOL Telefax: (+49) 40-239 39 334
V7P 1A5 Phone: (+357) 5 763 670
Phone: (+1) 604-985 61 73 Telefax (+357) 5 763 671 GREECE
Telefax: (+1) 604-980 44 76 Piraeus, (P)
DENMARK MacGREGOR (GRC) Ltd.
CHILE Copenhagen, (S) (P) 4-6 Efplias Street
Santiago, (S) MacGREGOR (DNK) A/S GR-185 37 PIRAEUS
EXIMTEC Ltda. Phone: (+30) 210-42 83 838
Smedeholm 11,
Neveria 4444 - Piso 9 Telefax: (+30) 210-42 83 839
DK-2730 HERLEV
Las Condes Phone: (+45) 44-53 84 84
SANTIAGO Telefax: (+45) 44-53 84 10 INDIA
Phone: (+56) 2-207 65 90 Bombay, (S)
Telefax (+56) 2-207 65 91 FINLAND Renascent Enterprises
Turku, (P) Flat 8, Building D/6-9
CHINA MacGREGOR (FIN) OY Radha Nagar, Barave Road
Hong Kong, (P) KALYAN (WEST), Pin - 421 301
Hallimestarinkatu 6
MacGREGOR (HKG) Ltd. Phone: (+91) 251 232 30 65
FIN-20780 KAARINA
Unit 3119, 35/F, Tower 1, Telefax: (+91) 251 232 06 43
Phone: (+358) 2-412 11
Millennium City 1, Telefax: (+358) 2-4121 517
388 Kwun Tong Road
KOWLOON
Phone: (+852) 2394 1008
Telefax: (+852) 2787 7652
Telefax: (+852) 2787 9878 (cranes)
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 AB Address Telephone Telefax

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

SERVICE & PARTS 6.004.1 E rev.: av 2004-12-10
ITALY Gdynia, (P) Dubai, (S) (P)

Genoa, (P) MacGREGOR (POL) Sp. z o.o. MacGREGOR (ARE) LLC.
MacGREGOR (ITA) S.p.A. Ul. Energetykow 5 P.O. Box 30029 Dubai
PL-81-184 GDYNIA Al Jadaf Shipyard area / GMMOS Yard
Via Al Molo Giano
Phone: (+48) 58-7855 110 DUBAI
16128 GENOA/PORTO
Telefax: (+48) 58-7855 111 Phone: (+971) 4-3241 335
Phone: (+39) 010-2770 412
Telefax: (+39) 010-24 61 194 Telefax: (+971) 4-3241 271
SINGAPORE 24h phone: (+971) 50-65 10 371
Singapore, (S) (P) (LC)
JAPAN UNITED KINGDOM
MacGREGOR (SGP) Pte. Ltd.
Tokyo, (S) (P)
No. 12 Benoi Crescent Newcastle, (P)
MacGREGOR-Kayaba Ltd. - 629975 SINGAPORE MacGREGOR (GBR) Ltd.
Head Office Phone: (+65) 6265 2322 1st Floor, Power House
9/F, Suzue Baydium Bldg. Telefax: (+65) 6264 1261 Silverlink Business Park
1-15-1, Kaigan Wallsend
Minato-Ku SPAIN NE28 9ND TYNE & WEAR
TOKYO 105 - 0022 Phone: (+44) 191-295 2180
Bilbao, (P)
Phone: (+81) 3-5403 1966 Telefax: (+44) 191-295 2188
Telefax: (+81) 3-5403 1953 MacGREGOR (ESP) S.A.
Edificio Inbisa
Amaya, 2 - 1o USA
KOREA
ES-48940 LEIOA - VIZCAYA New York, (S) (P)
Pusan, (S) (P) Phone: (+34) 94-480 7339 MacGREGOR (USA) Inc.
MacGREGOR (KOR) Ltd. Telefax: (+34) 94-431 6945 14 Ridgedale Avenue
Room No 1101, Dong Ju Building Suite 205
13-5 ka, Jungang-dong, Jung-ku Alicante, (S) Cedar Knolls
PUSAN Stanley van der Pers NJ 07927-1106
Phone: (+82) 51-441 0805 c/o Vanpershydro S.L. Phone: (+1) 973-285-7860
Telefax: (+82) 51-442 5777 Apartado de correos No. 7 Telefax: (+1) 973-285-7861
ES-03170 ROJALES - ALICANTE
NETHERLANDS Phone/telefax: (+34) 9667 13665 Norfolk, (S)
Rotterdam, (S) (P) Mobile: (+34) 620 953 722 MacGREGOR (USA) Inc.
MacGREGOR (NLD) B.V. 508 John Etheridge Road
Albert Plesmanweg 95-97 CHESAPEAKE, VA 23322
3088 GC ROTTERDAM SWEDEN Phone: (+1) 757-421-9406
Phone: (+31) 10-2832 121 Örnsköldsvik, (S) (P) Telefax: (+1) 757-421-2026
Telefax: (+31) 10-4293 219 MacGREGOR Cranes AB
Björnavägen 14 New Orleans, (S)
NORWAY SE-891 85 ÖRNSKÖLDSVIK MacGREGOR (USA) Inc.
Oslo, (P) Phone: (+46) 660-29 40 00 4757 River Road
MacGREGOR (NOR) A/S Telefax: (+46) 660-139 77 Jefferson
Malerhaugveien 25 www.macgregor-group.com/cranes LOUISIANA 70121
N-0602 OSLO Phone: (+1) 504-733-3321
Phone: (+47) 23-10 34 00 Gothenburg, (S) (P) Telefax: (+1) 504-733-3360
Telefax: (+47) 23-10 34 01 MacGREGOR (SWE) AB
Atlashuset, Banehagsliden 2
Bergen, (S) SE-414 51 GOTHENBURG
MacGREGOR (NOR) A/S Phone: (+46) 31 85 07 00
Bredalsmarken. 15-17 Telefax: (+46) 31 42 49 46
N-5006 BERGEN
Phone: (+47) 23-30 25 50 U. A. E.
Telefax: (+47) 23-30 25 51
POLAND
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 AB Address Telephone Telefax

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

SERVICE 6.008.2 E rev.:- 1999-06-01
Introduction
Before proceeding to trouble-shooting, the crane

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

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

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

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

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

- Was the operating speed first reduced, or did Electric circuit diagram
the movement run irregularly?
Electric circuit diagram
- What manoeuvre immediately preceded the
failure? Electric circuit diagram
Begin checking if there are any visible defects.

SERVICE 6.008.2 E rev.:- 1999-06-01
When consulting MacGREGOR Cranes for service Analysis of information collected

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

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

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

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

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

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

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

consulting MacGREGOR Cranes.

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

Service/Maintenance Work
WARNING !
When it is necessary to search for/or correct faults
in the crane's electrical, hydraulic or mechanical
systems with the crane powered up, only 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 6.120.16 E rev.: b 1998-02-25
Slewing Gearset
During operation, a substantial quantity of oil is dis- Oil filling and

gear-aerating
tributed within the housing's interior. We therefore (shown 15° displaced)
recommend that you check the oil level with the Overpressure valve
gearbox at standstill directly after putting the sys- (shown 30° displaced)
-blow up with 0.02-0.04 bar
tem into operation and that you top up the filling, if
necessary. The correct oil level has been reached Compressed oil connection-brake
if oil emerges from the oil monitoring plug. Since
the service life depends considerably on the qual- Oil level gauge
2x180° - shown 15° displaced Screws
ity of oil used, we recommend use only of the qual-
ity proposed in instruction "Lubrictaion for deck
Overflow plug
machinery". 2x180° - shown 15° displaced
Oil filling
Oil drain
The oil filling is ensued over the compensating tank. (4x90° - shown 7,5° displaced)
Remove the aerating filter and the overflow plug.
Fill with oil using an angled funnel or hose until it
overflows. Tighten the filling screw again.
See Fig. 1. Fig. 1. Slewing gearset
Checking the oil

