Glbe3025-2 2425GR PDF

INSTRUCTION MANUAL Project No.
Page
Dept. C7250 Date: 2012-02-16 2/10108.01RHM 1(6)
TABLE OF CONTENTS
No. of manuals 6 pcs:1 pcs CD rom
Certificate for
crane issued by: BV
Certificate for
foundation issued by: BV
IMO No. L9609677
Name of ship -
Newbuilding No. H6107
Shipyard HMD
Owners WESTERN GROUP
Project No. 2/10108.01RHM
Mfg. No. 62512724-Crane 1, 62512725-Crane 2, 62512726-Crane 3, 62512727-Crane 4
Type of crane GLBE3025-2/2425gr
Order specification 490 8998-801 - 804 /G
Mechanical spec. 490 8999-801 - 804 /B
Hydraulic spec. 490 9001-801 - 804 /A
Electrical spec. 490 9000-801 - 804 /A
Slewing spec. 490 6432-801 /-
SAFETY DOCUMENTS
Document names written with bold letters are documents with safety aspects.
INSTRUCTION NO. REV NAME OF INSTRUCTION
GENERAL 1 1.000.6 E b SAFETY INSTRUCTIONS

1.005 E e PREFACE
1.009 E a GENERAL INSTRUCTIONS, CLEANLINESS IN HYDRAULIC SYSTEMS
1.102 E c CONVERSION FACTORS
1.518.3 ED d HYDRAULIC AND ELECTRIC SYMBOLS
TECHN. DESCRIP. 2 2/10108.01RHM a TECHNICAL DATA

2.007.96 E a TECHNICAL DESCRIPTION
FUNCTION 3 3.110.127 E b ELECTRIC FUNCTION

3.110.132 E - HYDRAULIC BRAKE FUNCTION, ELECTRIC CRANE
3.142.41 E a CRANE CONTROL SYSTEM CC3000
3.155.6 E - THERMOSTATIC CONTROLLED VENTILATION FAN AND HEATER ELEMENTS
3.155.7 E a HEATING AND COOLING OF CABINETS IN ELECTRIC CRANES
OPERATION 4 PM40 1885-E00 a CREW CHECKLIST

PM40 5500-E00 b OPERATING INSTRUCTION
PM40 6494-E00 - OPERATION, START AND STOP
PM40 7546-E00 - CONTROLS AND INDICATORS
PM41 0001-E - EMERGENCY ESCAPE INSTRUCTIONS
PM41 0014-E00 a EMERGENCY ESCAPE INSTRUCTIONS, ROPE LADDER/FIXED LADDERS
4.620.31 E a PARKING THE CRANE, SEA STOWING, GENERAL INSTRUCTION
4.630 E - HANDLING HATCHES BY DECK CRANE
4.630.7 E - EMERGENCY OPERATION OF HATCH COVERS BY DECK CRANE
INSTRUCTION MANUAL Project No. Page
Dept. C7250 Date: 2012-02-16 2/10108.01RHM 2(6)
TABLE OF CONTENTS
MAINTENANCE 5 5.005.70 E - MAINTENANCE CHART

5.018 E b INSPECTION OF STRESSED COMPONENTS AND STRUCTURES
PM51 1733-E00 d LUBRICATING CHART
5.250.1 E - SLEWING BEARING STUDS
5.302.37 E - BRAKE UNIT
5.315.3 E - SAMPLING OF OIL TO VERIFY THE CLEANLINESS IN HYDRAULIC SYSTEM
5.421.60 E a LUBRICANTS FOR DECK MACHINERY
SERVICE 6
6.0 6.000 E e HOW TO ORDER SPARE PARTS

6.000.1 E c STATEMENT REGARDING DELIVERY OF SPARE PARTS TO SWIVELS, LIFTING B
6.000.2 E d RETURN FORM
6.004.1 E bc WORLDWIDE SERVICE NETWORK
6.005.10 E - INTRODUCTION
6.1 6.100.11 E a MEASURES BEFORE STARTING, DURING & AFTER COMPLETED SERVICE/MAIN
6.120.20 E - SLEWING GEAR
6.120.112 E b WINCHES, HOISTING/LUFFING
6.142.5 E a RECOMMENDATION FOR INSPECTION AND REPLACEMENT OF HYDRAULIC HO
6.189 E f HYDRAULIC PISTON ACCUMULATORS
6.2 6.214.1 E a TIGHTENING TORQUES, STUDS/SCREWS AND BOLTS

6.215.21 E b SERVICE DOOR (OPENING AND CLOSING), SERVICE AND LUBRICATION OF DO
6.216.116 E a ROPE REEVING FOR CRANE TYPE GLBE-2
6.222.1 E a HANDLING, INSTALLATION AND MAINTENANCE OF STEEL WIRE ROPES
6.223.26 E b REPLACEMENT OF WIRES, ONE OR TWO FALL RIGGING
625/1473 E c INDENTATION AND WEAR ON WIRE SHEAVES
625/1560 E f LIFTING BLOCK/BEAM
625/1579 E k MEASURING PROCEDURE FOR WEAR IN SLEWING BEARINGS FOR ROPE LUFF
625/1651 E - SLEWING BEARING GREASE SAMPLING PROCEDURE
6.3 6.303.61 E c CARD FRONT MENUS CT2, CC3000

6.303.66 E a TROUBLESHOOTING FOR CRANE CONTROL SYSTEM CC3000, ELECTRIC CRAN
6.303.67 E - ABSOLUTE ENCODER CALIBRATION, CC3000
424 0738 e SIGNAL OVERVIEW, CRANE CONTROL SYSTEM CC3000
424 0739 f ERROR MESSAGES, CRANE CONTROL SYSTEM CC3000
1000004064 B INSULATION TEST, ELCTRICAL CRANE
6.305.19 E - ELECTRICAL EQUIPMENT, GENERAL MAINTENANCE
6.306.7 E a INSTALLATION OF POWER SUPPLY CABLE AND CABLE FOR "GRAB...
6.307.11 E b SLIP-RING UNIT
6.311.14 E - OIL LEVEL TEMPERATURE SENSOR, BRAKE UNIT
6.320.386 E b LIMIT SWITCHES AND SOFTWARE LIMITS IN HOISTING AND LUFFING WINCH ..
6.321.18 E - SLACK WIRE SAFETY SWITCH, HOISTING AND LUFFING WINCHES
6.324.1 E b PREPARATION FOR OVERLOAD (OL) TEST MODE
6.324.2 E - PREPARATION FOR RIG MODE
6.990.61 E c EMERGENCY OPERATIONIN CASE OF COMPLETE POWER FAILURE, OPERA
EXTRA EQUIPMENT 7 7.075.11 E - MacHEAVYVISOR RELEASE 3.3

7.076.2 E c USER MANUAL DISPLAY, CC PILOT XS
7.082.1 E - INSTALLATION OF MAINTENANCE PLATFORM ON FOUNDATION, (CUSTOMER D
INSTRUCTION MANUAL Project No. Page
Dept. C7250 Date: 2012-02-16 2/10108.01RHM 3(6)
TABLE OF CONTENTS
APPENDICES 8
SPARE PARTS 9 SEE SEPARATE TABLE OF CONTENTS

PARTS MANUAL Project No. Page
Dept. C7250 Date: 2012-02-16 2/10108.01RHM 4(6)
TABLE OF CONTENTS
GROUP DESCRIPTION PART NUMBER FIG
9.0 HOW TO ORDER SPARE PARTS e 6.000 E
9.1 HOISTING WINCH 1212912 -/ 625-1450.212

LUFFING WINCH 1187739 B/ 625-1450.184
WINCH MOUNTING SET 289 5365-801 -/ 625-2250.022
ASSEMBLY SET 1192483 -/ 625-1440.195
ASSEMBLY SET 1192647 A/ 625-1440.196
ASSEMBLY SET 1192648 -/ 625-3254.029
DRIVE IN, COMPLETE 875 13004-157 -/ 625-3256.016
SLEWING GEAR ASSEMBLY SET 391 0246-801 D/ 625-3254.023B
SLEWING GEAR 1189838 -/ 625-3255.040
9.2 BRAKE PUMP UNIT 1219768 A/ 625-4935.245A
9.3 CRANE HOUSE ASSEMBLY 1219977 C/ 625-6102.580

SLEWING SPECIFICATION 490 6432-801 A/ 625-6122.029A
SLEWING BEARING MOUNTING 391 0032-801 A/ 625-6123.003
SLEWING BEARING YARD MOUNTING 391 0033-801 B/ 625-6124.003
COVER MOUNTING 390 3274-801 -/ 625-6169.005A
COVER ASSEMBLY 390 3282-801 -/ 625-6169.006
JIB BEARING HOUSING 1184754 -/ 625-6170.082
JIB BEARING ASSEMBLY 1191812 -/ 625-6170.085
JIB TOP MOUNTING 1195433 -/ 625-6244.077
LIMIT SWITCHES BOX 289 5323-801 -/ 625-6245.635B
LIMIT SWITCHES BOX 289 5449-801 -/ 625-6245.643
LIMIT SWITCHES BOX, MOUNT. 489 6415-801 C/ 625-6248.001B
SLACK WIRE DEVICE 289 3396-801 B/ 625-6250.023
CRANE JIB, YARD MOUNTING 489 5409-801 C/ 625-6275.004C
MOUNTING WIRE LOCK JIB TOP 390 3374-801 -/ 625-6404.001
MOUNT. WIRELOCK JIB TOP 1184729 -/ 625-6404.003
LOAD CELL ASSEMBLY 1223123 -/ 625-6404.004
CRANE JIB MOUNTING 1195432 -/ 625-6408.120
CRANE TOP MOUNTING 1195405 -/ 625-6459.074
PROTECTIVE PLATE MOUNT. 390 7581-801 -/ 625-6459.051
INCLINOMETER, C 388 0176-801 B/ 625-6509A
CABIN ASSEMBLY CRANE HOUSE 1189584 -/ 625-6540.042
CABIN ASSEMBLY 1189585 -/ 625-6545.072
EMERGENCY DOOR ASSY 390 4053-801 A/ 625-6546.001
CAB DOOR ASSEMBLY 390 8573-801 A/ 625-6546.008
CAB CUPOLA ASSEMBLY 289 2251-801 A/ 625-6560.007A
WINDSCREEN CLEANER 387 6227-802 F/ 625-6561.001C
VENTILATION FAN 390 2115-801 B/ 625-6625.014A
VENTILATION FAN ASSEMBLY 1192902 -/ 625-6625.027
LIFTING BLOCK 1205161 -/ 625-7013.126
LOAD WIRE ROPE: SEE TECH. DATA 1221289 -/ -
LUFF. WIRE ROPE: SEE TECH. DATA 1188175 -/ -
9.4 VALVE UNIT 1204092 A/ 625-7207.018

DIRECTIONAL VALVE 1204093 -/ 625-7322.082
Dept. C7250 Date: 2012-02-16 2/10108.01RHM 5(6)
TABLE OF CONTENTS
9.4 PRESSURE SWITCH, C 387 7053-803 L/ 625-7444

ACCUMULATOR 1219345 -/ 625-7951.007
HYDRAULIC HOSES 625-7970G
TUBING BRAKE 1219586 A/ 625-7994.004
HYDRAULIC SYSTEM SPECIFICATION 1226154 -/ 1000019019
9.5 DRIVERS DESK 1189978 A/ 625-8563.069

EL. INST. CRANE HOUSE 1212847 A/ 625-8564.023
EL. INST. JIB LIGHT, CRANE 124 0647-801 A/ 625-8567.045A
EL. INST. JIB LIGHT (PACKING) 124 0648-801 B/ 625-8567.046C
CONTROLLER, C 314 2721-802 C/ 625-8595
CONTROLLER, LUFFING/SLEWING 314 2006-802 D/ 625-8592C
CONTROLLER 414 6792-801 A/ 625-8596
CONTROL PANEL 1189898 -/ 625-8597.057
EL. INST. JIB LIGHT (CABIN) 324 2043-801 A/ 625-8597.061
EL. INST. DECK LIGHT (CABIN) 324 1722-801 A/ 625-8597.062
EL. INST. FORCE LIMIT GRAB (CA 324 1724-801 A/ 625-8597.063
EL. INST. VENTILATION FAN (CAB) 324 2098-801 B/ 625-8597.069
EL. INST. AIR CIRCULAT FAN (CAB) 324 1848-801 A/ 625-8597.074
CABIN DISPLAY ASSEMBLY 1182879 -/ 625-8597.081
ELECTRICAL CABINET CT1/CT2 1213177 -/ 625-8598.140
EL. CABINET (CT10) 1213017 -/ 625-8598.141
ELECTRICAL CABINET (CT13) 1213018 -/ 625-8598.142
EL. CABINET (CT14) 1189233 C/ 625-8598.110A
RELAY CARD WITH LED'S 324 0089-801 A/ 625-8599.020
CABINET CONTROL 1196427 A/ 625-8600.020
ELECTRIC MOTOR 1188770 A/ 625-8635.007
ELECTRIC MOTOR 1188769 A/ 625-8635.008
ELECTRIC MOTOR 1188771 A/ 625-8635.011
EL. INST. IMPULSE RELAY 224 0116-801 A/ 625-8650.001
EL. INST. FORCE LIMIT GRAB CT1 224 0547-801 A/ 625-8650.005
EL. INST. POWER SUPPLY (CT1) 224 0506-801 A/ 625-8650.010
CABIN DISPLAY 424 0715-801 C/ 625-8655.001
SLIPRING DEVICE 1192979 -/ 625-8750.023
POWER / CABLE CONNECTION 1000007286 -/ 1000007286
ELECTRICAL SYSTEM SPEC. 1212845 -/D 1000011517
MC-SPARE CARD 1194171 B/ -
CC-SPARE CARD 1194172 B/ -
9.7 MOUNTING ENCODER 390 9851-801 A/ 624-2180.014

MOUNTING ENCODER 390 9852-801 A/ 624-2180.015
ENCODER ASSEMBLY 1191997 -/ 624-2180.018
ABSOLUTE SINGLETURN ENCODER 324 1408-801 A/ 624-2180.023
INCREMENTAL ENCODER 5000 324 1409-801 A/ 624-2180.025
ELECTRICAL PEDESTAL ASSEMBLY 1196430 D/ 624-2196.001
JUNCTION BOX, X71A 1196543 A/ 624-2196.002
JUNCTION BOX, X71B 1196773 B/ 624-2196.003A
CABINET ADD. COMPONENTS 1201179 -/ 624-2196.005
PEDESTAL PUSHBUTTON 1202077 A/ 624-2196.015
HAND PUMP 189 6211-801 C/ 624-2498
Dept. C7250 Date: 2012-02-16 2/10108.01RHM 6(6)
TABLE OF CONTENTS
9.7 FIRE EXTINGUISHER, MOUNT 490 4074-801 A/ 624-2524A

CABIN DISPLAY ASSEMBLY 1182916 -/A -
LIFE LINE 388 0962-801 -/ -
GENERAL 1.000.6 E rev.: b 2011-12-07
Safety Instructions
Caution! Preparation for Use and Operation According to
Make sure that the frequency converters and other Manual
electronic equipments are disconnected before any
The crane operator, authorized by the responsible
welding in the crane house, and/or foundation and
officer onboard, must be familiar with all safety issues
the pedestal starts, because of risk of damage to the
contained in this Chapter and with preparation for use
electronic equipments.
and operating instructions before work is started.
Caution!
Insulation test, electrical crane Maintenance and Service
Before any kind of insulation test of electric cabinets, Prerequisite for proper use is regular maintenance
electric motors or any kind of electric equipment in the (see Chapter 5) and service (see Chapter 6).
crane house and/or foundation and pedestal starts,
carefully read and follow the steps in the instruction. MacGregor are available for full service of this cargo
Make sure that all electronic systems are prepared crane. MacGregor will take responsibility only for its
according to the instruction "Insulation test, electrical own professional services. Our product guarantee
crane", section 6.3 in the parts manual and section is not valid unless MacGregor authorized service is
19 in the installation manual. used.
Cargo Handling Equipment The use of proper Spares and Exchange details
The MacGregor crane is a cargo handling device. MacGregor shall be contacted for ordering of ex-
It is designed and manufactured to meet interna- change equipment and spares for this crane. Articles
tional cargo handling standards for quality, safety and supplied by MacGregor are designed and quality
performance within capacity specifications and out- tested for this application and are supplied with our
reach as per certificate. warranty for correct function and safe working of the
crane.
The crane is designed for operation in harbour or shel-
tered water environments where there is no significant MacGregor accepts no liability for the functioning of
movement of the ship due to wave action. the crane systems, nor for the safe use of the crane,
unless original spare parts are used.
Testing and examination

The crane shall be tested and thoroughly examined Supervision, Instructions, Signs, and Warnings
and certified by a competent person after any sub- Proper use of this crane and its equipment is possible
stantial repair. as long as the owners, users and operators maintain
the crane to meet full operational standards. This
includes the replacement of signs, instructions and
Safe Operating Conditions, Proper Instructions warnings as per delivery. MacGregor does not accept
and Precautions responsibility for any party who fails to ensure that this
manual, signs, instructions, and warnings are legible
The responsible officer onboard shall make sure that
and easily accessible to personnel.
the crane is operated under safe conditions, by per-
sonnel familiar with its functions and operating instruc-
tions. All safety and precautionary issues contained in
this manual must be observed. Proper instructions and
precautions are prerequisites for proper use.
1 (16)
GENERAL 1.000.6 E rev.: b 2011-12-07
Improper Use tain measures and procedures must be obeyed.