The oil must always be checked before a main op-
erating phase. If a continous loss of oil has occured,
operation must be stopped and the assembly be Checking for leakage
dismantled. On gearboxes allowing a visual check on all sides,
a check for leaks, particularly on the bottom shaft
Once a year the drained oil should be examined. seal ring, should be carried out daily.
For this purpose the used oil is dripped on a filter
fleece. Using a magnifying lens for instance coarse Draining the oil
grained solid matters may be found by visual in-
The same handling operations as for oil filling (see
spection. The foreign matters (max. 0,15 % of the
Fig. 2.) analogously apply. Remove first the
whole oil mass) may only consist of fine rubbed-off
lowermost and then the uppermost plug.
parts (part size up to 25µm). If there are coarse
grained parts (above 25µm) or spallings from the
tooth flanks of the gears then - irrespective of the Preservation
share of mass - the gearing must be dismantled Preservation is recommended if the unit is to be
beginning at the pinion end. The tooth flanks have shut down for a longer period of time. Drain off the
to be controlled by sight. In the case of normal wear old oil and pour in half the quantity of preservative
and after the running in period the tooth flanks have oil. Run the system for approx. 5-10 minutes at high
a smooth, bright, polished surface. In all other speed, but without load.
cases, like abrasive wear, scoring, scuffing, pitting,
spalling, cracking and plastic deformation the gears When putting the unit into operation again, drain
have to be changed respectively it is advisable to the preservative oil and pour in oil in accordance
cause a general overhaul. with the specifications.

SERVICE 6.120.16 E rev.: b 1998-02-25
Only preservative oil may be used which, accord- 1/6 1/2 1/5
ing to the manufaturer's specifications, later emul-
sifies with the specified type of lubricating oil. 13
2
1/3
General maintenance instructions
The motor must be inspected once a year to check 6 8
the spline shaft at the drive side. It must not show
7 1/4
plastic deformations or abrasive wear (tooth pro-
files are weared; steps can be stated). If there are
damages at the spline shaft, the parts have to be
replaced immediately.
If inspections or repairs are necessary we recom-

mend sending into the works under all circum-
stances so that a maximum of reliability is guaran-
teed.
1/13
Compressed media
Hydraulic oil is required for releasing the brake. Its 1/11 1/1
viscosity should not exceed 4-6° E at 50° C. ATF 1/12
oils belonging to SAE class 10 have proven their
worth. Special seals are required when using com- Fig. 2. Brake
pressed media other than oil in hydraulic systems.
This is why we should be consulted.
Attention: Unscrewing or removing of hydraulic
1/1 piston
pipes under pressure resp. of connections are haz-
1/2 cylinder
ardous. Take care that - in case of works at the
1/3 flange
brake (mounting/dismounting) - the brake and the
1/4 compression spring
belonging hydraulic pipes are depressurized.
1/5 seal ring set, exterior
1/6 seal ring set, interior
Shifting 1/11 fillister head screw
The brakes are designed for a maximum operating 1/12 hexagon nut
pressure of 320 bar. Three release pressure possi- 1/13 adapter sleeve
bilities are provided for releasing the brakes, 2 annual housing
achieved with three different. spring assemblies. 6 outer disk
The brakes can be activated in the main circuit. 7 inner disk
When the circuits are closed, it is advantageous to 8 compression spring
connect the brake to line of the feed pump. The 13 fillister head screw
brake is frequently connected to a separate control
circuit.
Emergency shifting
The brake can be opened mechanically if the hy- Brake maintenance
draulic system should fail. In the piston (1/1), there The brake readjusts itself automatically. If the pres-
are threaded holes through which - by means of sure load and shift frequency are high, slight quan-
corresponing screws (M6 or M8) - the piston can tities of leaking oil on the piston seals cannot be
be retracted. avoided.

SERVICE 6.120.16 E rev.: b 1998-02-25
When replacing the seals, all seal elements must

be renewed - not only the damaged rubber ring and To dismantle further, unscrew the two screws (1/
thus only as a full set. 11). It is now possible to pull the cover (1/3) with
the piston (1/1) out of the cylinder (1/2). When re-
Before opening the brake, it is absolutely neces- placing the outer and inner seals, pay attention to
sary to open it mechanically as described above, the positions of the respective back-up and quad
thus preventing abrupt separation of the spring- rings to ensure that they are re-installed in the same
loaded brake components. way. The chromium-plated and super-finished pis-
ton tracks must not be damaged in any way. En-
sure complete cleanliness! (Do not use cleaning
Lubrication instructions
wool.) When replacing discs, first guide the annu-
For protection against corrosion in the disc-room
lar housing (2) alone onto the gear center. The disk
and for having a constant frictional value at wet-
assembly should then be fitted. Ensure that the
running before assembling the motor an ATF-oil is
correct discs are fitted.
filled in.
Spare discs are supplied in sets. The designations
The quantity of the filled oil is 0.2 l.
of the discs and brakes as well as the size and
number of discs are specified on the packaging.
An separate oil change isn't necessary. Take care
For functional reasons, it is not possible to place
that after dismantling and later assembling of the
identification on the discs.
brake the oil is refilled again.
The oil should be changed at the same time as the Checking and adjusting slewing rim backlash
oil change of the gear. An oversize backlash between the pinion and the
slewing rim will cause irregularities in the slewing
movement of the crane. Read this instruction care-
Installation and maintenance faults fully prior to checking or resetting!
Checking backlash
Drops in brake moment
The backlash should be checked by a dial gauge
Replace the disc assembly if excessively worn. If or a feeler. When slewing the crane, the backlash
dry operation occurs, check whether it was possi- may vary from one position to another due to some
ble for leakage oil to escape. Replace discs if the slight excentricity of the slewing rim. It is therefore
disc assembly is clogged. recommended to check the backlash at four posi-
tions of the slewing rim.
Brake becomes warm
Check that the release pressure is sufficiently high. Proceed as follows:
The brake constantly receives an upstream pres- - Check the backlash at one spot
sure. - Slew the crane 90° and check
- Proceed to check the backlash at four 90-degree
position in the rim.
Dismantling and assembly
- Put the dial gauge on the tooth of the pinion. By
First insert two screws in the threaded bores of the manual turning at the input, the pinion can be
piston (1/1) opposite to each other at 180° on the moved in both directions up to contact with the
face ends. Each screw must be tightened alter- teeth. Now, the tooth flank clearance can be ex-
nately with a turn of one thread in each case. (Avoid actly measured on the dial gauge.
tilting the piston!) Then undo the screws (13). The - Check the backlash at one spot
closed brake can be removed from the gear. - Slew the crane 90°. Check again

SERVICE 6.120.16 E rev.: b 1998-02-25
- Proceed to check the backlash at four 90-degree tact surfaces and apply Loctite 640 Sealant or a
positions in the rim similar compound. Make sure not to strain the
- Compare the four backlash values hoses. Apply Loctite 242 on the screws holding the
Backlash values: upper part, reinstall and tighten.
Module 12: 0.25-0.5mm
Module 14 and 16: 0.3-0.6mm
The backlash shall be set at the position of the slew-

ing rim with the lowest backlash value.
Setting backlash
The backlash may be set by turning the entire
gearset one or more screw hole divisions.
Proceed as follows:
- Slew the crane into the position with the low-
est backlash value
- Remove all screws holding the gearset to
cranehouse floor
- Release the disc brake hydraulically by means
of a manual pump
- Turn the entire gearset one or more screw
hole to achieve the desired setting.
To turn the gearset, remove the hydraulic motor
and turn the spline sleeve on top of the gear.
Note!
The turning of the entire gearset may be restricted
by the hoses connected or by space limitations. To
overcome this problem, release the upper part of
the gearset by just removing the holding screws,
see Fig. 1.
Make sure that the upper part can be turned freely.