1. Elevation of persons.
2. Exposing persons to the risks of falling cargo. Chapter 6 contains:
3. Overloading. Measures before Starting Service/Maintenance Work.
4. Unlocking the crane or crane jib or operating the Handling, Installation and Maintenance of Steel Wire
equipment at sea without full acceptance and con- Ropes.
trol of personnel and equipment safety. Examine the brake adjustments. (Valid for winches
5. Unprofessional, intended or unintended, adjustment which have electric motors.)
of safety locks, hydraulic or electric adjustments. Electric Motors, Electrical Equipment, General Main-
6. Disregard of occupational and safety standards of tenance.
work.
Functions, Installations and Equipment Safety Functions and Equipment
Specific safety equipment is installed and delivered

General
with this crane and must be available for its intended
The MacGregor crane has built-in safety functions
use. The owner/operator of the ship and its equipment
and installations to allow for safe normal use, opera-
is responsible to make that safety functions, installa-
tion, care, and control. This is applicable to instructed
tions and equipment are maintained to operational
personnel without specific professional education or
standards and are not being removed, by-passed or
certification, but working according to this manual.
worn to non-working condition.
Specific service and repair of the electrical, hydraulic

This manual features important presentations of safety
and the mechanical functions, controls and adjust-
functions, installations and equipment. A summary is
ments require professional service personnel knowl-
presented below.
edgeable of risks involved.
1. Safety Functions
Regular Care and Control (Maintenance)
a. Manoeuvring functions:
This manual contains checklists for regular care and
1. All the crane’s working functions are stopped
control of crane equipment, wire ropes and hydraulic
and the brakes will automatically operate when
filters. These checklists routine contain inspections
the emergency stop button is pressed. The but-
and maintenance regularly prescribed for safe func-
ton is loacated in cabin. This action operates
tion, e.g.:
the safety stops and automatic lock positions.
2. The crane has several fail-safe functions to
Chapter 4 contains:
overrule or stop the operator’s manoeuvring in
Safety Precautions Checklist for Single and Twin
the event that the normal electrical or hydraulic
Cranes.
functions fail, a sudden uncontrolled movement
occurs or during uncontrolled speed operation
Chapter 5 contains, if applicable: (see below).
Inspection of Stressed Components and Structures. 3. There are limits for hoisting/lowering and luffing
Electrical chart,Crane. outreaches, which are controlled by software
Lubrication chart; Crane. limits which monitors the encoders' position in
Lubrication chart; Cable Winch and Stabilizing Equip- the limit switch box.
ment. 4. AutoLaodstep, stop limits and speed reduce for
Lubrication chart; Power Swivel. load-dependent outreach are controlled by the
Filters. software.
5. Safety cams are mechanical stop limits for
Before maintenance and service work is started, cer- hoisting, full/empty drum and luffing min/max
2 (16)
GENERAL 1.000.6 E rev.: b 2011-12-07
outreaches, if there is a failure in the software. receives information about the torque of the
6. A check cam in the centre of the working range electric motor from each frequency converter
of hoisting/lowering motion and luffing outreach- and is used to measure whether the value of
es, are used to verify the function of the encod- the loadcell is correct. See also "Crane Control
ers' position. System CC3000" in section 3 .
2. During a complete power failure all solenoid
b. Hydraulic functions: valves are de-energized and all multi-disc
1. Hydraulic valve functions are adjusted for exact brakes will be applied.
pressure. Any change in the adjustments ad- 3. The electronic cabinets have power failure
versely affects the crane operation and must indicators. This function closes the electronic
exclusively be adjusted by MacGregor supervi- signals down which automatically applies all
sor (see instructions Hydraulic function). multi-disc brakes.
2. In case of a ruptured control pressure the oil 4. The heat sensors in the electric motors stop the
pipe/hose or other control pressure drops, the operation that is working, i.e. luffing, hoisting or
oil control pressure will collapse. If the control slewing, and apply all multi-disc brakes.
pressure decreases the pump automatically If the electric motor is about to overheat temper-
starts and the control pressure increases. ature switch (klixon) ramps down each move-
3. Each winch has an electric motor flanged to ment, luffing, hoisting or slewing operation, of
the drive in complete. The hydraulic operated the crane and stops the crane.
multi-disc brakes provide braking of the winch. 5. The overcurrent protections on each electric
The winches have one brake each. motor prevent the electric motors from overload-
4. An electric motor is flanged to each slewing ing.
gear and provides hydraulic operated multi-disc Each electric motor is overcurrent protected
brake of the slewing gears. The slewing gears and stops the crane operation and applies the
have one brake each. brakes.
5. If there is a multi-disc brake failure of the parking 6. A separate electrical feed for the crane house
brake, caused by worn out brake discs, sticking lights, operator’s cabin and on jib, maintains
cylinder, brake pilot valve or valve spool, the function of lights even during feed disruption to
function of regenerative braking through the the crane operating functions. As there is not a
electric motor by the winches and slewing gears separate emergency illuminating system for the
is still available. Push the Start/Stop pushbutton crane (this is dependent on the ship’s systems)
position "0" and the system awaits the activating the owner of the crane must provide a battery
of the brakes and the crane then stops. type flash-light for the operator’s cabin.
6. In case of overheating oil in the hydraulic sys-
tem, or oil level drops below the minimum per- d. Mechanical functions:
missible level the crane stops and the multi-disc 1. Automatic sensors recognize dangerous wire
brakes are applied. slacks and stop hoisting and luffing movements
7. Efficient oil filters with exclusive bypass to the that threaten safe control and the equipment
hydraulic oil tank protect the system from harm- itself.
ful oil conditions. Dirty filter might cause mal-
function to the system.
c. Electrical functions:
1. The crane control system CC3000, adjusts the
crane outreach to suit each load. The load
is weighed by a loadcell and the outreach is
measured using an angle encoder. CC3000
3 (16)
GENERAL 1.000.6 E rev.: b 2011-12-07
2. Each working circuit has two independent brake 2. Covers for electric boxes must be opened only
systems. by authorized personnel.
Dynamic braking, deceleration, is achieved by
the regenerative function of the electric motor. c. Alert and warning signs:
True static braking (parking brakes) is pro- The crane has a system of danger, warning,
vided by multiple-disc brakes. caution, and notice signs. These signs are pre-
The mechanical brakes are automatically oper- sented on pages 6 - 15.
ated in the event of dangerous oil pressure.
High speed winches are provided with multiple- 3. Safety Equipment
disc brakes. One for each drive in complete on a. Locks, seals and keys:
the hoisting/luffing winch. 1. Functions and equipment that are essential
Each slewing gear unit has one multiple-disc for oil pressure adjustments, coordination of
brake. controls and crane movements or expose dan-
gerous high-voltage electricity are locked. All
keys to locked positions and switches must be
kept and controlled by the responsible officer
2. Safety Installations
onboard and are only to be used by approved
a. Warning lights, measuring instruments and me-
personnel.
ters:
2. Safety valves for hydraulic pressure adjust-
1. The operator’s panel has a warning light which
ments and switches for electric safety circuits
indicates "Low oil level" in the oil tank for the
are sealed to secure correct position and trim.
brake unit.
Sealed equipment may be opened and positions
2. During crane start-up a warning light on the
changed only after consulting the MacGregor
operator’s panel indicates that the starting pro-
service organization for proper handling.
cedures are still running and that the working
conditions are not acceptable before the lamp
b. Safety belt, rescue line, safety chains:
goes off. Manoeuvres are not to be ordered
1. For maintenance, service or entry to the open-
before the warning light goes off.
air outside the crane house, personnel must
3. A pushbutton siren is found in the crane op-
wear a safety belt. The connector hook should
erator’s cabinet, with which the operator can
be anchored to rails and fixed position while
tell persons in the working area (e.g. against
staying or working on the crane top.
prohibited riding on the load or against load
2. The rescue line and equipment for emergency
movements).
evacuation of the crane operator must always
4. Measuring instruments and meters (e.g. to ex-
be easily accessible on the interior wall-side
amine the crane functions, adjustment of valve
of the crane cabin. The equipment status and
positions and functional positions) are supplied
completeness must be inspected regularly by
as per agreement with the crane buyer/owner.
the responsible officer onboard.
Tools and equipment which are eliminated from
3. The safety chains on the open-air crane top and
the original order to MacGregor are delivered
work platforms inside the crane, must be used
at the discretion of the owner.
for attendant’s safety during stay and work.
b. Covers and houses:

c. Fire-fighting equipment:
1. Unauthorized visitors in the crane house, espe-
A fire extinguisher shall be made available by
cially during crane operation, is prohibited. The
the owner in the operator’s cabin.
crane is a dangerous working area and requires
The fire extinguisher is for emergency use inside
special permission to enter. Instructions given
the crane.
by the superintendent or responsible officer
The equipment must be regularly inspected for
must be obeyed.
4 (16)
GENERAL 1.000.6 E rev.: b 2011-12-07
proper pressure reading at the meter and must or policies to obey to avoid danger to the function
be serviced annually. This is to be supervised and operation of the equipment or damage to the
by the responsible officer onboard. equipment itself.
d. Test device: Responsible officers onboard must make sure that

At delivery, the MacGregor crane has two pres- the signs are in good condition and readable to any
sure gauges. person admitted to the crane area.
Replacement signs must refer to international and

Danger, Warning, Caution and Notice national standards. Signs of non-MacGregor de-
Signs sign are not allowed. MacGregor does not accept
responsibility for unauthorized signs.
Principles of Risk Classification

1. DANGER SIGNS are attached to equipment or are Specific Presentation of Signs and their Message
related to operations that will expose personnel to a All signs attached to the crane are illustrated on the
life-threatening danger (e.g. high-voltage electricity). following pages. Each sign is given a specific number
to which it is referred.
Safety installations, covers or houses prevent expo-
sure during normal working conditions, but cannot
eliminate the imminent risk for any unprofessional/
non-certificated person, should the danger sign not
be obeyed.
Those risks classified as DANGER sign are pre-

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

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

tions or devices are removed and if the procedures
are obeyed.
3. CAUTION SIGNS are attached to equipment or

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

provide references to procedures and instructions
5 (16)
GENERAL 1.000.6 E rev.: b 2011-12-07
Alert / Warning signs

All signs used in MacGregor cargo handling cranes are presented below. Each sign in your specific crane has a
number on it, which can be found in the list and in the illustrations below.
PM40 7101-E00 REPORT TO SUPERINTENDENT OR OPERATOR’S ROOM FOR PERMIT TO ENTER

Any visitor to the crane must obtain a special permit from responsible officer onboard.
For authorized entry during crane operation, the operator must be fully knowledge-
able of safety precautions. The foundation, platform and crane are a dangerous working
environment and requiers that the authorized visitor understands relevant safety.
NOTICE SIGN This sign is at the bottom entrance to the crane foundation.
PM40 7102-E00 DO NOT ENTER DURING CRANE OPERATION - MOVING CRANE HOUSE AND MACHINE
PARTS ...
Authorized entry requires that visitor is aware of the character of general risk and that visitor has ad-
equate manual information about how to avoid the exposure.
WARNING SIGN This sign is at the bottom entrance to the crane foundation.
PM40 7103-E00 HIGH NOISE LEVEL - USE EAR PROTECTION!

Motors and winches produce a noise level that is harmful to personnel
after lengthy exposure. To eliminate the risk, adequate ear protection is required.
CAUTION SIGN This sign is at the bottom entrance to the crane foundation.
PM40 7104-E00 LADDER WILL ROTATE WITH CRANE - WATCH OUT!

This is specifically warn of exposure of the ladder leading up to the crane house. Upon crane
rotation, this ladder rotates and moves suddenly without warning.
WARNING SIGN This sign is at the bottom entrance to the crane (twin) platform.
PM40 7105-E00 RISK OF GETTING CAUGHT BETWEEN WIRE AND DRUM - WATCH OUT!
At start of and during winch operation there is a risk of getting caught and jammed by moving wire. A safe
distance from wire and drums must be maintained and adequate caution must be regarded.
WARNING SIGN Attached to the crane wall surfaces close to winches.
PM40 7106-E00 RISK OF GETTING CAUGHT BETWEEN DRUM AND BRACKET - WATCH OUT!
This sign warns the visitor about the risk of getting jammed during drum rotation.
Adequate caution must be regarded.
WARNING SIGN Attached to brackets and walls of work platforms inside crane
6 (16)
GENERAL 1.000.6 E rev.: b 2011-12-07
PM40 7108-E00 RISK OF GETTING CAUGHT BETWEEN WIRES DURING CRANE OPERATION -
WATCH OUT!
This sign warns about the risk of moving wires that may catch and jam personnel.
The authorized visitor must be aware of the risk and be cautious to avoid being seriously hurt.
WARNING SIGN This sign is attached to the steel bracket side at the open-air crane top entry.
PM40 7109-E00 RISK OF FALLING DOWN - USE SAFETY BELT!

During any visit to the crane top (e.g. for service jobs), the authorizing officer and the person
entering to the area must fully understand the risks involved.
The safety belt must be worn during any visit to the crane top.
WARNING SIGN This sign is attached to the steel bracket side at the open-air crane top entry.
PM40 7111-E00 ROTATING FAN - KEEP HANDS OFF!

The rotating fans are protected by grids and the risk is for anyone who sticks fingers or hand
inside. This can be avoided by sign information.
CAUTION SIGN Attached to fan houses on the open-air crane top and to wall surfaces near the top roof of the
crane.
PM40 7112-E00 RIDING ON CARGO FORBIDDEN

For the attention of the crane operator, to observe that the crane is a Cargo Handling device.
The crane operator is obliged to stop operation and to alert any person riding to keep off.
The operator’s alarm bell, in the crane operator’s cabin, may be used, preferably.
DANGER SIGN Attached on the wall side of the crane operator’s cabin.
PM40 7114-E00 DANGEROUS OIL PRESSURE - BE CAREFUL!

The oil pressure inside oil pressure pipes is 25 - 100 bar.
Under normal working conditions, this exposes no risk for personnel because of rigorous pipe
quality control and dimensions and specifications applied to the equipment. For specific ser-
vice work, exchange of parts or equipment, the exposure may be dangerous for unqualified or
uninformed personnel.
Instructions for service must be followed and must be restricted to qualified personnel only.
WARNING SIGN Attached to surfaces close to pipes inside the crane house.
PM40 7115-E00 SLIPPERY SURFACES - WATCH OUT!

Also under normal working conditions, all walking surfaces are slippery from dirt, oil spill, etc. The re-
sponsible officers onboard must have the crane ladders and work platform surfaces cleaned regularly.
Any person who is admitted to the area must be aware of the risk of slippery surfaces.
WARNING SIGN This sign is attached generally to the walls of work platforms.
7 (16)
GENERAL 1.000.6 E rev.: b 2011-12-07
PM40 7117-E00 HIGH VOLTAGE INSIDE - DO NOT OPEN! AUTHORIZED PERSONNEL ONLY
High voltage equipment, couplings and boxes are covered and do not expose risk unless co-
vers or hoses are removed. Access is restricted to qualified and authorized personnel only.
DANGER SIGN Attached to electrical equipment and boxes where 110 V or 440 V is exposed after covers are
removed.
PM40 7118-E00 RISK OF FALLING DOWN - APPLY SAFETY CHAIN!

During any visit to the work platforms, the authorizing officer and the person entering the area
must fully understand the risks involved.
The safety chains (at work platforms) must be used to prevent personnel from falling.
WARNING SIGN Attached to the steel bracket side at the open-air crane top platform, and at the crane
work platforms inside the crane house.
PM40 7119-E00 HIGH VOLTAGE INSIDE - DO NOT OPEN BEFORE MAIN SWITCH (Q1) IS SWITCHED OFF!
AUTHORIZED PERSONNEL ONLY
High voltage equipment, couplings and boxes are covered and do not expose risk unless co-
vers or hoses are removed. Access is restricted to qualified and authorized personnel only.
DANGER SIGN Attached to electrical equipment e. g. electric main motor.
PM40 7122-E00 RISK OF BODILY INJURY - SUSPENDED LOAD - WATCH OUT!

The crane operator must ensure that the suspended load does not expose personnel below to
risks of falling material.
The crane operator must stop operation and alert personnel.

The operator’s alarm bell in the crane operator’s cabin is preferably used.
DANGER SIGN Applied on the wall side of the crane operator’s cabin.
PM40 7123-E00 RISK OF GETTING CAUGHT BETWEEN WIRE AND WIRE SHEAVES - WATCH OUT!
This sign warns of the risk of moving wires that may catch and jam personnel.
The authorized visitor must be aware of the risk and be cautious to avoid being seriously hurt.
WARNING SIGN This sign is attached to the steel bracket side of the open-air crane top entry.
PM40 7124-E00 RISK OF BODILY INJURY. EMERGENCY OPERATION, AUTHORIZED PERSONNEL ONLY
OPERATE WITH UTMOST CARE, SEE INSTRUCTION
Emergency operation of luffing and slewing, in the event of complete power failure or main
pump unit failure, is extremely difficult and dangerous.
This operation must be undertaken with great care and only
by skilled personnel. Instructions must be observed at all times.
DANGER SIGN Attached to the wall side of the crane operator’s cabin.
8 (16)
GENERAL 1.000.6 E rev.: b 2011-12-07
PM40 7125-E00 DANGER - KEEP OUT OF WORKING AREA!

The working area of the crane, over deck as well as over the deck-sides, is dangerous for
personnel, equipment or property. Items lifted or articles dropped may cause death, injury or
severe damage.
The crane operator must stop operation and alert personnel.
The operator’s alarm bell must also be used for attention.
DANGER SIGN Attached on both sides of the crane jib.
PM40 7129-E00 STARTS AUTOMATICALLY WITHOUT NOTICE AT +25°C (+80°F)

Under normal working conditions, of risk is not exposed to any person near of fans. During
service or upon removal of covers, the risk must be recognized. Such operation is restricted to
qualified personnel only.
NOTICE SIGN Attached to cooling fans, at the open-air crane top, and at the inside top roof.
PM40 7130-E00 DANGEROUS OIL PRESSURE. BE CAREFUL!

The oil pressure inside oil pressure pipes is 25 - 100 bar.
Under normal working conditions, this exposes no risk for personnel because of rigorous pipe
quality control and dimensions and specifications applied to the equipment. For specific ser-
vice work, exchange of parts or equipment, the exposure may be dangerous for unqualified or
uninformed personnel.
Instructions for service must be followed and must be restricted to qualified personnel only.
WARNING SIGN Attached to surfaces close to pipes inside the crane house.
This sign warns the visitor about the risk of getting jammed when the drum is rotating.
Adequate caution must be exercised.
WARNING SIGN Attached to brackets and walls of work platforms inside the crane.
PM40 7132-E00 HOT OIL AND SURFACES - WATCH OUT!

Surfaces of equipment in which there is hot oil can be extremely hot when
the crane is in operation. When service personnel are working on such equip-
ment (e.g. checking and setting valves) they must be aware of the danger.
NOTICE SIGN Attached to surfaces inside the crane housing, close to pumps, valves, pipes, and manifold
blocks. Also in the foundation, close to oil tank and pipes.
PM40 7134-E00 RISK OF GETTING CAUGHT BETWEEN WIRE AND DRUM. WATCH OUT!
When the winch is started and during operation, there is a risk of getting caught and
jammed by moving wire. A safe distance from wires and drums must be maintained and adequate
caution must be exercised.
WARNING SIGN Attached to the crane wall surfaces close to winches.
9 (16)
GENERAL 1.000.6 E rev.: b 2011-12-07
This sign warns the visitor about the risk of getting jammed when the drum is rotating.
Adequate caution must be exercised.
WARNING SIGN Attached to brackets and walls of work platforms inside the crane.
PM40 7136-E00 RISK OF GETTING CAUGHT BETWEEN WIRES DURING CRANE OPERATION - WATCH
OUT!
This sign warns about the risk of moving wires, that may catch and jam personnel.
Authorized visitors must be aware of the risk and be very cautious to avoid serious injury.
WARNING SIGN This sign is attached to the steel bracket at the open-air crane top entry.
PM40 7140-E00 HIGH VOLTAGE, SEPARATE FEED, EVEN WHEN MAIN SWITCH (Q1) IS SWITCHED OFF.
AUTHORIZED PERSONNEL ONLY.
High voltage equipment, couplings and boxes are covered and do not expose risk unless covers
or hoses are removed.
Boxes with this sign are powered even if main switch has shut off other electrical power. Access
is restricted to qualified and authorized personnel only.
DANGER SIGN Attached to electric cabinet CT1.
PM40 7142-E00 HIGH VOLTAGE INSIDE. DO NOT OPEN! AUTHORIZED PERSONNEL ONLY
This high-voltage equipment is covered and does not expose risk unless cover is removed.
The electrical equipment inside cover is powered even if the main switch has shut off other
electrical supply.
Access is restricted to qualified and authorized personnel only.
DANGER SIGN Attached to the cover of slipring device in the foundation.
PM40 7143-E00 DO NOT DISCONNECT MPC-CARDS BEFORE MAIN SWITCH Q1 IS SWITCHED OFF IN
ELECTRIC CABINET (CT1)
NOTICE SIGN Attached on the door inside the cabinet CT2.
PM40 7147-E00 STARTS AUTOMATICALLY WITHOUT NOTICE

Under normal working conditions, of risk is not exposed to any person near of fans. During
service or upon removal of covers, the risk must be recognized. Such operation is restricted to
qualified personnel only.
NOTICE SIGN Attached on the electric motor fan protection.
PM40 7148-E00 700V DC INSIDE. VOLTAGE REMAINS FOR 5 MINUTES AFTER ALL POWER IS
SWITCHED OFF. AUTHORIZED PERSONNEL ONLY
DANGER SIGN Attached on line units or where there is voltage after all power is switched off.
10 (16)
GENERAL 1.000.6 E rev.: b 2011-12-07
PM40 7150-E00 HIGH VOLTAGE INSIDE EVEN IF BOTH MAIN SWITCHES (Q1) ARE OFF. AUTHORIZED
PERSONNEL ONLY
DANGER SIGN Attached on connection box of luffing motors M31 and M32.<
1226128 INSULATION TEST (MEGGER TEST) CAN CAUSE SERIUOS DAMAGE ON ELECTRICAL
EQUIPMENT. SEE INSTRUCTION "INSULATION TEST, ELECTRICAL CRANE".
CAUTION SIGN Attached on the door outside the electrical cabinets
11 (16)
GENERAL 1.000.6 E rev.: b 2011-12-07
Fig. 4. PM40 7104-E00
Fig. 1. PM40 7101-E00
Fig. 5. PM40 7105-E00
Fig. 2. PM40 7102-E00
Fig. 6. PM40 7106-E00
Fig. 3. PM40 7103-E00 Fig. 7. PM40 7108-E00
12 (16)
GENERAL 1.000.6 E rev.: b 2011-12-07
Fig. 8. PM40 7109-E00 Fig. 12. PM40 7115-E00
Fig. 9. PM40 7111-E00 Fig. 13. PM40 7117-E00
Fig. 10. PM40 7112-E00 Fig. 14. PM40 7118-E00
Fig. 11. PM40 7114-E00 Fig. 15. PM40 7119-E00
13 (16)
GENERAL 1.000.6 E rev.: b 2011-12-07
Fig. 16. PM40 7122-E00 Fig. 20. PM40 7129-E00
Fig. 17. PM40 7123-E00 Fig. 21. PM40 7130-E00
Fig. 18. PM40 7124-E00 Fig. 22. PM40 7131-E00
Fig. 19. PM40 7125-E00 Fig. 23. PM40 7132-E00
14 (16)
GENERAL 1.000.6 E rev.: b 2011-12-07
Fig. 24. PM40 7134-E00 Fig. 28. PM40 7142-E00
Fig. 25. PM40 7135-E00 Fig. 29. PM40 7143-E00
Fig. 26. PM40 7136-E00 Fig. 30. PM40 7147-E00.
Fig. 27. PM40 7140-E00 Fig. 31. PM40 7148-E00.
15 (16)
GENERAL 1.000.6 E rev.: b 2011-12-07
Fig. 32. PM40 7150-E00.
CAUT I ON
INSULATION TEST
(MEGGER TEST) CAN
CAUSE SERIUOS DAMAGE
ON ELECTRICAL EQUIPMENT
SEE INSTRUCTION
1226128
“INSULATION TEST
ELECTRICAL CRANE”
Fig. 33. 1226128
16 (16)
GENERAL 1.005 E rev.: e 2003-09-09
Preface
This instruction manual covers the MacGREGOR Spare parts

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

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

sections cover the following subjects:
General
Contents list; Safety; Conversion tables; Hydraulic
and electric symbols.
Technical description
Technical data; description of crane design.
Function
Electric and hydraulic functions of the crane.
Operation
Operating instructions; crane operator’s checklist.
Maintenance
Lubricating chart and maintenance instructions.
Service
General service instructions for the hydraulic system,
mechanical, control system and electrical equipment.
Extra equipment
Extra equipment, if any; e.g. cargo handling equip-
ment.
Appendices
Other information, which cannot be referred to any of
the above mentioned sections.
1 (2)
GENERAL 1.005 E rev.: e 2003-09-09
THIS PAGE IS INTENTIONALLY LEFT BLANK
2 (2)
GENERAL 1.009 E rev.: a 1996-05-20
General Instructions
Cleanliness in Hydraulic Systems
General
The fundamental and foremost rule in all work with Use a brush for cleaning, wipe off with a non-
hydraulic systems and components is absolute linting rag, repeat the cleaning if necessary. Fin-
cleanliness. ish by spraying the area of operations - hose con-
nections etc. - with the solvent.
Many components, e.g. valves and pumps, have 4. Mount protective covers immediately after remov-
very narrow tolerances, therefore microscopic im- ing a component, a pipe or a hose. Components,
purities, invisible to the human eye, may have dis- shall also be fitted with covers and plugs in order
astrous effect on the function of a hydraulic sys- to prevent ingress of dirt.
tem. These covers must be kept in clean and closed
packages. After use, covers are to be cleaned in
The hydraulic system installation contains a cleaner the workshop.
with a cartridge designed to stop impurities pro- 5. Observe minute cleanliness when handling all
duced within the hydraulic system during operation. types of quick-release connectors. Spray both
Every care must be taken to prevent external im- connectors with solvent before making up a con-
purities from entering the system when servicing or nection. Clean all covers before reinstallation.
repairing it.
Storing and filling up of hydraulic oil
This also applies for components that have been
1. Store barrels, hoses and pump as clean as pos-
removed and or to be reinstalled. Sooner or later, a
sible and best of all in a warm room. The oil vis-
component that has been replaced will be inspected
cosity will then be considerably lower, which
in a test equipment somewhere. It is important that
make the filling through filter easier.
the component stays in the same condition as it was
2. Barrels, hoses and pump must be carefully han-
when it was removed, as it may otherwise be
dled and cleaned when necessary.
impossible to decide the real cause of a malfunction.
3. Store barrels horizontally, so plugs (or cocks) are
It may also be possible that a component sent in
below the liquid level and impurities (e.g., damped
for inspection is not defective at all, and will be
air) does not penetrate the barrels.
returned.
4. Observe minute cleanliness when filling up oil -
carelessness is one of the greatest sources when
Rules when working on the hydraulic system impurities penetrates the hydraulic system.
The following fast rules shall be observed during 5. Fill up hydraulic oil. See separate instruction.
working on the hydraulic system: 6. Never use the last drop in the barrel, as it often
consists of water and other impurities depend-
1. Carry out a rough general clean-up. ent on how many times the barrel has been
2. Protect the area where work shall be done. Use opened.
a sheet of plastic material or similar.
3. Clean well with white spirit or a similar solvent.
Remember that it is not enough to clean only the
parts immediately concerned, but also their sur-
roundings from where accumulated dirt may be
transferred in to the repair area. Do not forget to
clean the tools to be used.
1 (2)
GENERAL 1.009 E rev.: a 1996-05-20
2 (2)
GENERAL 1.102 E rev.: c 1999-09-14
Conversion Factors
Length Pressure
1 mm = 0,0393701 in (tum) 1 atm = 14,6959 lbf/in2 (psi)
1 m = 3,28084 ft (fot) 1 atm = 1,01325 bar
1 in = 25,4 mm 1 atm = 1,03323 at
1 ft (fot) = 304,8 mm 1 bar = 0,986923 atm
1 at = 14,2233 lbf/in2 (psi)
Volume 1 at = 0,980665 bar
10 lbf/in2 = 0,689476 bar
1 dm3 = 1 litre = 0,219969 gallon (UK)
10 lbf/in2 = 0,70307 at
1 dm3 = 1 litre = 0,264172 gallon (US)
1 bar = 1,01972 at
1 gallon (UK)= 4,54609 dm3
1 bar = 14,5038 lbf/in2 (psi)
1 gallon (US)= 3,78541 dm3 2
1 kp/cm = 14,2233 lbf/in2
1 bar = 100 kPa = 0,1 MPa
Mass 1 Pa = 1 N/m2
1 kg = 2,20463 lb 1 Pa = 10,2 · 10-6 kp/cm 2
1 lb = 0,45359 kg 1 Pa = 0,145 · 10 -6 lbf/in2
1 ton (metric) = 1000 kg 1 Pa = 7,5 · 10-3 mm Hg
1 ton (UK) = 1 longton (US) 1 kp/cm2 = 98,07 ·103 Pa
1 ton (UK) = 1016,05 kg
Power
Force 1 kW = 1,35962 hk
1 kp = 2,20462 lbf 1 kW = 1,34102 hp (UK, US)
1 kp = 9,80665 N 1 hk = 0,986320 hp (UK, US)
1 lbf = 4,44822 N 1 hp (UK, US) = 1,01387 hk
1 lbf = 0,453592 kp 1 hk = 0,735499 kW
1N = 0,101972 kp 1 hp (UK, US) = 0,745700 kW
1N = 0,224809 lbf
Temperature
Moment of force 0°C = 32°F
1 kpm= 9,80665 Nm 0°C = 273,15 K
1 kpm= 7,23301 lbf · ft 0°F = -17,7778°C
1 Nm = 0,737562 lbf · ft 0°F = 255,3722 K
1 lbf · ft = 0,135582 daNm 0K = -273,15°C
1 lbf · ft = 1,35582 Nm 0K = -459,67°F
1 lbf · ft = 0,13825 kpm
1 daNm = 1,01972 kpm 1
°C = (°F - 32) °F = 1,8 (K - 273,15) + 32
1 daNm = 7,37562 lbf · ft 1,8
1
°F = °C · 1,8 + 32 K= (°F - 32) + 273,15
1,8
Moment of inertia
°C = K - 273,15
1 kg · m 2 = 3417,17 lb · in2
1 lb · in 2 = 0,00029264 kg · m2 K = °C + 273,15
1 (2)
1.102 E rev.: c 1999-09-14
2 (2)
GENERAL/ALLGEMEINES 1.518.3 ED rev.: d 2007-06-08
Hydraulic and Electric Symbols
Hydraulische und elektrische Bildzeichen
This section covers a part of the symbols and port markings commonly
used in MacGREGOR (SWE) AB, Service Division hydraulic and electric
circuits, divided into three parts:
Diese Sammlung umfaßt einen Teil der allgemeinen Bild- und

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

Baugruppen
1. Hydraulic Symbols
Hydraulische Bildzeichen
Working oil line.

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

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

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

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

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

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

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

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

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

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

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

Filter mit Anzeiger.
Filter with by-pass valve.

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

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

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

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

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

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

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

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

Schieber, Grundzeichen.
Electrically controlled valve.

Schieber, elektromagnetisch gesteuert.
Pressure controlled valve.

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

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

Schieber, vorgesteuert, externer Steuerdruck.
Lever controlled valve.

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

Schieber, mechanisch gesteuert.
Valve with spring return.

Schieber mit Feder-Rückführung.
Valve with detent.

Schieber mit Lagehalter.
4/2 direction valve

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

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

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

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

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

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

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

Druckreduzierventil.
Pressure reducing valve with T-port.

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

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

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

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

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

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

Pumpe für Lastwinde.

13 (30)

Pump for luffing winch.

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

Pumpe für Einziehwinde.
Pump for luffing or slewing.

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

Pumpe für Schwenkantrieb oder Einziehwinde.
Pump for slewing.

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

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

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

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

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

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

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

Ventileinheit für Stabilisierungswinde.
Unloading unit for feed pump.