Turn the entire gearset (except the upper part), until
the desired setting is achieved. Watch the hoses!
- Replace and tighten the screws holding the

gearset to the cranehouse floor using ”Loctite
242” or a similar compound.
If the upper part has been removed

If the upper part has been removed, clean its con-

SERVICE 6.120.62 E rev.: f 2003-03-19
Hydraulic Motors, Hoisting and Slewing

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

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

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

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

connections.
Oil filling/Drain connection



T1 alternatively T2 can be used as oil filling and drain

connections.

SERVICE 6.120.62 E rev.: f 2003-02-19



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

Drain connection

The type of hydraulic oil must agree with the "Lubricating

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

Drain connection


Oil filling/
Drain connection

SERVICE 6.120.62 E rev.: f 2003-03-19

Drain connection

The type of hydraulic oil must agree with the "Lubricating

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

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

Drain connection
288 2158-801


Displacement Vg: 54.8 - 0 cm3/rev.

Oil filling/
Drain connection

Drain connection



SERVICE 6.120.72 E rev.: f 2004-06-03
Hoisting Winch
General
Installation, operating and service personnel must Check that all safety devices and safety guards are
always read through these operating instructions in proper working order or are attached before
carefully. All information and instructions on putting putting the unit into operation or commissioning it
into operation, maintenance and repair must be strictly and after carrying out maintenance work or repairs.
observed. The technical documentation must be kept
in the vicinity of the hoisting gear. We are unable to On no account the equipment and the operation
accept any liability for damage, loss and plant inter- conditions or the hoisting gear and its attachements
ruption resulting from noncompliance with the opera- may be converted or changed in an unauthorized
tion instructions. Should you have any queries, please manner because this will influence the safety of the
consult our After Sales Service or Spare Parts De- hoisting unit.
partment. This also applies to damage which has
occurred during transport and identified when the The load-carrying capacity of the hoists used must
consignment is received. be at least equal to the weight of the unit.
Work safety information Keep well away from the area beneath suspended
Always strictly adhere to the following work safety loads.
instructions:
Information on other risks dangers
Every person involved in installatin, commissioning,
Moving parts which have not been locked or pro-
operation or maintenance (servicing, repair) work on
tected with safety devices or guards by the hoist-
the hoisting gear at the user's plant must have read
ing gear manufacturer (particularly on drive and
through and understood the entire operating instruc-
output shafts) must be fitted with safety devices or
tions. We urge the user to have this confirmed in
guards by the operation.
writing by each person. The responsibility for instal-
lation, commissioning, operation and maintenance
Before disconnecting the hoisting gear it must be
must be clearly defined and observed, in particular
ensured that there are no static torsional loads
from the point of view of safety.
within the driving system. Such torsional loads must
be released at suitable points.
Work may be carried out at the hoisting gear and its
attachments with the system shut down under
The outside surfaces of the unit may become very
loadless conditions only.
hot during operation.
Caution! Severe burns may result from touching
Before carrying out work on the unit (maintenance
these surfaces. We recommend that you wear
and repair), the unit's drive and its attachements must
protective gloves and clothing.
be locked to prevent them being switched on unin-
tentionally. The system must be disconnected from
Oil is drained off when the transmission unit is hot
the electrical power supply and its shafts must be
by opening the oil drain plug.
locked to prevent them turning. Hydraulic and/or pneu-
Caution! Avoid scalding. We recommend that you
matic supply pipes must be pressureless.
wear protective clothing, including gloves and
goggles.
Safety devices and safety guards may be removed
and fitted only with the hoisting gear and other
equipment shut down.

SERVICE 6.120.72 E rev.: f 2004-06-03
Oil filling Checking the oil

During operation, a substantial quantity of oil is dis- The oil must always be checked before a main op-
tributed within the housing's interior. We therefore erating phase. If a continous loss of oil has occured,
recommend that you check the oil level with the operation must be stopped and the assembly be
gear box at standstill directly after putting the sys- dismantled.
tem into operation and that you top up the filling, if
necessary. The correct oil level has been reached
Sampling oil
if oil emerges from the oil monitoring plug. Since
Take a sample of gearbox oil for analysis at intervals
the service life depends considerably on the qual-
as described in the "Maintenance Chart".
ity of oil used, we recommend use only of the qual-
ity proposed in instruction "Lubricants for deck
Procedure for oil sampling:
machinery".
- The oil temperature in the gearbox should be
above +40 0C.
For the oil filling of the gear remove the overflow
- Special oil sampling bottles should be used that
and the filling screw. Fill with oil using a hose until
can be obtained from oil companies.
the oil overflows. Tighten the overflow and filling
- The oil sample should be taken from the oil drain
screw again.
on the winch, see Fig. 1.
- Drain 1-2 litres of oil into a bucket. This oil should
To prevent permature wear at the involute spline
be disposed of.
joint the room between motor and gear is filled with
- Fill the oil sample bottle.
oil. When filling oil remove the oil filling screw. Fill
- Send the oil sample to an oil company for analy-
oil until it overflows. Tighten the oil filling screw.
sis.
The oil company will be able to recommend if
The oil should be changed at the same time as the
the oil can be further used.
oil change of the gear.
Feedback on the oil analysis can also be obtained
from MacGREGOR Cranes.
Overpressure valve
Oil filling - gear box

Oil filling -
motor coupling
Oil overflow -
gear box
Oil overflow -
motor coupling
Oil drain -
motor coupling
Oil drain - gear box
Fig.1. Hoisting winch.

SERVICE 6.120.72 E rev.: f 2004-06-03
Greasing point - Oil filling - gearing Compressed oil

bearing bush connection - brake
Oil filling -
motor coupling
Overpressure valve -
motor coupling
Overflow - gearing
Oil drain -
motor coupling
Oil drain -
gearing
Fig. 2. Hoisting winch.
Oil discoloration
A darkish or black colour of the used oil suggests
Overall assessment
that temperatures in excess of 100°C have occurred
The maximum permissible amount of foreign mat-
in operation, causing accelerated ageing of the oil
ter carried by the oil is some 0.15 per cent of the
and impaired lubricating properties. In this case the
total mass of the oil in the gearbox. These impurities
oil should be changed at shorter intervals.
may only consist of very finely abraded matter (max.
25 µm). If the contamination keeps within these
If the oil sample displays a cloudy aspect, it may limits, continued operation of the gear set is
be that water has managed to seep into the oil. The permitted after the oil has been changed.
oil must then be changed at once, and the gearbox
If coarser abraded matter (above 25 µm) or flake-
flushed out very thoroughly several times with fresh
off material from the gear teeth is found, the gear
oil.
set must be dismantled, irrespective of the actual
amount of foreign matter present, beginning at the
The gearbox should preferably be dismantled for input end of the gear set.
inspection beginning at the input side, and the
components examined for signs of corrosion.
Draining the oil
Drain the oil at working temperature. First unscrew
Foreign solid matter the overflow screw so that air can steam when drain-
As a first simple test, drop some of the used oil ing. Then remove the drain screw - take the used
onto the filter fleece specified. Coarse foreign oil in an oil sump pan. After oil has been drained, fit
matter, if present, will then show up on inspection the drain screw again. Top up with oil in accordance
through (preferably) a magnifying glass. with regulations or the procedure described in "Oil
A better test can be made by diluting an oil sample filling".
with n-heptane, passing it through a diaphragm
filter, washing and drying it, and weighing it to Caution! Hot oil watch out.
determine the mass difference.