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

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

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

Leitungsverbindung, fest.
Conductor junction, separable.

Leitungsverbindung, trennbar.
Crossed conductor, no connection.

Kreuzende Leitungen, ohne Verbindung.
Slip ring with brush.

Schleifring mit Bürste.
Fuse, supply side indicated.

Sicherung, Zuführungsseite markiert.
Magnetic relay, contactor.

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

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

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

Kontakt mit Ausschalt-Verzögerung.
Contact with delayed closing.

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

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

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

Temperaturwächter, Thermostat.
Touch free contact.

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

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

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

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

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

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

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

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

Steuerknüppel, Einziehwinde und Schwenkantrieb.
29 (30)
30 (30)
TECHNICAL DATA Project No.: 2/10108.01RHM rev: a 2012-02-14
TECHNICAL DATA
GENERAL
Type of crane GLBE 3025-2/2425gr
Work order 2/10108.01RHM
Serial number 62512724 - CRANE No. 1

62512725 - CRANE No. 2
62512726 - CRANE No. 3
62512727 - CRANE No. 4
Ambient temp range -15 to + 45° C
BASIC DATA
Lifting height H 15 m
Lifting height K 25 m
Hoisting Hoisting Hoisting Jib radius, Jib radius,

capacity, capacity, capacity, Minimum Maximum
SWL GRAB PART SWL
(ton) (ton) (ton) (m) (m)

30 - 9 4 25
- 24 9 4 25
1 (8)
Speed - Hoisting
Hoisting Hoisting
capacity, speed,
SWL
(ton) (m/min)
4 36
30 18
Hoisting speed diagram
Fig. 1 Hoisting speed diagram
2 (8)
Speed - Luffing
Luffing speed, Luffing speed, Luffing speed
PART SWL MAX SWL
(ton) (ton) (sec)

0 to 12 - 40
- 9 to 30 60
Speed - Slewing
Slewing speed, Slewing speed, Slewing speed
PART SWL MAX SWL
(ton) (ton) (sec)

0 to 9 - 0.75
- 9 to 30 0.6
ELECTRICAL DATA - Frequency converters

LINE UNITS (UZ11, UZ12)
Input
Rated frequency 3 Phase ~ 50/60 Hz
Rated voltage 380 - 480 V
Rated current 490 A
Output UZ11
Rated voltage 708 V DC
HOISTING DRIVE (UF1)
Input
Output
Variable frequency 3 Phase ~ 0 - 100 Hz
Rated variable voltage 0 - 500 V AC
Rated current 210 A
3 (8)
ELECTRICAL DATA - Frequency converters

LUFFING DRIVE (UF2)
Input
Output
Variable voltage 0 - 500 V AC
Rated current 200 A
SLEWING DRIVE (UF3, UF4)
Input
Output
Variable voltage 0 - 500 V AC
Rated current 60 A
ELECTRICAL DATA - Electric motors

HOISTING MOTOR (M1)
Rated voltage 500 V AC
Rated frequency 3 Phase ~ 50 Hz
Rated power 75 kW
Rated current 159 A
4 (8)
LUFFING MOTOR (M2)
Rated power 63 kW
Rated current 99 A
ELECTRICAL DATA - Electric motors

SLEWING MOTORS (M3, M4)
Rated power 18.5 kW
Rated current 28 A
BRAKE UNIT MOTOR (M6)
Rated voltage 380 - 440 V AC
Rated power 0.55 kW
Rated current 3 x 440V - 60Hz 1.3 A
5 (8)
OIL VOLUME / OIL FILLING (per unit)
Hydraulic Brake unit oil tank 15 liters
Emergency brake unit oil tank 8.2 liters
Hoisting winch gearbox 10.5 liters
Hoisting winch, bevel gear oil tank 9.5 liters
Luffing winch gearbox 6.0 liters
Luffing winch, bevel gear oil tank 9.5 liters
Slewing gear 7.5 liters
WIRE ROPE
Hoisting wire rope Ø 30 mm × 235.5 m

No. 1221289
Luffing wire rope Ø 28 mm x 163 m

No. 1188175
6 (8)
Limit Switches in Hoisting and Luffing Winch Systems
7 (8)
LOADSTEP DIAGRAM
Fig. 2 Loadstep diagram
8 (8)
TECHNICAL DESCRIPTION 2.007.96 E rev.: a 2011-06-10
Technical Description
Jib top
Loadcell
Wire sheaves
Wire rope
Lifting block
Heating fan
CT14
CT1/CT2 Display
CT2
CT13
CT1
CT14
CT10 CT13
CT10
El. motors (SL)

Crane
operator's
Winch (Lu) cabin
Winch (Ho)
Heating fan
El. motor (Lu)

Slewing gear unit
El. motor (Ho)
Slewing bearing Brake unit
Fig. 1. Crane type GLBE.
1 (4)
MacGregor electric deck cranes are self-contained The crane house is an all-welded structure on a rigid
units with all machinery enclosed in the crane house baseplate, and encloses all mechanical and hydraulical
and, thus, well protected against external abuse. machinery and associated electrical equipment for an
adequate protection against rain, sleet and waves
When delivered, the cranes are mechanically, breaking over the ship. Catwalks, ladders, platforms,
hydraulically and electrically complete in every respect and handrails facilitate the maintenance of the crane.
and ready to be installed on a suitable foundation fixed
in the ship’s deck or on a crane carriage travelling on The top of the crane house and of the jib head are
deck. fitted with sheaves for the hoisting and luffing wire
ropes. All sheaves and their shafts are secured by
lockplates.
Design
All crane movements - hoisting, luffing and slewing -
Various software limits, encoders, load cell (SWL)
are driven by electric motors. These are connected
together with jib outreach are supplied.
to frequency converters, which allows stepless speed
control of the motors for each electric circuit. The
The cranes are supplied with test certificates to the
converters are linked to the LINE-units via a DC-bus.
requirements of National Swedish Board of Shipping
The LINE-units allow powerflow in both directions.
and Navigation. The design meets the requirements
LCL-filters for each LINE-unit eliminates harmonics
of ILO and the relevant classification societies whose
and any disturbances that may occur during back
certificates will be supplied if specially ordered.
power generation.
The hoisting winch is driven by an electric motor. A Overload protection

brake is integrated in the winch gear set. When the To prevent the crane from being overloaded, i.e. lifting
winch is running, the brake is automatically released a too heavy load, the electrical system has an overload
by a hydraulic unit. The hoisting winch have also a system. Pressure sensing switches, which normally
pressure roller and one layer of wire on the drum. enable the operation, stop the hoisting movement if a
too heavy load is lifted at the current jib outreah. The
Slackwire limit switches on the hoisting and luffing pressure sensing switch or load cell gives a signal to
winches operate if the wire slackens and to preclude the control system overload logic, which senses the
the complete unwinding of the wire from the wire overload input signal to the control system CC3000.
drums.
Crane operator’s cabin
The crane jib is raised and lowered by the luffing winch
The crane operator’s cabin affords an allround view of
whose general design is similar to that of the hoisting
the entire work area.
winch.
The cabin contains of control panels with various
switches, pushbuttons and signal lamps and joysticks
The crane has several slewing gears and the slewing
for hoisting and luffing/slewing movements.
drive of the crane uses the electric motors. On
Air conditioning is available as an optional feature.
customer’s order encoders can be supplied to define
The emergency exit is through the cabin's side window.
the slewing range of the crane.
A display in the cabin shows continuous information
about load, outreach, possible movements etc.
The temperature and brake oil levels of the brake
circuits are monitored by the control system CC3000.
2 (4)
Jib Crane control system CC3000

The jib is made of two box girders joined by transverse Control of the outreach is load depending.The load
tubular steel struts. The foot of the jib mounts on two cell gives information about the load (SWL) to the
trunnion journals at the sides of the crane house. A control system CC3000 and compares the outreach
halogen floodlight is mounted on the jib. through the encoders for luffing outreach and stops in
the chosen software limits.
Electrical equipment
Certain electric cables outside of the crane house, Hydraulic hoses
e.g. on the jib, are carried in steel conduit. All cables The hydraulic hoses are high-pressure tested and
and electrical accessories are specially designed for carefully cleaned and inspected before assembly.
marine use.
Cargo handling gear
The slip-ring unit linking the crane network with the
The swivel, hook, shackles, rings, and chains, all have
shipboard network is put under the crane, inside the ample safety margins for the maximum load to be
foundation and is bolted to the bottom plate. handled by the crane. The non-rotatory, langs lay wire
ropes are galvanised and oiled.
The electric cabinets are put on the inside wall of the
crane house. The cabinets contain contactors, relays,
fuses, frequency converters, line units, and various Surface treatment
other components of the electrical installation. The All surfaces of the crane are carefully prepared by
main power switch is put on the cabinet CT1. sandblasting before being given a coat of Primer. As
standard the crane is painted with an anti-corrosive
system basically based on a two-component epoxy
Lighting
paint and an acrylic finishing coat.
Lighting is installed in the crane house and cabin. Can
also be installed in the foundation and pedestal, if
required.
Deck lights
Two deck lights are installed in front under the cabin
and are controlled from cabin and bridge. Optional extra
deck lights can be installed upon request.
3 (4)
4 (4)
FUNCTION 3.110.127 E rev.: b 2012-02-02
ELECTRICAL FUNCTIONS
WARNING! Separate feed in the cabinet CT1 and WARNING! Voltage remains for 5 minutes in the elec-
electric motors! tric cabinets CT10, CT13 and CT14 when power is
Some components in the crane are still energized switched off. The electric cabinets store the frequency
when the main power switch is off. Refer to electric converters and line unit.
diagram for information about energized components.
General Electric system

The following description refers to the standard elec- The winches for the hoisting, luffing and slewing gears
tric system of MacGregor electric deck cranes, normal are driven by electric motors. These are connected
version. to the motor inverters, which invert the DC-current
Minor variations in the electric system may occur in in- to AC-current and supply variable stepless speed
dividual cranes of the same type, and the objective of control of the motors. The inverters are linked to the
this description is only to provide a general orientation LINE-unit through a DC-bus. The line unit rectifies
concerning the arrangement of the electric system. the current from AC to DC and supplies power to the
motor inverters. LCL-filter for the line unit protects
The complete electrical system drawing, relat- the electric network by eliminating harmonics and
ing specifically to your crane, will be found in any disturbances that may occur during back power
the instruction manual, section “Spare Parts”, generation. The electrical system allows powerflow
Group 9.5. in both directions.
Symbols
Every electric component is represented by a special
symbol in the circuit diagram. The meaning of the sym-
bols is explained in section “General” in the Manual.
1 (4)
FUNCTION 3.110.127 E rev.: b 2012-02-02
Line unit
(Rectifier)
LCL-filter
UF1 UF4 UF3 UF2
Fig. 1. Electrical system.
2 (4)
FUNCTION 3.110.127 E rev.: b 2012-02-02
Starting and stopping Other electric functions

Preheating Overheating protection
Note! The heating fans are to make sure that the An analogue temperature sensor in each electric mo-
temperature in the crane house is always kept above tor is connected to its respective frequency converter.
-10°C. This is necessary for the operation of the fre- When the electric motor begins to overheat, the ramp
quency converters and line units. time increases during acceleration. If the temperature
continues to rise above the maximum permitted level,
The heating fans for the crane house are started with the motion is ramped down to a stop.
a switch on the electrical cabinet CT1. These heat-
ing fans, which are controlled with a thermostat in A temperature switch in the electric motor stops the
the cabinet CT1, stop if the temperature in the crane crane if the motor is about to overheat. It switches off
house exceeds +15°C. the current at a higher temperature than that permit-
ted by the analogue sensor, and therefore acts as a
The heating elements in the electric cabinets will back-up to the analogue sensor.
warm up the electric and electronic equipment inside
the cabinets automatically. They are thermatatically
Oil level in brake unit
controlled.
If the oil level in the hydraulic oil tank drops too low
the crane ramps down and stops. An alarm system
Starting sequence is switched on by the float oil level switch. Indicator
When the start button is pushed, the DC bus is pre- light H5 comes on.
charged and then the main contactor operates. The
frequency converter system and the motor fans start.
Siren
The pump for the brake system also starts. Now there
The pushbutton "SIREN" in the cabin allows the crane
is communication between the control system and the
operator to warn people on deck.
frequency converters.
Ventilation fan
Operating sequence
A ventilation fan is installed in the crane house. This
Input from the control levers magnetizes the electric
is controlled by a thermostat, BT1, which is installed
motor and the brakes are released. The permitted
in the cabinet CT1.
outreach is controlled by the value of the load cell.
Maximum speed is based on the current load. The
control system continously feeds the desired speed Lighting and heating
to the motor inverters. The motor inverters control Electric power is supplied by separate slip-rings for
the electric motors accordingly. The ramp time for the lighting in the crane house, in the operator’s cabin,
hoisting and luffing movement is based on constant and on the jib and heating in the cabin.
acceleration and the retardation to standstill takes
the same amount of time regardless of the maximum The crane house lighting is operated by switches on
current load. the roof of the platform. The cabin lighting and the jib
light are operated by switches on the control panel
in the cabin.
Stop sequence (normal operations)
The stop button, S13, needs only to be pushed once,
then the system waits for the brakes to be applied. Control system error
When the brakes are applied, the crane stops. If an error is detecteded by the crane's control system
in the cabinet CT2 the indicator light H2 comes on.
Examine the cabinet CT2 refer to the instruction
"Crane Control System CC3000" in section 6.3.
3 (4)
FUNCTION 3.110.127 E rev.: b 2012-02-02
4 (4)
FUNCTION 3.110.132 E rev.: - 2012-01-13
Hydraulic Brake Function
General Control-pressure, brake circuit
This description refers to the hydraulic brake circuit The control-pressure, brake circuit have these main
of a MacGregor electric deck crane. components, see Fig. 1:
This is a general description of the hydraulic brake 4111 Pump

circuit, and may not be fully correct with your crane. 4102 Filter unit
A complete hydraulic circuit diagram for your crane 4333 Oil level /temperature guard
will be found in the instruction manual, section 9.4. 4145 Pressure switch
4148 Pressure relief valve (safety)
There are separate hydraulic brake circuits for brake 4161 Accumulator
release of the hoisting winch, luffing winch and slew- 1 Gauge connection
ing gears. The control pressure brake circuit is the
brake unit. The brake circuits have one pump located in the brake
unit. When crane starts the pump starts to charge
the accumulator and supply fluid to the brakes. The
Symbols
system operates between switching pressure 3.0-6.0
Every hydraulic component is represented by a spe-
MPa (30-60 bar).
cial symbol in the circuit diagram. The symbols are
explained in section “General” in the manual.
Pressure switch 4145 has a min pressure set to 3.0
MPa (30 bar) and a max pressure set to 6.0 MPA (60
Component identification bar) and is measured at gauge connection 1.
The main components are identified by four-digit num- Control fluid is supplied by the pump in the brake unit.
bers in the diagram and on the actual components If control pressure decreases below 3.0 MPa (30 bar)
in the crane. The first digit of each number is the circuit the pump in the brake unit automatically starts or if
to which the component belongs: the control pressure increases more than 6.0 MPa
(60 bar) the pump stops.
1... Hoisting brake circuit
2... Luffing brake circuit The pressure relief valve (safety) 4148 is set to 7.0
3... Slewing brake circuit MPa (70 bar) and is measured at gauge connection 1.
4... Control-pressure, brake circuit
5... Additional programming equipment *)
Note!
7... Other additional hydraulic equipment *)
For exact pressure settings, see pressure list in the
hydraulic diagram.
*) Equipment installed at request of customer.
1 (4)
FUNCTION 3.110.132 E rev.: - 2012-01-13
Safety funtions
- Control pressure in the hydraulic brake circuit is
monitored by the control system CC3000.
- The pressure relief valve (safety) 4148 is set to 7.0
MPa (70 bar) and is measured at gauge connection
1.
- The oil level sensor / temperature sensor 4333
ramps down and stops the crane if the oil level is
too low or if the oil temperature exceeds +85°C.
It is not allowed to adjust sealed safety valves without

contacting Cargotec Service Organisation.
Fig. 1. Control pressure, brake circuit, example.
2 (4)
FUNCTION 3.110.132 E rev.: - 2012-01-13
Hoisting winch, brake circuit Luffing winch, brake circuit
The hoisting winch brake circuit have these main The luffing winch brake circuit have these main com-
components: ponents:
1211 Hydraulic brake 2211 Hydraulic brake

1226 Direction valve 2226 Direction valves
1227 Direction valve 2227 Direction valves
1249 Test nipple - air 2249 Test nipple - air
1381 Low pressure switch 2381 Pressure switch
The luffing and slewing movements are operated by

Brake release
the same control lever, see Fig. 2.
When the hoisting/lowering control lever is in neutral
position the brake is engaged and holds the load.
When the control lever is moved forward or backward Brake release
the motor gets magnetized and the brake 1211 is When the luffing control lever is in neutral position the
released. Direction valves 1226 and 1227 connects brake is engaged and holds the load. When the control
full control pressure to the hydraulic brake circuit to lever is moved forward or backward the motor gets
release the brakes. magnetized and the brake 2211 is released. Direction
valves 2226 and 2227 connects full control pressure
to the hydraulic brake circuit to release the brakes.
Maintenance
If air is in the hydraulic brake circuit, use connection
"test nipple - air" 1249 to bleed air out of the brake Maintenance
system. If air is in the hydraulic brake circuit, use connection
"test nipple - air" 2249 to bleed air out of the hydraulic
system.
Hoisting safety function
Pressure switch 1381 stops the crane if the control
pressure is too low. Luffing safety function
pressure is too low.
Luffing-out (lowering jib)
Luffing-in (raising jib)
Fig. 2. Control lever, luffing/slewing.
3 (4)
FUNCTION 3.110.132 E rev.: - 2012-01-13
Slewing circuit
The slewing brake circuit have these main compo-

nents:
3211 Hydraulic brake

3212 Hydraulic brake
3226 Direction valve
3227 Direction valve
3249 Test nipple - air
3381 Pressure switch
The luffing and slewing movements are operated by

the same control lever, see Fig. 3.
Brake release
When the control lever is in neutral position and the
electrical motors are running, the brakes are engaged.
When the control lever is moved to the right or left
the motor gets magnetized and the brakes 3211 and
3212 are released. Direction valves 3226 and 3227
connects full control pressure to the hydraulic brake
circuit to release the brakes.
Maintenance
If air is in the hydraulic brake circuit, use connection
"test nipple - air" 3249 to bleed air out of the hydraulic
system.
Slewing safety function

pressure is too low.
Slewing left
(Counterclock- Slewing right
wise) (Clockwise)
Fig. 3. Control lever, luffing/slewing.
4 (4)
FUNCTION 3.142.41 E rev.: a 2010-12-14
Crane Control System CC3000

General
The following description refers to the microcomputer For detailed information about the control system a
based crane control system CC3000 for MacGregor complete electrical circuit specification, relating
Cranes electric deck cranes, single crane versions. specifically to your crane, will be found in the
instruction manual, section "Spare Parts", Group 9.5.
Minor variations in the use of the control system input Detailed information about the hydraulic brake sys-
and output signals due to differences in the hydraulic tem, a complete hydraulic circuit specification, can
system for the brakes and electric system can occur. be found in section "Spare Parts", Group 9.4.
The objective of this description is only to supply a
general orientation concerning the principles of the
control system.
CT2
MC
"Ho" Fieldbus Motor
inverter HOISTING
Main Run Enable Ho
hoist
Brakes
Brake valve
Brake valve
3-phase
DC-
supply
bus PWM
Hoisting
CC Fieldbus El-
winch
motor
"Sc"
Line
Run enable Unit
Super
-visory
MC
"Lu" Fieldbus Motor
inverter LUFFING
Luffing Run Enable Lu
Brakes
Brake valve
Memory
Card Brake valve
DC-bus
PWM
Luffing
El-
winch
motor
MC
Fieldbus Motor Motor
"SL"
Inverter Inverter SLEWING
Run Enable SL SL
Slewing
Brakes
Brake valve
Brake valve
DC- Slewing
gear
bus PWM PWM
El-
motor
El-
motor
Fig. 1. Crane control system with interfaces to control levers and frequency drive system.
1 (4)
FUNCTION 3.142.41 E rev: a 2010-12-14
Crane control system - interfaces and

principle of operation
Control levers (joysticks)

The right control lever controls the hoisting winch.
The left control lever controls the luffing and slewing
motions. Each joystick is connected to the respectively
MC card ( "Ho" for hoisting, "Lu" for luffing and "SL"
30
50 50
31
50 50
459
458 457
32
455 453
451 449
Hardware Hardware Hardware Hardware 448 438
324 1670-901 324 1665-901 324 1665-901 324 1665-901 437 436
33
435 434
ErrorMP SP ErrorMP SP ErrorMP SP ErrorMP SP 433 432
Input Output Input Output Input Output Input Output 431 430
34
07 18 27 33 36 33 36 33 36 429 427
07 07 07 426 425
08 19 28 39 43 39 43 39 43
09 20 29 34 37 34 37 34 37 420 419
08 08 08 418 417
10 26 30 40 45 40 45 40 45
35
415 414
for slewing).
11 49 31 09 31 09 31 09 31
30 30 30 412 411
12 51 32 10 32 10 32 10 32
13 56 33 19 Sw19 19 Sw19 19 Sw19 408 407
Encoder
36
14 57 34 20 Sw20 55 20 Sw20 55 20 Sw20 55 404 403
402 401
calibration 15 58
16 59
35
36
11 14 Sw14
56 Sw56
11 14 Sw14
56 Sw56
11 14 Sw14
56 Sw56
17 60 37 12 15 Sw15 12 15 Sw15 12 15 Sw15
24V 38 26 27 26 27 26 27
50 50
42 359
Com 39 58 59 58 59 58 59
358 357
C1 R1 40 49 17 29 49 17 29 49 17 29
356 355
C2 R2 53 51 18 53 51 18 53 51 18 53
Normal 353 349
C3 R3 61 52 54 52 54 52 54
348 338
S1
C4 MP 57 C1 R1 57 C1 R1 57 C1 R1
Em.Op. 337 336
C2 MP C2 MP C2 MP
335 334
Com Com Com
333 332
CC MC MC MC 331
329
330
327
326 325
320 319
Sc Ho Lu Sl 318
315
312
317
314
311
308 307
Select / Info Select / Info Select / Info Select / Info 304 303
Normal 302 301
Rigg OL-Test Up Up Up Up
50 42
Down / Exit Down / Exit Down / Exit Down / Exit 50 42
50 42
50 50 50 42
50 50 50 42
259 258 98 97
257 256 96 95
PC COM PC COM PC COM PC COM 255 254 94 93
253 252 92 91
251 249 90 89
248 247 88 87
Software Software Software Software 245 243 86 85
CC3K H01.00 CC3K H01.00 CC3K H01.00 CC3K H01.00 241 240 84 83
The joystick linear potentiometers are supplied with

Rev B Rev B Rev B Rev B 239 238 82 81
237 236 80 79
235 234 78 77
SC IO SCSupervisory
HOHoisting LULuffing SLSlewing AUAuxiliary IOInput/Output 233
231
232
230
76
74
75
73
C3 C3 A1 C1 A1 C1 A1 C1 A1 C1 A1 C1 A1 C1 229 227 72 71
C28
C36
C44
C52
C17
C6
SC_C3 1
IO_C3 1
SC_C1 1
LU_C1 1
SL_C1 1
AU_C1 1
1
226 225 70 69
HO_C1
IO_C1
220 219 68 67
SL_A1
LU_A1
SC_A1
AU_A1
HO_A1
IO_A1
218 217 66 65
P115 P1115 P108 P208 P308 P408 P508 P1108 215 214 64 63
P101 P201 P301 P401 P501 P1101 212 211 62 61
C4 C4 A2 C2 A2 C2 A2 C2 A2 C2 A2 C2 A2 C2 210 209 60 27
C29
C37
C45
C53
C18
C7
1
SC_C2 1
HO_C2 1
LU_C2 1
SL_C2 1
AU_C2 1
IO_C2 1
208 207 26 25
204 203 24
SL_A2
LU_A2
SC_A2
AU_A2
SC_C4
HO_A2
IO_A2
IO_C4
202 201 23
P109 P209 P309 P409 P509 P1109 50 50 22
P116 P1116 P102 P202 P302 P402 P502 P1102 50 50 21
485.2 485.2 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1 42 42 20
42 42 19
SC_485.2 1
IO_485.2 1
SC_485.11
HO_485.11
LU_485.11
SL_485.11
AU_485.11
IO_485.1 1
0V, +6V and +12V. The output level is approximately
161 160 18
SL_A3
LU_A3
SC_A3
AU_A3
HO_A3
IO_A3
158 157 17
P103 P110 P203 P210 P303 P310 P403 P410 P503 P510 P1103 P1110
153 151 16
P117 P1117
149 143 15
485.3 485.3 Sp SSI Sp SSI Sp SSI Sp SSI Sp SSI Sp SSI 141 137 14 13
C12
C11
C34
C33
C42
C41
C50
C49
C58
C57
C23
C22
136 135 12 11
SC_485.3 1
IO_485.3 1
1
134 133 10 9
132 131 8 7
LU_SSI
SL_SSI
SC_SSI
AU_SSI
HO_SSI
IO_SSI
SL_Sp
SC_Sp
LU_Sp
AU_Sp
HO_Sp
IO_Sp
130 128 6 5
P118 P1118
127 126 4 3
125 119 2 1
118 117 456 454
A A
P107 P106 P207 P206 P307 P306 P407 P406 P507 P506 P1107 P1106
116 115 452 354
114 113 351 241
112 111 240 239
110 109
108 107
104 103
102 101
+6V with the joystick in neutral. The output signal is

controlled by the joystick and is decreased to
approximately +1.5V and increased to approximately
+10.5V, depending on the joystick movement.
The joystick for hoisting gives 24V signals for hoisting

and lowering. The joystick for luffing/slewing gives 24V
signals for selecting luffing in/luffing out and slewing
left/slewing right.
Crane control system

The crane control system consists mainly of four
microprocessor cards. One Communication Card
(CC) is used for internal communication between the
cards and a parameter memory card. Three Motion
Control cards (MC) handle all input and output signals Fig. 2. Crane control system CC3000 in cabinet CT2.
for each crane motion, hoisting, luffing and slewing.
Each MC card is separately controlled by respective
joystick. Cabinet CT2
Cabinet CT2 contains the crane control system and is
The rampformer gives smooth acceleration and
protected against humidity by a casing with protection
deceleration to the crane motions.
class IP54 (dust and splash water proof).
The brake release logic circuit releases and applies

the brake in the correct sequence when the electric 19" subrack with electronic cards
motor starts and stops. All electronic cards are installed in a standard 19" alu-
The brake circuit contains two separate control sign- minium subrack. The system is powered with 24V via
als, each signal can be manouvered separately and the backplane card. To be able to read the connection
contains one relay and one hydraulic valve each. points for sensors and communication each CC and
CC3000 and the VFD can close the brakes MC Card is connected to the extended backplane card.
independently. The configuration of the crane is stored in the memory
At power on each brake control circuit is independently card.
checked to ensure the double controllability.
2 (4)
FUNCTION 3.142.41 E rev.: a 2010-12-14
Electric motors Each MC card is a complete stand-alone

The electrtic motors are controlled by the variable microprocessor system with processors, several types
frequency drives. The current from the common DC of memories and communication channels, analogue
bus, which is supplied by the Active Line Module and digital inputs as well as analogue and digital out-
(ALM), is converted by the VFD to required voltage put current drivers. Each card can fully handle all in-
and frequence corresponding to requested speed from put and output signals needed for one variable
CC3000. frequency drive, i.e. one crane motion.
Overload protection The safety system consists of a secondary

Cranes are protected from lifting heavier loads than microprocessor, which monitors the behavior of the
specified Safe Working Load (SWL). This is obtained main processor.
by using a load cell where the measured value is
compared with the maximum load parameter. As an Software
extra precaution the value from the load cell is All cards, CC and MC, are programmed with the same
compared to the motor torque. crane control software. Each card senses, which rack-
position and hence which function/crane motion it
For empty hook and lighter loads it is possible to run controls.
at higher speed than with max SWL. If the crane is
specified with different outreaches depending on the All cards identify themselves by showing a two-
load then the overload varies. character abbreviation of the function/motion name on
the front panel display:
All safety function based on overload are handled by - Sc - supervisory
the crane control system CC3000. - Ho - hoisting
- Lu - luffing
Hoisting winch limit switch box - SL - slewing.
The limit switch box contains cams with limit switches
and encoders. They prevent operation outside working The leftmost card, the CC "Sc", is only used for
area. supervisory functions such as communication with
other cards and distribution of control system para-
meters from the parameter memory card.
Luffing winch limit switch box
The limit switch box contains cams, limit switches New versions of the crane control software can be
and encoders. They prevent operation outside working loaded/programmed into the cards by using a stan-
area. dard notebook PC.
Slackwire limit switches Parameter memory card

The limit switch for hoisting stops the lowering mo- All parameter values are stored in the memory card.
tion, and the limit switch for luffing stops both the luffing Stored parameter values are not dependent on power
out and hosting motions. supply or battery. There is, however, a battery on the
card used for a calendar, giving all cards date and
time information. The card is located inside the rack
Microprocessor Cards - CC and MC and is assembled on the backplane card that also holds
all the card connectors. The lifetime of the battery is
Hardware 10 years.
The control system consists mainly of one CC card

and three MC cards. All MC cards are identical and
interchangeable.
3 (4)
FUNCTION 3.142.41 E rev: a 2010-12-14
Anti-condensation heating Error messages

To avoid condensation on the electronic cards, the
temperature inside the cabinet must be higher than Built-in diagnostic system
the temperature outside. Heating elements are
The CC3000 control system has its own built-in
therefore installed behind the terminal strip. They are
diagnostic system which is capable to detect several
powered with 24V AC when the control system is
types of malfunctions.
switched off or when the crane is not operational.
Internal problems such as loss of communications and

loose connections are continuously checked.
Signal overview CC3000
At power on the system checks that the control lever
is in zero position.
Coloured LEDs
Signals to and from each card are indicated by green, Error message sign
yellow and red LEDs (Light-Emitting Diodes) on the
If a malfunctions found the "control system error" lamp
front panel of each card.
in the cabin start flashing. The error codes can be
read on the card display or on the cabin display. The
- Green LEDs are used for normal input and outputs.
procedure to retrieve the error information is described
- Yellow LEDs indicate that the crane motion
in the ERROR MESSAGES sign located in the cabinet
concerned is driven with slower speed.
or in section 6.3.
- Red LEDs indicate that the motion is stopped.
Signal overview sign

All signals indicated with LEDs are listed on the SIGNAL
OVERVIEW sign inside the cabinet, see section 6.3.
4 (4)
FUNCTION 3.155.6 E rev.: - 2010-10-27
Thermostatic Controlled Ventilation Fan and Heater Elements
General Thermostat BT5

The heater elements are automatically switched off
The ventilation fan and heater elements are if the temperature exceeds +15°C inside the crane
thermostatic controlled and installed inside the crane house. The thermostat bulb is installed outside the
house, see Fig. 1. cabinet. The thermostat can be adjusted, see Fig.
3.
Function
Thermostat BT1
With the main switch Q1 in position "1" (on-position)
the ventilation fan starts by thermostat BT1, posi-
tioned in the cabinet CT1, see Fig. 2. The thermostat
bulb is installed outside the cabinet.
Thermostat BT1 starts at +25°C. The thermostat

can be adjusted, see Fig. 3.
Thermostat BT1
Thermostat bulbs
Thermostat BT5
Fig. 2. Thermostats BT1 and BT5 installed in cabinet

CT1.
Fan
Heater element
Heater element
Fig. 1. Crane house. Fig. 3. Thermostats BT1 and BT5.
1 (2)
FUNCTION 3.155.6 E rev.: - 2010-10-27
2 (2)
FUNCTION 3.155.7 E rev: a 2010-12-03
Heating and Cooling of Cabinets in Electric Cranes
Anti-condensation Cooling
To keep the moisture away from the electric cabinets, It is of great importance that the frequency converters
all mounting plates have heater elements. They are and line units have enough cooling air. The big modu-
supplied with 24V and are shut off when the crane les have their own built-in fans. The small converters
starts. need an additional cooling through a separate fan in
the door. It is important to replace the air filters in the
Heating cabinets refer to instruction "Maintenance Chart" in
section 5 in the manual.
To achieve a good climate for the frequency
converters each cabinet has thermostat controlled
heaters. The temperature inside the cabinets is
measured with temperature sensors. The control sys-
tem only allows the crane to start if the temperature
inside all the cabinets is more than 0°C. The crane
computer tells if the temperature is too low in any of
the cabinets.
1 (2)
FUNCTION 3.155.7 E rev: a 2010-12-03
Position of heaters and fans in the

electric cabinets
All fans and heaters are labelled in the electrical

system specification.
M8 Fan with filter for the airflow of cabinet

CT2.
See instruction "Maintenance Chart" in
section 5.
EH3/10 The heaters in the cabinets CT2 and

CT10 are controlled by thermostats.
The thermostat in cabinet CT2 is not
adjustable.
Adjustment of the thermostat in cabinet
C10, see the electrical system
specification.
R1, R2, R3 Heater elements for the anti-condensation

in cabinets CT1/CT2, CT10 and CT14.
CT2.
section 5.
R4, R5, R6 Heater elements for the anti-condensation

in cabinet CT13.
EH13/14 The heaters in the cabinets CT13 and

CT14 are controlled by thermostats.
Adjustment of the thermostats, see the
electrical system specification.
CT2.
section 5.
CT14.
section 5.
2 (2)
OPERATION PM40 1885-E00 rev.: a 2012-02-02
CREW CHECK LIST

BEFORE OPERATION
Note! When the crane is rigged ready for operation, all keys for all lockable switches must be stored in a safe place
by the responsible officer on board.
Read sections Operation and Maintenance in the instruction manual and make sure that maintenance is done
refer to Maintenance Chart.
Make sure that nobody enters the crane without permission from responsible officer on board.
Make sure that there is nobody in the crane house, who might be caught in the machinery or strangled by the
wire ropes.
Below checks and procedures must be done before operation.