SERVICE 6.120.72 E rev.: f 2004-06-03
Preservation
Preservation is recommended if the unit is to be In case of brake integrated in the lifting gear, any
shut down for a longer period of time. Drain off the leakage oil can escape itself and emerge through
old oil and pour in half the quantity of preservative the opening in the motor flange. A lekage oil con-
oil. Run the system for approx. 5-10 minutes at high nection is provided for all non-integrated brakes.
speed, but without load.
The connection for this purpose may be optionally
When putting the unit into operation again, drain made at the same height as the pressure port or
the preservative oil and pour in oil in accordance offset by 180° in respect of the latter. The leakage
with the specifications. oil bore must point vertically downwards.
Only preservative oil may be used which, accord- When the seals are replaced, all sealing elements
ing to the manufaturer's specifications, later emul- must be renewed and not just damaged rubber ring;
sifies with the specified type of lubricating oil. i.e. seals must be replaced in sets.
Compressed media Before removing the brake, it is essential that it is

mechanically opened as described in "Manual op-
Hydraulic oil is required for releasing the brake. Its
eration".
viscosity should not exceed 4-6° E at 50° C. ATF
oils belonging to SAE class 10 have proven their
worth. Special seals are required when using com-
pressed media other than oil in hydraulic systems.
This is why we should be consulted.
Operation
The brakes are designed for a maximum operating
pressure of 320 bar. Three release pressure possi-
bilities are provided for releasing the brakes,
achieved with three different spring assemblies. The
brakes can be activated in the main circuit. The
brake is often connected to a separate control cir-
cuit.
Manual operation
If the hydraulic system fails, the brake can open
mechanically. Threaded bores are provided in the
piston (1/1), through which the piston can be pulled
back using corresponding screws (M10 or M8).
Brake maintenance
The brake adjusts itself automatically. Low leak-
age oil quantities at the piston seals are unavoid-
able as a result of high pressure forces and fre-
quent switching.

SERVICE 6.120.72 E rev.: f 2004-06-03
Motor disassembly
The motor must be disassembled once a year to
check the spline shaft at the drive side. It must not
show plastic deformations or abrasive wear (tooth
profiles are weared; steps can be stated). If there
are damages at the spline shaft the parts have to
be replaced immediatly.
If inspection or repairs are necessary, we recom-

mend sending the motor to MacGREGOR Cranes
AB under all circumstances so that a maximum of
reliability is guaranteed.
1/6 1/2 1/5
13
1/1 piston
1/2 cylinder
2 1/3
1/3 flange
6 8 1/4 compression spring
1/4 1/5 seal ring set, exterior
7 1/6 seal ring set, interior
1/11 fillister head screw
1/12 hexagon nut
1/13 adapter sleeve
2 annual housing
6 outer disc
7 inner disc
8 compression spring
1/13 13 fillister head screw
1/11 1/1
1/12
Fig. 3. Brake.

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 6.214 E rev.: h 2003-01-09
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
ven. Apply Molycote 1000 Lubrication on the threads a lower surface notch indicating that the permitted
and under the bolt head. For stainless elements and tension 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 Molycote 1000 Untreated bolts greased with Molycote 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.: h 2003-01-09
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
SAE flange for high pressure hose couplings 8 7.8 17 22
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.: h 2003-01-09
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.: h 2003-01-09
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 6.216.69 E rev.: c 2004-10-19
Rope Reeving Diagram for Cranes Type GP and HH

1-Part Rigging
Hoisting wire rope

SERVICE 6.216.69 E rev.: c 2004-10-19

2-Parts Rigging
Hoisting wire rope
Locking plate
Lock washer
Screw
Spacer
Wire thimble
Note! The wire rope thimble should be safety secured.

SERVICE 6.216.69 E rev.: c 2004-10-19

4-Parts Rigging
Hoisting wire rope
Locking plate
Lock washer
Screw
Spacer
Wire thimble
Note! The wire rope thimble should be safety secured.

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 manufac-
turer 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 lubri-
cant might damage the wires when the rope trav-
els 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 but because of the great length of rigid connection
reel 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.
thinner rope one must make sure that the connec- These 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 instance between two boards. Structural changes
wrap a tape around the whole rope length to be would deform the rope beyond repair.
held by 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% up to the fix point. A pulling jack can be used to pull
of 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 "bro-
ken-in", so that the component
The rope is tightly wrapped for a distance of approx.
parts can settle and adjust them-
three rope diameters.
selves to the actual operating con-
ditions. It is most unfortunate that
in practice only too often the ex-
act opposite of this recommenda-
tion is performed: quite frequently
after installing the rope overload
tests are carried out with loads be- Both ends of the seizing wire are then pulled tight
yond the safe working load of the and twisted together for a length of one rope diam-
system. 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- The twisted connection is then hammered into a
quired for larger sizes. gusset between the strands. After preparing the
other side of the intended cut accordingly the rope
can now be cut.
The best method is to use a high speed disk cutter.
Unless the rope is being scrapped the use of flame
cutting equipment is not recommended.
Careless cutting can result in the balance of 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- Instead of using one long seizing it is also possible
preformed as part of the manufacturing specifica- to apply at least three seizing the size of one rope
tion. 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- The maintenance of steel wire ropes
ing tape cannot prevent strand movement, so an-
nealed (iron) wire should always be used. Steel wire ropes must be serviced regularly, the kind
of maintenance depending on the lifting device, its
After marking the position of the cut the end of the use and the selected rope. Regular maintenance
seizing wire is laid along the rope axis leaving suf- may considerably increase the service life of a steel
ficient length to secure both ends by twisting when wire rope.
the seizing complete.

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 inter- This applies particularly to ropes operating in ex-
vals, depending on their use, particularly along the tremely abrasive conditions and to those that take
zones subjected to bending. If for operational rea- up chemicals.
sons relubrication cannot be carried out, shorter
service life of the rope is to be expected and the Effective cleaning without proper tools is quite a
inspection intervals have to be arranged accord- laborious job. For cleaning steel wire ropes the Ca-
ingly." nadian Rigging Manual recommends an appliance
with three rotating wire brushes and an air blast
When choosing the relubricant, it must be ensured drying system to follow. An American manufacturer
that it is in accordance with the recommendations offers a "rope porcupine", a sleeve equipped with
of the rope manufacturer. 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- Removing broken wires
ing or swabbing.
If during an inspection ends of broken wires are
Quite often the lubricant is applied at a sheave, detected which might cross adjacent wires and
sometimes a continuous drip method is used. If only destroy them when running over sheaves, these
a little lubricant is required, pressure spray noz- broken wire ends must be removed.
zles can be applied.
Under no circumstances should the broken wire
Maximum penetration of the lubricant into the gaps ends be pinched off with a pair of nippers. The best
of the rope, can only be quaranteed if high pres- method is to move the wire ends backwards and
sure lubrication is applied with the help of a pres- forwards until they break deep in the valley between
sure lubricator. two outer strands. With thicker wires a tool should
be moved backwards and forwards on the surface
With this method the two halfs of a sleeve, which of the rope, thus bending the wires until they break.
is equipped with rubber sealings, are clamped round
the rope and screwed together. While the rope runs
through the lubricator the lubricant is pressed into
the sleeve at a pressure upto about 30 bars.

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 INFORMATION
625/1473 E rev.: a 2002-12-20
Wear on Wire Sheaves
In the table below we have given recommended

maximum wear on wire sheaves.
The reasons for the given recommendations are:

- Increased wear on the wire.
- Decreased strength on wire sheave.
a
t max
16 4
12 3
10 2.5
8 2
6 1.5

SERVICE INFORMATION
625/1560 E rev.: b 2003-03-20
Lifting Block
Warning! Maintenance and Service

Where equipment has swivelling and moving parts
there are potential safety hazards.Care should be Inspection should be carried out, on every occa-
taken when working with or repairing such equip- sion before taking into operation.
ment. If used incorrectly breakage could occur in-
flicting injury or death. Particular attention should be paid to the following:
1. Wear in hook, centre pin, becket and threads in
General Safety hook and nut.
2. Play in sheave bushes or bearings.
When equipment is in use, do not put hands: 3. Spacer bolts, nuts and lynch pins.
4. Check for cracks in welds.
1. Between sheaves, sideplates and guards. 5. Condition of safety catch and grease nipples.
2. In area of becket, hook, hooknut and crosshead 6. Wear to holes in sideplates and becket.
Take great care to avoid clothing becoming trapped. If cracks or heavy gouges appear, the equipment
should not be used and qualified opinion should be
Repair and reeving should be carried out by trained sought. If grooved and the section reduced by more
personnel only. Power should be switched off be- than 5% the item should be replaced.
fore operations are carried out. Work should only
take place when equipment is supported on a firm
surface.