Note: To lubricate the slewing bearing slew the crane at least one revolution before operation.
Make sure that the heating fans keep the crane house temperature above -10°C. This is necessary for the
operation of the frequency converters and line filter units.
Summer - Heating fans Oil level and oil temperature
Make sure that:
- The hydraulic oil level is sufficient
- The oil temperature in the oil tank
is more than +5oC
1 2
- The oil level in the slewing and
winch gears are sufficient.
Unclamp jib and loose gear

Set the summer switch Set main switch Unclamp jib and loose gear from its
to position "1" if ambient in cabinet CT1 to parking position.
temperature is more than position "1".
+15°C.
Winter - Heating fans
Wires and sheaves

1 2 Make sure that:
- The wires run correctly in the sheaves
- The wire ends are correctly clamped.
Set the two position switch Set main switch

to position "2" if ambient (Q1) in cabinet
temperature is less than CT1 to position
+15°C. The heating fans "1" approximately
turn off when crane house 24 hours before
temperature is more than operation.
+15°C.
1 (4)
DURING CRANE OPERATION

List Trim
Make sure that the ship does not list more than 5 Make sure that the ship does not trim more than 2 de-
degrees. grees.
Max 5
Max. 2
IF CRANE DOES NOT START IF CRANE STOPS

Do below check: Do below checks:
- Make sure that the emergency stops are not oper- a. Crane overheated (indicated on display in cab-
ated. in).
Reset all the emergency stops, see instruction - Examine motor circuit breakers for all fan motors.
"Controls and Indicators" in section 4. b. Overcurrent
- Examine all circuit breakers in cabinet CT1.
c. Oil level
- Examine oil level in oil tank.
- Fill oil if necessary. (See Lubricating Chart).
d. Current setting list
- Examine current setting list inside the
electric cabinet door CT1.
- Change current setting, if necessary.
AFTER CRANE OPERATION

Park the crane
Park the crane refer to separate instruction in sec-
tion 4 of the instruction manual.
2 (4)
AFTER SEA STOWING

Anti-condensation heating
e anti-condensation heaters are powered when the
crane's control system is off.
Examine that all the heating elements in the electronic

cabinets operate.
C-00218
Also see instruction "Crane control system CC3000"
in section 3.
C-00221
Heating elements in CT10 cabinet
C-00216
Heating elements in CT2 cabinet Heating elements in CT13 cabinet
C-00220
C-00217
Heating elements in CT1 cabinet Heating elements in CT14 cabinet
3 (4)
4 (4)
OPERATION PM40 5500-E00 rev.: b 1996-08-08
OPERATING INSTRUCTION
Handling of dangerous cargo

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

and health in dock work.
The crane is not designed for transport of passengers.
1 (2)
OPERATION PM40 5500-E00 rev.: b 1996-08-08
2 (2)
OPERATION PM40 6494-E00 rev.: - 2011-08-26
OPERATING INSTRUCTION
START - STOP
MacGREGOR cranes are designed for operation in harbour or sheltered water environments where there is no
significant movement of the ship due to wave action.
WARNING!
Only ship's crew is allowed to operate the key switches. Keys must be stored in a safe place by responsible officer.
Notify responsible officer onboard before taking crane into operation.

Make sure that there is nobody in the crane house who might be caught in the machinery or strangled by the wire
ropes.
When using grab or magnet, handling log or palletized cargo the lifting capacity must be reduced to 80% of SWL
if there is no "GRAB" switch in cabin.
BEFORE STARTING
Read instructions carefully before crane operation.
Make sure that the control levers are in neutral position. If not, notify
responsible officer.
START STOP
WARNING
LIGHT
START STOP
1 0
Push pushbutton, position 1 (START) to start the crane. - Let go of control levers
The crane starts within 20 seconds and is operational - Push pushbutton, position 0 (STOP). The crane
when the red warning light goes off. turns off within 3 seconds.
Do not operate on red light.
1 (4)
EMERGENCY STOP
If the crane gets out of control...

- LET GO both control levers; they will return automatically to their neutral positions.
- Push Emergency Stop button!
WARNING!
Do not push Emergency Stop when "Brake, low oil level" lamp is on.
The load can fall uncontrolled.
Lower the load slowly in case of emergency when "Brake, low oil level" lamp is on.
CRANE OPERATION
CONTROL LEVER, CONTROL LEVER,

SLEWING / LUFFING HOISTING / LOWERING
Luffing out Lowering
Slew left Slew right Neutral
Luffing in Hoisting
With the slewing/luffing control lever in neutral, the With the hoisting winch control lever in neutral, the
brakes are engaged. winch brake is engaged and holds the load.
Moving the lever a short distance from neutral releases Moving the hoisting winch lever in hoisting or lowering
the brakes. The load stands still at brake opening. direction releases the winch brake. The load stands still
at brake opening. The maximum speed is depending
Moving the lever left or right starts the crane to slew on the load.
in the direction chosen.
Moving the lever forwards or backwards starts opera-

tion of the luffing winch.
2 (4)
DURING CRANE OPERATION
Max 5
Max. 2
List Trim
Make sure that the ship does not list more than 5 Make sure that the ship does not trim more than 2 degrees.
degrees.
LIFT LOADS
Dragging loads is not permitted!
Do not drag loads - lift them.
SHORT BREAKS IN OPERATION

... or if a technical malfunction has developed:
1,5 m
- Raise hoisting block to approx. 1.5 m below jib head,
if possible.
- Return control levers to neutral.
- Push STOP button.
3 (4)
4 (4)
Controls and Indicators

CT3 Display CT3
Luffing out Lowering

32 31
Slew Slew
left right
Luffing in Hoisting
Fig. 1. Controls and indicators in the crane cabin.
Warning!
Only ship's crew is allowed to operate key switches. H3 BRAKE FAILURE
Indicator light. Comes on when an error is sensed in
WARNING! the brake system. Carefully lower the load and park
Store Keys Safely the crane in its support and stop the crane.
When the crane is rigged ready for operation, all keys
for all lockable switches must be stored in a safe place R
by the responsible officer on board. H4 RESET EMERGENCY STOP
Pushbutton with indicator light.
H1 DO NOT OPERATE The indicator light comes on when the emergency stop
Indicator light. Comes on during starting sequence button(s) is/are pushed. The crane cannot be started.
of the crane (main electric motor and supply to elec- - To reset the emergency stop indicator light, stop
tronics). the crane.
- Push the "RESET EMERGENCY STOP" button.
! - Start the crane again. Use pushbutton START/
H2 CONTROL SYSTEM ERROR STOP S13.
Indicator light. Comes on when an error is sensed by - If the pilot light still illuminates any of the emergency
the crane control system in the electronic cabinet CT2. stops operate. Make sure that all emergency stops
are reset.
1 (6)
H5 BRAKE, LOW OIL LEVEL S17 SIREN

Indicator light. Comes on as a warning for low oil level Pushbutton. Starts the siren.
in the brake unit. If light comes on, lower the load and
fill oil in the brake unit oil tank.
J
WARNING!
S18 JIB LIGHT
Do not push Emergency Stop when "Brake, low oil
Pushbutton. Switches on/off the jib light.
level" indicator light is on. Lower the load slowly. Check
for possible oil leaks. Fill oil to the correct level.
P
0
1
!
H6 OVERLOAD
S20 PARKING OF JIB
Indicator light. Comes on at overload.
Key switch with two positions, 0/1.
0 - Normal position
1
1 - Parking
0 The parking position is used when maximum outreach
S13 START / STOP
is reached for the jib. Further lowering is possible for
Pushbutton with two positions, 1/0:
parking of the jib when switch is in parking position "1".
1 - Start
Position “1” starts the complete crane. During the
starting sequence the ”DO NOT OPERATE” indicator 0
1
light comes on.
S22 WIPER
0 - Stop
Switch. 0/1 (On/Off). Starts and stops the window wiper.
Position “0” stops the complete crane. The power
supply to the main electric motor and electronics will
be broken.
0
1
R
S23 CAB LIGHT
F14 RESET WIPER Switch. 0/1 (On/Off).
Pushbutton. Resets the wiper motor (automatic fuse),
when the wiper motor has stopped due to a surge in
current.
0
1
RGENC
ME Y
S24 CAB HEATER
E
Switch , 0 / 1(On/Off). Starts and stops the cabin heater.

S15 EMERGENCY STOP
Pushbutton. Stops the complete crane in case of
emergency. The pushbutton has to be reset, otherwise
0
the crane cannot be started again. 1
S25 FAN 0/1

D Switch, 0 / 1(On/Off). Starts and stops the ventilation
S16 DECK LIGHT fan in the cabin.
Pushbutton. Switches on/off the deck light placed
under the cabin.
2 (6)
S31 CONTROL LEVER, HOISTING/LOWERING

0 1 Note! Joystick for hoisting/lowering motion must be in
neutral position when starting the crane. If the joystick
S26 CARGO / GRAB HANDLING has been moved in any direction when pressing the
Key switch with two positions, 0/1. start button the motion is blocked. Move the joystick
to neutral position then operation is possible.
0 - Cargo
Normal SWL. When the control lever is in neutral position the brake
is engaged and holds the load. Moving the control
1 - Grab lever in hoisting or lowering direction gives an input
- Reduced SWL for operation with grab. to the electric motor, the motor is magnetized and the
- Interlock connection of "grab control equipment". brake is released.
See instruction "Installation of Power Supply Cable The hoisting speed is dependent of the load. To give
…", section 6.3. a smooth acceleration and retardation to the winch
movement the control system contains a function for
ramp forming.
The ramp time is the time it takes to increase the winch

speed from standstill to maximum speed, when the
control lever is moved rapidly from zero to maximum
speed position. In the same way it also takes the cor-
responding ramp time to decrease the winch speed
from maximum speed to standstill, if the control lever
is dropped.
The ramp time is based on that acceleration is constant

regardless of load. The ramp time for retardation is the
same regardless of current maximum speed, see Fig. 2.
The ramp time for the hoisting system is 2 seconds.
With the control lever in neutral position the brakes

are engaged.
Control lever movement
Start - acceleration Retardation -stop
Speed Empty hook
Max. load
Time
2 sec. 2 sec.
Acceleration Retardation
Fig. 2. Hoisting/Lowering.
3 (6)
S32 CONTROL LEVER, LUFFING/SLEWING
Note! Joystick for luffing motion must be in neutral Control lever movement
position when starting the crane. If the joystick has
been moved in any direction when pressing the start
button the motion is blocked. Move the joystick to
neutral position then operation is possible.
Start - acceleration Retardation - stop
With the control lever in neutral position the brakes
are engaged. Empty hook
Speed
Moving the control lever short distance from neutral Max. load
gives an input to the electric motors, the motors are
magnetized and releases the brakes for luffing winch
or/and slewing machinery.
Time
Moving the control lever furthermore in luffing or
slewing direction means continued speed increase 3 sec. 3 sec.
from zero to maximum speed.
To give a smooth acceleration and retardation to the

luffing winch movement and the slewing movement, Fig. 4. Slewing.
the control system has a function for ramp forming.
The ramp time is the time it takes to increase the speed

for the luffing winch or the slewing machinery from
standstill to maximum speed when the control lever is
moved rapidly from zero to maximum speed position.
In the same way it also takes the corresponding ramp
time to decrease the speed for the luffing winch or
the slewing machinery from maximum to standstill if
the control lever is dropped.
The ramp time for luffing is 2 seconds and for slewing

3 seconds. See Fig. 3 and 4.
Control lever movement
Start - acceleration Retardation - stop
Empty hook
Speed
Max. load
Time
2 sec. 2 sec.
Fig. 3. Luffing.
4 (6)
Cabin Display
The display gives the real-time information about the

status of the crane during its operation. The informa- CONTROL LEVER INDICATOR, (S32)
tion presented depends of the crane's configuration.
The circle with four green arrows represents the left
The application in the display is called MacHeavyvisor, control lever and the four motions it controls. (Luffing
see section 7. in/out and slewing left/right)
Note! If there is no communication with the CC3000 Note! If an arrow goes yellow the motion is speed
system, the message "Disconnected" will appear on reduced by CC3000. If an arrow is crossed with a
the screen. white cross, the motion is not permitted by CC3000.
In case of overload indicated by CC3000 there will be

an audible alarm and a text warning.
LOAD DIAGRAM
The default view includes a load diagram with a white

marker, that shows the current load and outreach. CONTROL LEVER INDICATOR, (S31)
The specific diagram for this crane can be found in The circle with two green arrows and a small white ball
Technical Data in section 2 of this manual. represents the right control lever and the two motions
control hoisting and lowering.
During operation of the hoisting winch, the white ball

will move along the circle to indicate the direction and
LOAD IN HOOK speed during hoisting and lowering. Clockwise rota-
The current load in the hook. If the value exceeds the tion means hoisting and counterclockwise rotation
overload limit the box background will flash in red and means lowering.
an audio warning is also given. The overload informa-
tion is indicated by CC3000. Note! If an arrow goes yellow the motion is speed
reduced by CC3000. If an arrow is crossed with a
white cross, the motion is not permitted by CC3000.
JIB OUTREACH
The current jib outreach. When reached the limit the
box will flash in yellow.
HOISTING/LOWERING SPEED
The current hoisting/lowering speed in m/min.
5 (6)
Electric Cabinet CT1
1 2 CT2
S50 SUMMER/WINTER
Switch with two positions, 1/2, that controls the heating
fans in the upper and lower parts of the crane house.
1 - Summer - Heating fans

Set the two position switch to position "1" if the crane
house temperature is more than +15°C.
Set main switch (Q1) to position "1".
2 - Winter - Heating fans

Set the two position switch to position "2" if the crane Hour meter
house temperature is less than +15°C.The heating fans
turn off automatically when crane house temperature S50
is more than +15°C.
Set main switch (Q1) to position "1" approximately 24
hours before operation.
Socket
RGENC
ME Y
E
S51 Emergency Stop

S51 EMERGENCY STOP
Pushbutton. Stops the complete crane in case of Q1
emergency. The pushbutton has to be reset, otherwise
the crane cannot be started again. CT1
Q1 MAIN POWER SWITCH Fig. 5. Electric cabinet CT1/CT2.

Switch with two positions 0/1 (OFF/ON).
0 - OFF 1
Stops the power supply to the electric cabinet CT1. S52 CRANE HOUSE LIGHT SWITCH
Switch. 0/1 (On/Off). Turns on and off the crane house

1 - ON lights. Switch is installed on the roof of the pedestal.
Starts the power supply to the electric cabinet CT1.
WARNING!
Some components in the crane are still energized ME
RGENC
Y
E
when the main power switch is off. Refer to electric

diagram for information about energized components. S71 EMERGENCY STOP
Pushbutton. Positioned at the bottom of the pedastal

(deck level) near the access door.
Stops the complete crane in case of emergency.