SERVICE INFORMATION
625/1560 E rev.: b 2003-03-20
Repairs should be effected by grinding. NO weld- Limitation of use

ing should be carried out unless prior authoritly is
obtained. 1. Safe working load should never be exceeded.
If the holes in the crosshead, sideplates, becket, 2. Crane blocks should be used in vertical lift only.
eyes or yaws are enlarged by more than 5%, the 3. Rigging blocks should be used only as in design
part should be replaced. specifications.
Blocks should not be used for towing, unless spe-
All repairs should be carried out by responsible cifically designed and marked for that purpose.
personnel, and great care should be taken in the 4. Swivels should be used in either the vertical or
re-assembly of the equipment and retaining parts, horizontal plane only.
i. e., grub screws, lynch pins, etc. Check and refit 5. Horizontal and vertical lead sheaves should only
only correct sizes and threads. be used as indicated in the description.
6. Shock or side loading should not be applied, un-
Important: less equipment is desigend for that purpose.
When replacing genuine parts an overload test of 7. Load should always be in seat of hook or eye.
the complete unit must be performed and new cer-
tificate must be issued.
Allowed wear on lifting eyes and links
Lubrication Wear and tear is allowed to take away maximum

5% of the diameter. Thereafter the component has
As a general rule sheaves, crossheads and bodies either to be replaced or repaired. The repair
should be oiled through nipples every 100 working recommended is a hardened cage, which shall be
hours, see also separate lubrication chart. shrinked according to the instruction from
MacGREGOR Cranes.
Fig. 1. Lifting eye.

SERVICE 6.305.11 E rev.: - 1999-06-08
Electrical Equipment, General Maintenance
Introduction Portable control boxes

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

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

Check crane system earth connections, and clean
contact surfaces as required.

SERVICE 6.990.41 E rev.: c 2004-10-15
Emergency Lowering in Case of Complete Power Failure

Operation of Crane Using a Hand Pump (Optional)
Introduction
In the case of a power failure the hoisting, luffing and All necessary material, also the hydraulic pressure
slewing circuits of a deck crane may still be operated to source, is included, Fig. 1.
a limited extent by releasing their respective brakes,
while observing the greatest care.
CAUTION!
- This work has to be done by skilled persons with
The release of the brakes must be done by means of
great caution.
a separate hydraulic pressure source with variable
- Only one function to be activated at the time.
pressure.
- Verify that no persons are within the working area
of the crane.
This instruction describes an emergency brake
release of crane by using a hand pump.
Emergency stop
Emergency stop
Fig. 1. Hand pump with brake opening parts Fig. 2. Hydraulic circuit hand pump (optional).
(optional).

SERVICE 6.990.41 E rev.: c 2004-10-15
Hoisting circuit, Fig. 5
Hoisting machinery with fixed high speed motor and After operation
multiple disc brake. - When the operation has been completed, close
the ball valve 105.
Preparation - Remove hand pump.
- Open ball valve 105 on the winch, see Fig. 3.
- Connect hand pump to quick coupling 108, see
Fig. 4.
- Set handle 1A, on main valve 002, in lowering
position, 19.5°, see Figs. 4 and 5.
Operation
- To release the brake, press and hold the emergency
stop on the hand pump unit, see Figs. 1 and 2, and 19.5°
start pumping oil into the multiple disc brake until it
begins to open.
- When the winch starts to move the greatest care
must be observed so that the speed is not too high.
If the speed increases too much the emergency
stop should be released immediately so that
the brake is closed.
1A Quick coupling 108
002
105
Hand pump
Fig. 3. Winch with fixed motor. Fig. 4. Hand pump connected to main control valve.

SERVICE 6.990.41 E rev.: c 2004-10-15
Example:
A complete hydraulic circuit diagram relating
specifically to your crane will be found under section
9.4 in the parts manual.
Fig. 5. Part of hoisting circuit with fixed hydraulic motor.

SERVICE 6.990.41 E rev.: c 2004-10-15
Hoisting circuit, Fig. 8
Hoisting machinery with high speed variable motor - When the winch starts to move the greatest care
and multiple disc brake. must be observed so that the speed is not too high.
If the speed increases too much the emergency
stop should be released immediately so that
Preparation the brake is closed.
- Open ball valve 105 on the winch, see Fig. 6.
- Remove orifice plug 104-6 from motor valve 104
After operation
and replace it with plug, see Figs. 7 and 8.
- Connect hand pump to quick coupling 108 on main - When the operation has been completed, close
control valve, see Fig. 4. the ball valve 105.
- Set handle 1A, on main valve 002, in lowering - Remove the plug and install the orifice plug 104-6
position 19.5°, see Figs. 4 and 7. again, se Fig. 6.
Operation
- To release the brake, press the emergency stop on
the hand pump unit and start pumping oil into the A
multiple disc brake until it begins to open.
Valve 104
104-6 - Orifice plug
105
A-A
Note! Plug, used for lowering the load, is delivered

together with hand pump set.
Fig. 6. Winch with variable motor. Fig. 7. Motor valve 104.

SERVICE 6.990.41 E rev.: c 2004-10-15
Example:
Fig. 8. Part of hoisting circuit with variable hydraulic motor.

SERVICE 6.990.41 E rev.: c 2004-10-15
Luffing circuit, Fig. 10
Slew the crane to a suitable position. Lowering of

the jib can be done as follows:
- Remove protective cap.

- Note measure A, see Fig. 9.
Cap
- Loosen the locking nut, then carefully loosen the Locking
nut Set screw
set screw on valve 204, see Figs. 9 and 10, until
the jib begins to lower slowly.
Fig. 9. Valve 204.
Note! After lowering of the jib tighten the set screw
to its position, measure A and lock with the locking
nut.
Example:
Fig. 10. Part of luffing circuit.

SERVICE 6.990.41 E rev.: c 2004-10-15
Slewing circuit, Fig. 12
Slewing machinery with high speed motor and multiple 307

disc brake. Quick
coupling 308
Preparation
309
- Close the brake line to tank by closing the shut-off
valve 307, Figs. 11 and 12.
Brake
- Open valve 309. connection
- Connect the hand pump to the quick coupling 308,
Figs. 11 and 12.
Operation
- Release the brake by pumping oil from the hand
pump into the disc brake so that slewing machinery
is released.
- The crane may now be slewed to the desired
position by means of another crane.
After operation
Hand pump
- Close valve 309.
Fig. 11. Hand pump connected to the slewing

machinery.
Example:
Fig. 12. Part of slewing circuit.

E 625-0017
9.0 How to order

spare parts
9.1 Machinery
Parts Manual
9.2 Pump unit

Oil cooler
9.3 Mechanical
equipment
9.4 Hydraulic
components
9.5 Electric
components
9.6
Address:
9.7 Extra equipment
MacGREGOR Cranes AB
E 2003-01-31
S-891 85 ÖRNSKÖLDSVIK, Sweden

Telephone: 46 - 660 - 29 40 00
Telefax: 46 - 660 - 139 77 (Spare Part & Service Dept.)
Telefax: 46 - 660 - 29 42 81 (Technical Info. Dept.)
www.macgregor-group.com/cranes

PARTS MANUAL Date Group Fig. Page
2002-11-21 9.1 625-1260.098 1 (2)
WINCH MOUNTING
2002-11-21 9.1 625-1260.098 2 (2)
WINCH MOUNTING
Item Qty Article no Description Supplementary data
000 1 289 2002-803 WINCH MOUNTING
002 1 188 1769-801 . HYDRAULIC MOTOR
003 8 489 4472-001 . WASHER
006 4 2121 2034-540 . SCREW M6S 12 x 40 -8.8 -A4-80
007 4 2121 2030-789 . SCREW M6S 30 x 160 -10.9
008 4 2126 2038-130 . NUT M6M 30 -10
009 4 2151 2052-178 . WASHER TBRB 13 x 24 FZB
011 1 289 2001-803 . WINCH 5 tonnes

2004-06-10 9.1 625-1260.097A 1 (2)
WINCH
2004-06-10 9.1 625-1260.097A 2 (2)
WINCH
000 1 289 2001-803 WINCH 5 tonnes
010 1 875 14108-014 . GEAR, COMPLETE SEE FIG. 625-1261.030
030 1 875 14107-001 . FLANGE, COMPLETE SEE FIG. 625-1261.002
040 1 875 14101-011 . DISC BRAKE, COMPLETE SEE FIG. 625-1261.005
060 1 875 14106-011 . LIMIT SWITCH, COMPLETE SEE FIG. 625-1261.009
070 1 875 14113-001 . MOTOR FLANGE
080 8 2121 2532-500 . SCREW MC6S 10 x 45 -8.8 FZB; DIN 912
090 3 875 14112-002 . COUPLING
100 1 875 14035-002 . O-RING 120 x 2
110 3 875 14059-003 . PLUG M12
120 3 875 14086-003 . SEALING
130 1 875 14015-001 . VENTILATION FILTER M10
140 1 875 14086-002 . SEALING
220 24 2121 2545-497 . SCREW MC6S 10 x 35 -10.9; DIN 912
240 1 875 14114-005 . CABLE FIXING
250 4 2122 2515-489 . SCREW SK6SS 10 x 16 -45H; ISO 4029
520 22 2121 2545-534 . SCREW MC6S 12 x 25 -10.9; DIN 912

2003-02-20 9.1 625-1260.112 1 (2)
WINCH MOUNTING
2003-02-20 9.1 625-1260.112 2 (2)
WINCH MOUNTING
000 1 289 2002-804 WINCH MOUNTING
002 1 188 1769-801 . HYDRAULIC MOTOR
003 8 489 4472-001 . WASHER
006 4 2121 2034-540 . SCREW M6S 12 x 40 -A4-80
007 4 2121 2030-789 . SCREW M6S 30 x 160 -10.9
008 4 2126 2038-130 . NUT M6M 30 -10
009 4 2151 2052-178 . WASHER TBRB 13 x 24 FZB
012 1 289 2001-804 . WINCH 5 tonnes

2004-06-10 9.1 625-1260.113B 1 (2)
WINCH
2004-06-10 9.1 625-1260.113B 2 (2)
WINCH
000 1 289 2001-804 WINCH 5 tonnes
010 1 875 14108-014 . GEAR, COMPLETE SEE FIG. 625-1261.030
030 1 875 14107-001 . FLANGE, COMPLETE SEE FIG. 625-1261.002
040 1 875 14101-011 . DISC BRAKE, COMPLETE SEE FIG. 625-1261.005
060 1 875 14106-011 . LIMIT SWITCH, COMPLETE SEE FIG. 625-1261.009
070 1 875 14113-001 . MOTOR FLANGE
090 3 875 14112-002 . COUPLING
100 1 875 14035-002 . O-RING 120 x 2
110 3 875 14059-003 . PLUG M12
120 3 875 14086-003 . SEALING
130 1 875 14015-001 . VENTILATION FILTER M10
140 1 875 14086-002 . SEALING
220 24 2121 2545-497 . SCREW MC6S 10 x 35 -10.9; DIN 912
240 1 875 14114-005 . CABLE FIXING
250 4 2122 2515-489 . SCREW SK6SS 10 x 16 -45H; ISO 4029
520 22 2121 2545-534 . SCREW MC6S 12 x 25 -10.9; DIN 912

2004-05-04 9.1 625-1261.030 1 (2)
GEAR, COMPLETE
2004-05-04 9.1 625-1261.030 2 (2)
GEAR, COMPLETE
000 1 875 14108-014 GEAR, COMPLETE
260 1 875 14061-020 . SHAFT SEALING
270 1 875 14056-004 . V-SEAL
2004-03-03 9.1 625-1261.002A 1 (2)
FLANGE, COMPLETE
2004-03-03 9.1 625-1261.002A 2 (2)
FLANGE, COMPLETE
000 1 875 14107-001 FLANGE, COMPLETE
030 1 875 14110-001 . DRIVER
040 1 875 14040-001 . BEARING
050 1 875 14034-001 . SEALING RING
060 1 875 14045-005 . CIRCLIP
070 1 875 14061-004 . SHAFT SEALING
090 1 2545 2011-021 . GREASE FITTING M 6 x 1; DIN 71412
110 1 875 14035-012 . O-RING 128 x 2

2004-06-21 9.1 625-1261.005A 1 (2)
DISC BRAKE, COMPLETE

2004-06-21 9.1 625-1261.005A 2 (2)
DISC BRAKE, COMPLETE

000 1 875 14101-011 DISC BRAKE, COMPLETE
010 1 875 14007-003 . PRESSURE UNIT Includes item 11-13.
011 16 875 14012-005 .. SPRING Change all 32 springs at the same time.
013 1 875 14069-001 .. PIN
020 16 875 14012-006 . SPRING Change all 32 springs at the same time.
030 13 875 14003-003 . MULTIPLE DISC, OUTER Change all 26 discs at the same time.
040 13 875 14025-003 . MULTIPLE DISC, INNER Change all 26 discs at the same time.
050 1 . DISC CARRIER Not sold separately.
060 1 . SUN WHEEL HUB Not sold separately.
070 12 2121 2532-473 . SCREW MC6S 8 x110 -8.8 FZB; DIN 912.
080 1 . FLANGE Not sold separately.
090 1 . FLANGE Not sold separately.
100 1 875 14035-020 . O-RING 98 x 2
105 14 875 14079-004 . U-SEAL
110 1 875 14035-013 . O-RING 90 x 2
140 1 875 14042-001 . BEARING
150 1 875 14045-002 . CIRCLIP
160 1 . ADAPTER Not sold separately.
170 1 875 14045-001 . CIRCLIP
180 2 875 14061-014 . SHAFT SEALING
200 1 875 14035-007 . O-RING 150 x 2

2004-04-29 9.1 625-1261.009A 1 (2)
LIMIT SWITCH, COMPLETE

2004-04-29 9.1 625-1261.009A 2 (2)
LIMIT SWITCH, COMPLETE

000 1 875 14106-011 LIMIT SWITCH, COMPLETE
100 3 875 14111-001 . DRIVING SCREW
120 1 875 14109-002 . SEALING
150 2 875 14014-001 . DIRECTIONAL VALVE
240 3 2126 2032-116 . NUT M6M 6 -8 FZB
250 4 875 14035-003 . O-RING 8 x 1.5
255 2 875 14035-022 . O-RING 5 x 1.5
260 1 875 14035-001 . O-RING 100 x 2