The pushbutton has to be reset, otherwise the crane
cannot be started again.
6 (6)
OPERATION PM41 0001-E rev.: - 1994-06-16
EMERGENCY ESCAPE INSTRUCTIONS

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

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

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

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

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

reverse it after each lowering operation.
1 (2)
OPERATION PM41 0001-E rev.: - 1994-06-16
2 (2)
EMERGENCY ESCAPE INSTRUCTIONS

Rope Ladder / Fixed Ladders
Leaving Crane Operator's Cabin Using
Rope Ladder 1
1. Exit through the window to the escape ladder on

the outside of the cabin. See Fig.1 pos.1.
2. Release the rope ladder from the bracket by remo- Rotating
ladder
ving the straps and pull the rope ladder out and let Emergency
it fall towards the deck. See Fig.1 pos. 2. ladder
Hand rail
1
Fixed ladder Foot rail
Deck level
Strops
Fig. 2. Fixed emergency ladders.
Emergency rope ladder attached to bracket

After the emergency rope ladder has been used it is
important that the emergency rope ladder is put back
correctly, see Fig. 3.
Fig. 1. Emergency rope ladder.
Leaving Crane Operator's Cabin Using

Emergency Ladders
1. Exit through the window to the emergency ladder

on the outside of the cabin. See Fig. 2 pos. 1. Fig. 3. Emergency rope ladder attachment.
1 (2)
2 (2)
OPERATION 4.620.31 E rev.: - 2012-01-12
Parking the Crane, Sea Stowing

General Instruction
General 2. Secure lifting block to deck with lashing lines, the

lashing needs to have a manual stretching screw,
Prior to sea voyage the crane should be parked cor- fibrestrops with low ultimate load or similar. See Fig.
rectly. Parking according to recommendations will re- 2.
lieve mechanical equipment from unnecessary stress 3. Tighten the lashing manually. Do not exceed 50 kN
during sea voyage and extend the lifetime of the com- pulling force on lifting block.
ponents.
CAUTION!
Parking jib in support It is strongly recommended to tighten and loosen lash-
ing lines manually. The lifting block will start to hoist
When the jib enters the parking area beyond maximum when the brake in the winch is released, which can
outreach the function “Force Limitation” is automati- cause damage to lashing lines.
cally activated and limits the pulling force and speed
for hoisting, luffing, and slewing motions. See also
instruction “Limit switches…” in section 6.3. PARKING OF JIB
0 0
1. Place the jib at maximum outreach above the jib 1 1
support.
2. Turn key switch “PARKING OF JIB” to position “1”
and lower the jib. See Fig 1. The key switch is spring
loaded and must be held in position “1” until the jib Fig.1. Key switch on control panel, "Parking of Jib".
reaches the jib support.
3. Place the lifting block in correct parking position.
4. Stop the crane.
Securing of jib in support by lashing lifting block

to deck
1. With the lifting block in its parking support it is nec-

essary to secure the jib prior to sea voyage.
Rope connec-
tion
Stretching
screw turn-
buckle Note! Hand-tighten
Deck only to the extent that
the tightening gear is
not slack.
Fig. 2. Jib parked on support and hook secured to deck.
1 (4)
OPERATION 4.620.31 E rev.: a 2012-01-12
Jib parking arrangement with hatch covers open
Note! The hatch cover can not be in open position

when lowering the lifting block down to deck store
level. The lifting block must be forced by manpower
to its parking position and lashed above deck store.
UPPER DECK UPPER DECK
Fig. 3. Jib parking arrangement with lifting block angled to deck.
C-00255
Fig. 4. Jib parking arrangement with lifting block at right angle to deck.
2 (4)
OPERATION 4.620.31 E rev.: - 2012-01-12
Parking of cranes shoulder to shoulder, with jib

support welded to the foundation
Fig. 5. Cranes parked should to shoulder.
Service platforms
Standing on the service platforms it is possible to
lubricate the wire sheaves on the jib top (central lu-
brication). See also instruction in section 4.
Warning! Risk of falling down. Use safety belt!
Fig. 6. Service platforms.
3 (4)
OPERATION 4.620.31 E rev.: a 2012-01-12
Extra equipment (optional)

Parking suggestions of electro-hydraulic grab
It is recommended to park the grab separately prior
Power cable and stabilizing wire
to sea voyage, this to aviod excessive wear on equip-
Power cable and stabilizing wire should be parked on
ment.
jib top during sea voyage. Parking on hook block is
for temporary use only. See also separate instruction.
Park the grab accordingly to manufacturers recom-
mendation.
Parking suggestions of power swivel
It is recommended to park the power swivel separately The grab should be lowered to the deck when the
from block prior to sea voyage, this to aviod excessive crane is temporarily parked, this to avoid load on the
wear on equipment. wires.
It can be possible to park the power swivel with lifting

block but it is not recommended.
Tighten the lifting block to

deck with four wire ropes
Deck Deck
Angle bar Angle bar
Fig. 7. Power swivel secured to deck. Fig. 8. Power swivel with lifting block secured to deck.
4 (4)
OPERATION 4.630 E rev.: - 1994-02-04
Handling Hatches by Deck Crane
Handling hatches
When pulling hatch covers by means of deck Always check that the pulley blocks are correctly
cranes, it is very important that the pulley blocks are positioned, so that the hoisting ropes cannot deviate
so placed that the hoisting wire can be maintained more than 5°, at the most, from the crane house
very nearly vertical during operation. The crane jib centre line.
should be set at an angle where it will not require
any subsequent shifting in order to achieve the N.B. The capacity of the wire pulling the hatch cover
required lifting height. may limit the force which can be applied by the
crane.
The included angle between the hoisting wire and
the vertical centre line of the crane house must not
exceed 5°.
Fig. 1. Fig. 2.
1 (2)
OPERATION 4.630 E rev.: - 1994-02-04
2 (2)
OPERATION 4.630.7 E rev.: - 2011-04-01
Emergency Operation of Hatch Covers by Deck Crane
Emergency operation of hatches Connection before operation
General
This instruction is only applicable to hatches adjecent
to the crane, see Fig. 1.
Emergency operation of hatches with crane is only
a temporary solution when all normal handling does
not work.
Operate crane in as slow speed as possible and with
great caution when lifting hatches.
- The crane's full SWL will be used.
- The crane can not open the hatch cover to its fully
open due to the min jib outreach.
1 3 2
- Do not exceed the maximum safe pull of the
hoisting sling wire.
- No extra limit switches are operated for handling
4
hatches.
Before emergency operation with the crane for hatch

covers read the instruction manual for hatch covers
C-00120
held onboard. Make sure you have read all warnings
and understand the function of the hatches.
Fig.1 Connection of sling wire to lifting block and
During crane operation of the hatch covers there must eye on the pedestal
be another person observing the operation from the
opposite side, prepared to stop the operation in case 1. Lifting block
of an equipment malfunction or an emergency. 2. Lifting eye
3. Sling wire
4. Acting cleats
1 (4)
OPERATION 4.630.7 E rev.: - 2011-04-01
Lift the hatch
WARNING!
Make sure that the lifting sling wire is correctly at-
tached to the lifting eye on the pedestal and to lifting
block. If it loosens persons can be hurt and equipment
can be damaged.
CAUTION!
The hoisting wire must be straight. If the angle between
the hoisting wire and the centre line of the crane house Max
exceeds 5o, the luffing winch can be overloaded. 5°
When opening and closing hatches by means of the

Max
C-00124
deck crane, it is extremely important that the hoisting
5°
wire remains vertical during the whole operation. The
hoisting wire must not deviate more than 5o from the
Fig. 3 Sling wire between foundation and hatch, seen
centre line of the crane house. See Fig. 2. Adjust
from above
hoisting wire angle by luffing the jib out or in.
The sling wire between foundation and hatch must
not deviate more then 5° to the left or right from the
lifting eye, refer to Fig. 3.
Max 5°
2
C-00121
C-00119
Fig. 4 Lifting of hatch cover.
Fig. 2 . Handling hatches with crane. 1. Lifting block

2. Lifting eye
2 (4)
OPERATION 4.630.7 E rev.: - 2011-04-01
Maximum lifting height Release sling wire
Maximum lifting height is when the hoisting sling wire When hatch cover is in fully open position make sure
is in horisontal position between lifting eye on the that the folding pairs are in locked position at both
pedestal and the pulley on the hatch cover. Hatch must sides of the hatch cover.
only be lifted to maximum 60°. See Fig 5. Slacken the sling wire and release the chain blocks.
Remove the sling wire.
Carefully lift the hatch cover to max lifting height. Make The crane can now be used for normal operation.
sure that the sling wire holds the hatch cover at max
lifting hight.
Attach chain blocks to eyes on both sides of the hatch

cover and the eyes on the wheelarm. Release the
tension of sling wire. Pull in the hatch cover with both
chain blocks equally operated to fully open position.
1 4 2 3
5 5
C-00123
4 2 3 Fig. 6 Hatch cover in stowed position

Max
60° 1. Sling wire
2. Chain block
3. Lifting eye on wheel arm
C-00122
4. Lifting eye on hatch cover

5. Folding pairs
Fig. 5 Horisontal position of the sling wire, max lifting
height.
1. Sling wire
2. Chain block
3. Lifting eye on wheel arm
4. Lifting eye on hatch cover
5. Horisontal position of the sling wire, max lifting height
3 (4)
OPERATION 4.630.7 E rev.: - 2011-04-01
4 (4)
MAINTENANCE 5.005.70 E rev.: - 2012-01-05
Maintenance Chart
Lubricate crane according to LUBRICATING After 50 operating hours (running-in pe-

CHART. riod)
Daily or before taking crane into operation

Oil tank, power swivel (optional)
- The first oil change see instruction, section 7.
Oil tank, brake unit
- Examine oil level. See instruction "Oil tank, Brake
Unit" in section 5.
Every month
Oil tank, bevel gear hoisting winch

- Examine oil level. See "Hositing Winch" instruction, Escape device
section 6.1. - Visual inspections should be carried out with par-
ticular attention being paid to the condition of the
rope.
Slewing gear
- Examine oil level. See instruction, section 6.1. The
oil quantity is marked on the name plate and in
instruction "Technical Data", section 2.
Every 200 operating hours or every two
Winches gearbox, hoisting and luffing months
- Examine oil level. See Winch instructions, section
Pump, brake unit.
6.1. The oil quantity is marked on the name plate
- Make sure there are no leaks.
and in instruction "Technical Data", section 2.
Limit switches; compare section 6.3 instruction Multiple-disc brake, slewing gear/winches
for stop position
- The drain plug shall be taken out every 200 hours
- Testrun all functions and make sure that they are of operation, to drain off oil that may have been
working properly. collected.
Slack wire switch Slewing bearing screws, studs/nuts

- Function test, see instruction, section 6.3. - Inspect visually the slewing bearing screws or
studs/nuts from deck and inside pedestal. If any
screw or stud/nut shows any tendency to slacken,
Loose gear
tighten all screws or studs/nuts with a torque wrench
- Make sure that the block, beam, hook, swivel, and
or a hydraulic tensioner refer to drawing "Slew-
shackle are intact refer to instruction "Lifting Block/
ing bearing, yard mounting" and "Slewing bearing,
Beam", section 6.2.
mounting", section 9.3.
1 (4)
Wire rope sockets - Wire ropes are inspected refer to stipulations issued
- Make sure that wire rope thimbles are safely se- by classification associations and national bodies.
cured. - Make sure that the wire rope clamps on the wire
- Examine split pin for wear and damage. drums are safely secured.
- Replace, if necessary.
Wire sheaves
Load cell (optional) - Inspect for wear.
- Make sure that the load cell are safely secured. - Make sure that the shafts are safely secured.
Climb protection, jib top

- Inspect the climb protection for wear and damage.
- Measure the play between wire sheave and climb
After 200 operating hours protection. See instruction in section 6.2.
Slewing gear Slack wire device

- The first oil change. (Running-in period 200 hours.) - Inspect rollers for wear or damage.
See instruction, section 6.1.
Electrical equipment including slip-ring unit
Winches gear box, hoisting and luffing - Inspect refer to “Electrical Equipment, General
- The first oil change. (Running-in period 200 hours.) Maintenance” in section 6.3.
See instructions, section 6.1.
Heating elements, cabinet CT2
- Make sure that the elements in cabinet CT2 are
Oiltank, Bevel gear working i.e. get warm.
- The first oil change. (Running-in period 200 hours.)
See instruction "Lubrication Chart", section 5
See instruction "Hoisting Winch", section 6.1 Crane house, foundation and jib welding joints
- Inspect for any sign of cracks.
See "Inspection of Stressed Components and
Structures", section 5.
Oil analysis, oil tank brake unit

Every 500 operating hours or every six - Get a sample of oil and analyse the oil every six
months month.
Hand pump
- Do a functional test of the hand pump refer to in- Oil filter, oil tank brake unit
struction "Emergency Lowering in Case of Com- - Replace oil filter element. See instruction "Oil Tank,
plete Power Failure, Operation of Crane Using a Brake Unit", section 5.
Hand Pump (Optional)", section 6.3.
Air filter, oil tank brake unit

Wire ropes, wire rope clamps - Examine air filter, replace if clogged. See instruction
- Inspect for wear. See instruction "Handling, Instal- "Oil Tank, Brake Unit", section 5.
lation and Maintenance of Steel Wire Ropes" in
section 6.2.
2 (4)
Slewing gear, pinion Oil tank bevel gear, Hoisting winch

- Measure the backlash. - Change oil. See instruction "Hoisting Winch" sec-
Slewing bearing tion 6.1.

- Examine the seals.
Hydraulic accumulators
- Measure the pressure. If necessary, charge again.
Slip-ring unit See instruction “Hydraulic Piston Accumulators”,
- Examine brush holders and wire brushes refer to section 6.1.
instruction in section 6.3.
Fan with air filters in cabinet CT2/ CT10/ CT13/

External access ways
CT14
- Inspect for wear and damage.
- Replace the air filters.
Emergency escape ladder (optional)

Cable winch (optional)
- Inspect for wear or damage.
- V-belt, check tension.
- Slip-ring unit, check.
- Brake discs, check.
- Brush holders, check.
See instruction, section 7.
Every 1000 operating hours or at least
every year
Multiple-dics brake, motor side
- Do a leakage check.
Emergency handpump - Examine the braking torque. See instruction "Winch-
- Change oil. es, Hoisting/Luffing", section 6.1.
Slewing bearing
Slewing gear
- Grease sampling, see instruction " Slewing bearing
- Change oil. See instruction "Slewing gear" in section
grease sampling procedure", section 6.2.
6.1.
Frequency converters
Hoisting winch - Dust deposits inside the device must be removed at
- Change gearbox oil. regular intervals (or at least once a year) by qualified
- Oil analysis . See instruction "Hoisting Winch" sec- personal on line with the relevant safety regulations.
tion 6.1. The unit must be cleaned using dry compressed air.
- The ventilation openings in the devices must never

Luffing winch
be obstructed. The fans must be checked to make
- Change gearbox oil.
sure that they are functioning correctly.
- Oil analysis . See instruction "Luffing Winch" sec-
tion 6.1.
- Cable and screw terminals must be checked regu-
larly to ensure that they are secure in position and
Oil tank brake unit if necessary retightened. Cabling must be checked
- Change oil. See instruction "Oil Tank, Brake Unit", for defects. Defective parts must be replaced im-
section 5. mediately.
3 (4)
Every 2000 operating hours or every two Every five years or every 5000 operating
years hours
Multiple-disc brake, slewing gear Multiple-disc brake, motor side

- Do a leakage check. - Replace the brake discs.
- Examine the discs. - See instruction "Winches, Hoisting/Luffing", section
- See instruction "Slewing Gear", section 6.1. 6.1.
Multiple-disc brake, winches Hydraulic hoses inside crane house

- Do a leakage check. - Examine the hydraulic hoses for damage. See in-
- Examine the discs. struction, section 6.1.
- See instructions "Hoisting Winch" and "Luffing
Winch", section 6.1.
Oil tank, cable winch (optional)

Every ten years
- Drain oil, turbo coupling.
- Drain oil, spur gear.
- Replace all hydraulic hoses. See instruction, section
See instruction, section 7.
6.1.
Oil tank, power swivel (optional)

- Drain oil and clean the reservoir. See instruction,
section 7.
Every four years or every 4000 operat-

ing hours
Slewing bearing screws, studs/nuts

- Tighten all screws or studs/nuts with a hydraulic
screw tensioner or a torque wrench. Tightening
torque, see separate drawing, "Slewing bearing,
yard mounting" and "Slewing bearing, mounting",
section 9.3
- Consult MacGregor Cranes, Service Division, Örn-
sköldsvik, Sweden, before replacement of studs or
screws with any other specifications than recom-
mended.
4 (4)
MAINTENANCE 5.018 E rev.: b 2004-05-24
Inspection of Stressed Components and Structures
Introduction
Stressed parts of the crane structure subjected to This inspection should be performed at intervals ac-
high loads require inspection for signs of cracks and cording to the Maintenance Chart.
other damage at regular intervals.
Note!
Cracks detected at an early stage do not generally Rust on a painted surface does not necessarily
impair the handling safety of the crane unless they mean that there is a crack in the underlying mate-
are not repaired. rial.
For safety reasons, service routines should include

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

A thorough visual inspection is fairly easy to carry ways contact MacGREGOR Cranes, Service De-
out as cracks will generally show by cracking or partment for advice.
flaking of the paint followed by a brownish discol-
oration by rust.
(Inspect welds and surrounding material.)
Example:
Fig. 1. Crane structure. Fig. 2. Parking support.
1 (2)
MAINTENANCE 5.018 E rev.: b 2004-05-24
2 (2)
LUBRICATING CHART PM51 1733-E00 rev.: d 2012-01-11
Item Part of crane (see page 2-4 for location) a b c d e

1 Wire sheaves, Crane house top: 1 nipple/sheave (5-8 nipples) *
2 Wire sheaves, Jib stay: 1 nipple/sheave (1-2 nipples) (if installed) *
3 Wire sheaves, Jib top: 1 nipple/sheave (4-9 nipples) , loadcell jib top (if installed) *
4 Wire sheaves, Lifting block: 1 nipple/sheave (1-2 nipples) *
5 Wire rope sockets/thimble: 2 pcs (in some cases on jib or block) **
6 Swivel, Lifting block (Single) or Lifting beam (Twin): 1 nipple
7 All wire ropes
8 Electric motors: 2 nipples/motor
9 Door hinges: 3 nipples, see Instruction manual section 6.2.
10 Jib bearings: 2 nipples
11 Oil tank, brake unit
12 Air breather cap (or filter), brake unit
13 Oil filter, brake unit
14 Slewing gear
15 Slewing bearing teeth
16 Slewing bearing (10 or 20 nipples, see section 9.3 Slewing specification/Slewing Bearing)
17 Hoisting + Luffing winches, journal bearing: 1 nipple/winch *
18 Hoisting + Luffing winches, gearbox oil
19 Oil tank, bevel gear, winch(es)
20 Oil tank, emergency hand pump
Key to symbols Key to symbols

a Daily Grease for ball and roller bearings
b Every 100 working hours Grease for plain bearings
(or before taking winch into operation, item 17) Grease for wire ropes
c Every 200 working hours or every two months Grease for open spur gears
d Every 500 working hours or every six months Grease for jib bearings
e Every 1000 working hours or every year Oil level, check
Oil filters, replace
Air breather cap, check
Hydraulic oil, replace
Gearbox oil, replace (Replace oil after the first
200 hours, running-in period)
Instructions with supplementary data:

Oil quantity required: “Technical data”, section 2
Maintenance intervals: “Maintenance chart”, section 5
Lubricants: “Lubricants for deck machinery”, section 5
Note! The crane must to be lubricated more frequently in tropical climates.