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

1998-11-19 9.1 625-3255.004A 1 (4)
SLEWING GEAR
1998-11-19 9.1 625-3255.004A 2 (4)
SLEWING GEAR
000 1 288 0820-801 SLEWING GEAR Module 10
001 4 875 14059-001 . PLUG G1/2"
002 4 875 14086-001 . SEALING
003 1 875 14059-004 . PLUG M22
004 1 875 14086-004 . SEALING
005 2 875 14037-003 . OIL SIGHT GLASS M22
006 1 875 14006-001 . VENTILATION FILTER R1/2"
007 1 875 14102-002 . OIL TANK
008 1 875 14103-004 . OIL PIPE
009 1 875 14103-005 . OIL PIPE
030 1 875 14101-003 . DISC BRAKE, COMPLETE Includes item 31-58.
031 1 .. SUN WHEEL HUB Not sold separately. See item 30.
032 1 2122 2521-364 .. SCREW MS6SS 6 x 10; DIN 914
033 1 .. DISC CARRIER Not sold separately. See item 30.
034 1 .. FLANGE Not sold separately. See item 30.
035 1 .. MOTOR FLANGE Not sold separately. See item 30.
036 1 875 14035-013 .. O-RING
037 4 875 14035-001 .. O-RING
038 10 2121 2532-455 .. SCREW MC6S 8 x 30 -8.8 FZB; DIN 912
039 12 2121 2532-467 .. SCREW MC6S 8 x 80 -8.8 FZB; DIN 912
040 1 875 14007-003 .. PRESSURE UNIT Includes item 41, 42.
041 16 875 14012-005 ... SPRING Change all 32 springs at the same time.
042 1 875 14069-001 ... PIN
043 16 875 14012-006 .. SPRING Change all 32 springs at the same time.
1998-11-19 9.1 625-3255.004A 3 (4)
SLEWING GEAR
1998-11-19 9.1 625-3255.004A 4 (4)
SLEWING GEAR
044 8 875 14003-003 .. MULTIPLE DISC, OUTER Change all 15 discs at the same time.
045 7 875 14025-003 .. MULTIPLE DISC, INNER Change all 15 discs at the same time.
046 1 875 14015-001 .. VENTILATION FILTER M10
047 12 2121 2532-461 .. SCREW MC6S 8 x 50 8.8 FZB; DIN 912
048 1 875 14104-003 .. ADAPTER
049 1 875 14061-007 .. SHAFT SEALING
050 1 875 14042-002 .. BEARING
051 1 875 14045-003 .. CIRCLIP
052 1 875 14045-004 .. CIRCLIP
053 1 875 14059-005 .. PLUG M14
054 1 875 14086-005 .. SEALING
055 2 875 14059-002 .. PLUG M10
056 3 875 14086-002 .. SEALING
057 1 875 14059-003 .. PLUG M12
058 1 875 14086-003 .. SEALING

2000-03-07 9.1 625-2205.017 1 (2)
HYDRAULIC MOTOR
2000-03-07 9.1 625-2205.017 2 (2)
HYDRAULIC MOTOR
001 1 188 1227-801 HYDRAULIC MOTOR
002 1 489 6120-801 . GASKET SET

1999-06-10 9.2 625-4935.067 1 (2)
PUMP DRIVE
1999-06-10 9.2 625-4935.067 2 (2)
PUMP DRIVE
000 1 289 0543-801 PUMP DRIVE
001 1 188 1097-801 . PUMP
002 1 288 1629-801 . ELECTRIC MOTOR
003 1 388 6362-801 . CARDAN SHAFT
004 1 388 7217-001 . PUMP BRACKET
005 1 489 4369-801 . FLANGE BOLT FITTINGS
006 1 2152 2115-555 . O-RING
007 1 2152 2115-526 . O-RING
008 2 2183 2021-126 . LIFTING EYE
010 12 2121 2032-540 . SCREW M6S 12 x 40 -8.8 FZB; DIN 933
011 12 2151 2022-178 . WASHER BRB 13 x 24 FZB
012 4 2121 2032-544 . SCREW M6S 12 x 60 -8.8 FZB
013 4 2126 2636-122 . NUT NYLOC -M6M 12 -8 FZB
014 8 2151 2022-178 . WASHER BRB 13 x 24 FZB

1999-06-09 9.2 625-4945.012 1 (2)
PUMP
1999-06-09 9.2 625-4945.012 2 (2)
PUMP
001 1 188 1097-801 PUMP
002 1 489 6144-801 . GASKET SET

2004-08-03 9.3 625-6244.001B 1 (2)
JIB TOP
2004-08-03 9.3 625-6244.001B 2 (2)
JIB TOP
000 1 288 0136-801 JIB TOP
001 2 388 7440-001 . SHAFT
002 1 388 7441-001 . SHAFT
003 3 388 7278-001 . CLIMB PROTECTION
004 2 489 4488-801 . WIRE SHEAVE
005 2 489 4345-002 . LOCKING PLATE
006 1 489 4345-001 . LOCKING PLATE
007 2 489 4465-008 . SPACER
008 3 2545 2110-001 . GREASE NIPPLE G 1/4 A2-50
010 6 2114 2014-201 . SPLIT PIN SP 4 x 40 A4
011 2 2121 2034-491 . SCREW M6S 10 x 20 -A4-80
012 4 2121 2034-532 . SCREW M6S 12 x 20 -A2 -70
013 4 2154 2233-178 . LOCK WASHER 13 RF
014 2 2154 2233-173 . LOCK WASHER 10.5 BR = 20 RF
015 15 489 4473-002 . WASHER

2004-10-18 9.3 625-5882.022A 1 (2)
CYLINDER ASSEMBLY
2004-10-18 9.3 625-5882.022A 2 (2)
CYLINDER ASSEMBLY
000 1 289 3177-801 CYLINDER ASSEMBLY
001 1 289 3176-801 . HYDRAULIC CYLINDER
002 2 388 9101-001 . SHAFT
003 2 489 4345-003 . LOCKING PLATE
004 2 489 4346-003 . LOCKING PLATE WELDED
005 4 2121 2034-628 . SCREW M6S 16 x 40 -A4-80
006 4 2151 2027-185 . WASHER RB 17 x 30 -A4
007 2 2545 2110-001 . GREASE NIPPLE AG 1/4 A2-50

1999-05-27 9.3 625-7013.005D 1 (2)
HOOK BLOCK
1999-05-27 9.3 625-7013.005D 2 (2)
HOOK BLOCK
000 1 388 7531-801 HOOK BLOCK SWL 5 tonnes
001 1 875 12401-005 . SHEAVE, COMPLETE Incl. bearing and lock rings.
002 1 875 12054-006 .. BEARING
003 2 875 12062-004 .. LOCK RING
004 2 875 12009-001 .. SPACER
005 1 875 12404-003 . SHAFT, COMPLETE Incl. retainer, screw, nipple.
006 1 2545 2011-025 .. GREASE NIPPLE M10 x 1; DIN 71412
007 4 875 12406-004 . SPACER, COMPLETE Incl. spacer tube, screw, nut.
008 1 875 12409-004 . CABLE LEADER, COMPLETE Incl. screws, nuts.
009 1 875 12073-002 . SHACKLE
010 1 875 12001-004 . HOOK, COMPLETE

2004-05-16 9.3 625-6170.023A 1 (2)
JIB BEARING ASSEMBLY

2004-05-16 9.3 625-6170.023A 2 (2)
JIB BEARING ASSEMBLY

000 1 288 0837-801 JIB BEARING ASSEMBLY
001 1 388 9148-001 . SHAFT JIB BEARING
002 2 489 4371-001 . FLANGE, BEARING
003 1 489 4345-004 . LOCKING PLATE
004 1 489 4346-004 . LOCKING PLATE WELDED
005 2 2121 2034-672 . SCREW M6S 20 x 40 -A4-80
006 2 2151 2027-192 . WASHER RB 21 x 37 -A4
007 2 489 4453-001 . BOLT
008 2 2545 2110-001 . GREASE NIPPLE G 1/4 A2-50

1998-08-11 9.4 625-7322.008 1 (2)
DIRECTION VALVE
1998-08-11 9.4 625-7322.008 2 (2)
DIRECTION VALVE
000 1 188 1342-801 DIRECTION VALVE
001 1 489 4422-801 . GASKET SET
002 3 . MECHANICAL ACTIVATION PVM
003 1 . END PLATE PVSI
004 3 . COVER FOR HYDR. ACTIVATION PVH
005 1 . BASIC MODULE PVB SLEWING
006 1 . BASIC MODULE PVB LUFFING
007 1 . BASIC MODULE PVB HOISTING
008 1 . PUMP SIDE MODULE PVP

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

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

2000-05-08 9.4 625-7330.006 1 (2)
BALANCE VALVE
2000-05-08 9.4 625-7330.006 2 (2)
BALANCE VALVE
001 1 289 0839-801 BALANCE VALVE
002 1 489 5703-801 . GASKET SET

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

PAR
PAR TS MANU
ARTS AL
MANUAL Date Group Fig. Page
1995-07-06 9.4 625-7335 1 (2)
FILTER
PAR
PAR TS MANU
ARTS AL
MANUAL Date Group Fig. Page
1995-07-06 9.4 625-7335 2 (2)
FILTER
000 1 287 9463-801 FILTER
001 1 489 4436-801 . FILTER ELEMENT

1998-10-19 9.4 625-7620.001 1 (2)
LIMIT VALVE
1998-10-19 9.4 625-7620.001 2 (2)
LIMIT VALVE
001 1 388 7388-801 LIMIT VALVE
002 1 489 6393-801 . GASKET SET

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

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

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

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

2004-04-26 9.4 625-7990.043 1 (2)
HYDRAULIC CYLINDER
2004-04-26 9.4 625-7990.043 2 (2)
HYDRAULIC CYLINDER
000 1 289 3176-801 HYDRAULIC CYLINDER 160 / 115
001 1 875 16403-001 . GASKET SET Includes item 11-25.
011 1 .. ROD WIPER
012 1 .. ROD SEAL
013 1 .. O-RING (approx. Ø150)
014 1 .. SUPPORT RING
015 6 .. BEARING RING
017 1 .. PISTON SEAL
108 2 875 16401-001 . BEARING
109 4 2545 2110-003 . GREASE NIPPLE A-M 10 x 1 -A2-50; DIN 71412
110 4 2121 2550-453 . SCREW MC6S 8 x 25 -A4 -80; DIN 912
118 1 2122 2519-447 . SCREW MSK6SS 8 x 12 -A4; DIN 916
119 2 2522 2105-014 . PLUG WITH SEAL G 1/4; DIN 908
120 3 2545 2112-003 . GREASE NIPPLE C-M 10 x 1 -A2-50; DIN 71412

2003-12-02 9.5 625-8630.026 1 (2)
EL. CENTRAL/STARTER
2003-12-02 9.5 625-8630.026 2 (2)
EL. CENTRAL/STARTER
000 1 324 0870-801 EL. CENTRAL/STARTER
001 1 5829 4196-101 . EL.CABINET
002 1 314 3675-801 . TRANSFORMER 1 PHASE
003 1 5354 4273-063 . CONTACTOR
004 1 5627 4216-054 . OVERLOAD RELAY
005 1 5381 4227-080 . LOAD SWITCH
006 1 4762 4105-075 . CURRENT TRANSFORMER
007 1 5672 4248-103 . CIRCUIT BREAKER
008 1 5692 4740-221 . HOUR METER
009 1 5697 4337-075 . AMMETER
010 1 5298 2057-002 . INDICATOR HEAD
011 3 5298 2058-001 . LAMP HOLDER BLOCK
013 3 5911 4509-122 . BULB
014 1 5672 4248-003 . CIRCUIT BREAKER
015 1 5372 2038-001 . PUSH BUTTON
016 1 5372 2038-003 . PUSH BUTTON
017 1 5372 2016-004 . CONTACT BLOCK
018 1 5372 2016-005 . CONTACT BLOCK
025 11 2663 4382-025 . TERMINAL BLOCK
029 2 2647 4155-025 . EARTH TERMINAL
030 1 2647 4180-101 . EARTH PLINTH
034 2 5354 4137-501 . AUXILIARY CONTACT BLOCK
035 2 5354 4137-510 . AUXILIARY CONTACT BLOCK
038 2 2631 4123-252 . BRIDGE CONNECTOR
041 1 2166 2304-302 . CABLE PIT
042 1 5381 4227-001 . HANDLE
043 1 5381 4227-002 . SHAFT
049 1 5298 2057-003 . INDICATOR HEAD
066 1 5298 2057-004 . INDICATOR HEAD
071 1 424 0494-801 . SIGN

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INSTRUCTION MANUAL Date Project No.

GENERAL 1 1.005 E e PREFACE

TECHN. DESCRIP. 2 SL04046-3 TECHNICAL DATA

FUNCTION 3 3.110.70 E a HYDRAULIC FUNCTION

OPERATION 4 PM40 0803-E00 b OPERATING INSTRUCTION

MAINTENANCE 5 5.005.25 E f MAINTENANCE CHART

6.0 6.000 E b HOW TO ORDER SPARE PARTS

The Original Manufacturer of HÄGGLUNDS Cranes

6.0 6.008.2 E - INTRODUCTION

6.2 6.214 E h TIGHTENING TORQUES, SCREWS AND BOLTS

6.3 6.305.11 E - ELECTRICAL EQUIPMENT, GENERAL MAINTENANCE

SPARE PARTS 9 SEE SEPARATE TABLE OF CONTENTS

The Original Manufacturer of HÄGGLUNDS Cranes

9.0 HOW TO ORDER SPARE PARTS b 6.000 E

9.1 WINCH MOUNTING 289 2002-803 A/ 625-1260.098

9.2 PUMP DRIVE 289 0543-801 A/ 625-4935.067

9.3 JIB TOP 288 0136-801 A/ 625-6244.001B

9.4 DIRECTION VALVE 188 1342-801 -/ 625-7322.008

9.5 EL. CENTRAL/STARTER 324 0870-801 B/B 625-8630.026

The Original Manufacturer of HÄGGLUNDS Cranes

This instruction manual covers the MacGREGOR Spare parts

Every manual belongs to a specific crane or piece of

The manual contains nine sections. The various

The Original Manufacturer of HÄGGLUNDS Cranes 1 (1)

The Original Manufacturer of HÄGGLUNDS Cranes 1 (1)

The Original Manufacturer of HÄGGLUNDS Cranes 1 (1)

Hydraulic and Electric Symbols

Hydraulische und elektrische Bildzeichen

Diese Sammlung umfaßt einen Teil der allgemeinen Bild- und

1. Hydraulic symbols, basic.

Hydraulische Bildzeichen, einfach.

2. Hydraulic symbols, composite.

Hydraulische Bildzeichen, kombiniert.

The Original Manufacturer of HÄGGLUNDS Cranes 1 (29)

Hydraulic symbols and valve assemblies

Hydraulische Bildzeichen und Ventil-

Working oil line.

Plug, plugged connection (alternative symbols).

Restriction unaffected by viscosity.

2 (29) The Original Manufacturer of HÄGGLUNDS Cranes

Crossed pipes, no connection.

Tank line, tank.

Enclosure of component assembly.

Pump, fixed displacement, 1 direction of flow.

Pump, variable displacement, 2 directions of flow.

The Original Manufacturer of HÄGGLUNDS Cranes 3 (29)

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

Motor, 2 displacement, 2 directions of flow.

Motor, variable displacement, 2 directions of flow.

Filter with contamination indicator.

Filter with by-pass valve.

4 (29) The Original Manufacturer of HÄGGLUNDS Cranes

Pressure electric switch, normally open.

Pressure electric switch, normally closed, adjustable.

Non-return valve, spring loaded with certain opening

Non-return valve, spring loaded with certain closing

The Original Manufacturer of HÄGGLUNDS Cranes 5 (29)

Quick coupling or gauge connection.

Non-return valve with variable restriction.

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

6 (29) The Original Manufacturer of HÄGGLUNDS Cranes

Valve, basic symbol.

Electrically controlled valve.