Note! Lubricate the crane before storage.
Note! If the crane has not been operated for an longer period of time it must be lubricated before operation.
* Check the number of nipples for your crane, see section 9.3. Make sure you apply grease to all nipples.
** Before greasing:
If the jib is parked on parking support: - Park the crane in support and slacken the luffing and hoisting wire.
If the jib is parked in wires: - Lower the lifting block to deck to slacken the hoisting wire.
- Hoist the block up against the jib top to slacken the luffing wire.
1 (4)
5. Luffing wire thimble
1. Wire sheaves
CT2
CT1
CT10
9.Door hinges
8. El.motor CT14
(luffing)
CT13
8. El. motor
(hoisting)
8. El. motor
10. Jib bearing 19.Oil tank, winch (slewing)
bevel gear.
11. Oil tank
brake unit
17, 18 Winch (luffing)
14. Slewing gear
17, 18 Winch (hoisting)
10. Jib bearing
16. Slewing bearing

15. Slewing bearing teeth
2 (4)
Example: Central greased jib top with lifting block and load cell
7. All wire ropes
Load cell
5. Wire rope socket,
hoisting wire
4. Wire sheave,lifting block
3. Wire sheaves
and load cell, 6. Swivel (optional)
central greased
1 Example: Wire sheaves crane top, manually 8 Electric motor

greased Grease nipples
Grease nipples
Grease nipples
3 (4)
16 Slewing Bearing Lubrication

The slewing bearing is lubricated with grease trough grease nipples placed around the bearing. They are in the
foundation between the bearing and the crane house bottom. There are 10 or 20 grease nipples.
Relubricate the slewing bearing when the crane turns. If that is not possible, relubricate bearing through all grease
fittings, then slew the crane approximately 0.2 m at the bearing and relubricate again. Repeat this procedure until
the whole bearing circumference is filled with new grease at the gaps and seals. Approximately five rotations is
sufficient. Use approximately 2 kg grease.
Note! The figure is only an example of a bearing.
1
Grease nipple
C-00226
20 Emergency handpump, oil tank.
Oil filling directly into oil tank.
Oil filling
4 (4)
Slewing Bearing Studs
General Yard Mounting for inner studs and Slewing Bearing

Mounting for outer studs.
The slewing bearing studs are screwed in to correct
detpth and streched with a special tensioning tool 1. Make sure the studs are screwed in at the correct
before the nut is tightend. depth.
2. Stretch the studs with a hydraulic tensioner. Stretch
the stud two times to get correct pre-stressing force.
Inspection of studs 3. Stretch the studs in correct order, see Fig 2.
4. Repeat the process on the first tightened nuts, until
Hit the nuts with a hammer to make sure that the all studs have the correct pre-stressing force. The
studs are tight. If one stud is not tight, all studs must tightening of other nuts reduces the load on the first
be stretched to the correct tension. tightened nuts.
Contact Cargotec Services if you remove/install the

Tighten slewing bearing studs complete crane for the correct assembly and tension-
ing at the slewing bearing studs.
This instruction is valid for both inner and outer studs
on the slewing bearing, see Fig 1. Make sure you use a Note!
correct tensioning tool and that you know how to use it. The drawings are examples for guidence only, type
of bearing and number of studs may be different on
Refer to the spare part pictures for correct assembly of your crane.
studs and correct prestressing force, Slewing Bearing
2 1
X
3 4
C-00227
C-00228
1. Inner studs
2. Outer studs
3. Install depth of studs Fig. 2. Tightening sequence
4. Pre-stressing force
Fig. 1. Slewing bearing studs
1 (2)
2 (2)
Brake Unit
General Oil level check
The oil level is shown (cm) on the level/temperature
The brake unit with oil tank is placed on the crane sensor display, see Fig 1.The oil level must be between
house floor or wall. The pump is located inside the oil 14 and 16 cm. The oil tank has also an oil level dipstick
tank and supplies oil to the control system. The oil to show if there is oil in the tank, see Fig. 1.
returns to tank via a drain line. Refer to "Hydraulic
Brake Function" in section 3 for more info. Note!
If the oil level is to low the "BRAKE, LOW OIL LEVEL"
indicator light on the control panel in the cabin comes
Maintenance
on. Refill oil.
For maintenance intervals refer to the "Lubricating

Chart" and "Maintenance Chart" in section 5. Replace oil
For type of oil and grease refer to "Lubricants for Deck 1. Connect a drain hose to the oil drain, see Fig. 1.
Machinery" in section 5. 2. Open the ball valve to drain the oil.
For oil volume refer to the "Technical data" in section 2. 3. Remove a drain hose, see Fig. 1 item 2.
4. Make sure the oil tank is clean. If necessary, re-
move the tank top and clean the oil tank.
5 6 4. Fill new oil, see Fig. 1.
5. Fill oil until the level sensor display show 16 cm,
or until the oil level is 4 cm below the top of the oil
tank.
4
Oil level/temperature sensor

The display shows the oil level (cm). Refer to "Oil
3
level/temperature sensor, Brake unit" in section 6.3
for more info.
Pressure switch
The display shows the pressure (bar).
2
Replace filters
Replace oil filter and air breather, see Maintenance
1
chart.
1. Oil drain, ball valve G½"

2. Oil filling (drain hose connected)
3. Oil level/temperature sensor
4. Oil filter
5. Pressure switch
6. Oil dipstick/Air breather
Fig. 1. Oil tank, brake unit.
1 (2)
2 (2)
Sampling of Oil to Verify the Cleanliness

in Hydraulic System
General Procedure for oil sampling

This service information describes sampling oil from - Oil temperature in the system should be 40-50oC.
a hydraulic crane system. - Special oil sampling bottles should be used and
can be purchased from oil companies.
This procedure is general and there can be some - Open ball valve 4332, see Fig. 1 and bleed out
differences depending of crane type. approximately 0.5 litre of oil in a bucket. This oil
to be disposed.
Type of oil to be used in the system can be found - Fill the oil sample bottle.
in Section 5. - Send the oil sample to an oil company for
analysis.
When to sample oil The oil company will be able to recommend if the
oil can be further used.
To verify the oil condition, an oil sample should be
Feedback on the oil analysis can also be obtained
taken every six months and sent for analysis. This
from MacGREGOR (SWE) AB.
analysis is done by the oil companies and can be
of different levels. When the result is received, a Procedure if oil sample is showing too high
recommendation is normally given if the oil is ap- contamination
proved or has to be changed.
If the oil analysis shows too high contamination, the
For maximum particle contamination in the system, oil and the filters should be changed. The crane
see Table 1. should be driven for approx. 1 hr and a new oil sam-
ple should be taken and sent for analysis.
Oil tank
Ball valve 4332

Bucket
Oil sample bottle
Fig. 1. Sampling hydraulic oil.
1 (2)
Cleanliness Level Correlation Table
Particles/millilitre
ISO ≥ 5 Micro- ≥ 15 Micro- ACFTD NAS Disavowed
Code meters meters Gravimetric 1638 "SAE" Level
Level, mg/L (1964) (1963)
26/23 640.000 80.000 1000
25/23 320.000 80.000
23/20 80.000 10.000 100
Not
21/18 20.000 2.500 12
OK
20/18 10.000 2.500
20/17 10.000 1.300 11
20/16 10.000 640 10
19/16 5.000 640 10
18/15 2.500 320 9 6
17/14 1.300 160 8 5
16/13 640 80 1 7 4
15/12 320 40 6 3
14/12 160 40
14/11 160 20 5 2
OK 13/10 80 10 0.1 4 1
12/9 40 5 3 0
11/8 20 2.5 2
10/8 10 2.5
10/7 10 1.3 1
10/6 10 .64 0.01
Table 1. Cleanliness level correlation table.
2 (2)
MAINTENANCE 5.421.60 E rev.: a 2011-12-09
Lubricants for Deck Machinery
A. OILS
The oil shall be refined oil containing additives against

Cable winch, turbo coupling (if applicable)
oxidation, rust and foaming, as well as wear inhibitor
Viscosity 22 cSt/40°C (ISO VG 22).
and/or EP additives.
Example: SHELL MORLINA.
Slewing gear unit
Synthetic oil (polyglycol type). Cable winch, spur gear (if applicable)
Viscosity 220 cSt/40°C. Synthetic oil brand.
Viscosity index (VI) 210. Example: MOBILE Glygoyle 30.
Solidification point -30°C or better.
The oil must fulfil specifications according to DIN Hydraulic system, oil tank emergency
51354, FZG stage 12. hand pump
CAUTION! The oil must not be mixed with mineral oil For service in normal conditions:
or synthetic gear oil on PAO-basis. The oil can also Viscosity 34.6 cSt/40o C approx. (ISO VG 34.6 HV).
dissolve paints and some seals. Viscosity index (VI) min. 160.
Example: Shell Tivela S220 or similar. Solidification point -39o C or better.
Example: SHELL DONAX TA (D-21666).
Oil tank, winch bevel gear SHELL SPIRAX S3 ATF MD3
Synthetic oil (polyglycol type). Note!
Viscosity 220 cSt/40°C. Fill up with the same oil type as in the brake unit.
Viscosity index (VI) 210. Do not mix the oil types.
Solidification point -30°C or better.
The oil must fulfil specifications according to DIN
51354, FZG stage 12.
B. GREASES
CAUTION! The oil must not be mixed with mineral oil
or synthetic gear oil on PAO-basis. The oil can also
dissolve paints and some seals. Plain bearings and wire rope sockets
Example: Shell Tivela S220 or similar. Lithium grease with molybdenum disulphide.
Base oil viscosity 150 cSt/40°C.
Hoisting/ luffing winches and bevel gear Dropping point 180°C.
Synthetic oil (polyglycol type). Example: MOBILGREASE Special 530303.
Viscosity 220 cSt/40°C.
Viscosity index (VI) 210. Crane jib bearing
Solidification point -30°C or better. Lithium/mineral oil-based grease.
The oil must fulfil specifications according to DIN NOTE: MUST NOT contain molybdenum disulphide.
51354, FZG stage 12. Example:
CAUTION! The oil must not be mixed with mineral oil SKF LGMT2 or SKF LGEP2. (-30°C to +110°C)
or synthetic gear oil on PAO-basis. The oil can also TEXACO MULTIFAC EP2. (-30°C to +100°C)
dissolve paints and some seals.
Example: Shell Tivela S220 or similar. Roller/ball bearings
Grease with EP additives.
Hydraulic system, brake unit Must withstand wet conditions.
For service in normal conditions: Example: SHELL Alvania EP (LF) 2 (-20 to +130°C).
Viscosity 34.6 cSt/40o C approx. (ISO VG 34.6 HV). Arctic climate: SHELL Albida PPS2.
Viscosity index (VI) min. 160.
Solidification point -39o C or better.
Example: SHELL DONAX TA (D-21666).
SHELL SPIRAX S3 ATF MD3
1 (2)
MAINTENANCE 5.421.60 E rev.: a 2011-12-09
Lubricants for Deck Machinery

Ropes
Grease resistant to salt water and with antirust pro-
perties. (Very thin.)
Temperature range -30 to +100°C.
Viscosity 9.8 cSt/40°C.
Example: FUCHS Cedracon.
Arctic climate: FUCHS Ceplattyn.
Open spur gear units

Grease with good adhesion properties.
Example: SHELL MALLEUS GL95 (-15 to +150°C).
SHELL MALLEUS GL65 (-30 to +150°C
Please contact Cargotec Service Organisation, when

choosing lubricants for extreme temperatures.
2 (2)
How to order
Cargotec Sweden AB
MacGregor Cranes spare parts 6.0
Sjögatan 4G
SE-891 85 ÖRNSKÖLDSVIK, Sweden
Telephone: 46 - 660 - 29 40 00
Telefax: 46 - 660 - 139 77
www.cargotec.com
SERVICE
Hydraulic system 6.1
Mechanical
equipment 6.2
Electrical
6.3
equipment
SERVICE 6.000 E rev.: e 2010-09-08
How to Order Spare Parts
Important details when enquiring or ordering spare parts
Please send your inquiry or order to closest MacGregor global service station, see instruction "MacGregor Global
Services", 6.004.1 E.
To speed up the process we request you to provide us with below information:
State name of company as well as your name
Vessel's name and IMO number (and/or Lloyd's number)
Crane type (see manual or name plate in operator's cabin)
Crane place on the vessel. No. 1 counted from the fore
Crane serial number (see manual or name plate in operator's cabin)
Spare part figure or drawing number. To be found in section 9 in the manual
Part description
Item number from spare part figure or drawing respectively
Part number, if available, from spare part figure or drawing respectively
Quantity required
When you order a wire rope or lifting block, please specify which certificate is needed.
Deadline - when or where in the world do you need the parts?
Delivery details such as: consignee as well as phone and fax numbers
Terms of delivery: by DHL, air freight direct or consignment, by truck or shipping freight
The more you can provide us with above details the faster and more reliable replies and deliveries will be made.
Address:
Cargotec Sweden AB
MacGregor Cranes
Phone: 46 - 660 - 29 40 00
Telefax: 46 - 660 - 139 77
www.macgregor-group.com
1 (2)
6.000 E rev.: e 2010-09-08 page 2 (2)
Tel: 46 - 660 - 29 40 00
Direct: Fax: 46 - 660 - 139 77
Date: ................................................
Spare parts/Service specification

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

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

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

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

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

(b) after any renewal or repair of a stress-bearing
part.
1 (2)
SERVICE 6.000.1 E rev.: c 2007-01-08
2 (2)
SERVICE 6.000.2 E rev.: d 2009-03-05
RETURN FORM
How to return parts from deck crane manufacturing,
installation or guarantee exchange
Delivery address: MacGREGOR Cranes

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

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

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

have to be enclosed.
The above refers only to the return shipment as such.
1 (2)
SERVICE 6.000.2 E rev.: d 2009-03-05
RETURN FORM
To be packed inside return box or parcel
Date:
Sent by:
Newbuilding no.:
Ship’s name:
IMO no.:
Crane place on board:

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

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

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

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

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

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

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

Cargotec Sweden AB SE-891 85 ÖRNSKÖLDSVIK (+46) 660-29 40 00 (+46) 660-139 77
www.macgregor-group.com/cranes Sweden
2 (2)
SERVICE 6.005.10 E rev.: - 2007-03-23
Introduction
Before proceeding to trouble-shooting, the crane ope-

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

used in the circuit diagrams to facilitate tracing the
probable fault in the circuit diagrams, Fig. 2 and 3,
checking the findings afterwards in the crane proper.
Trouble-shooting may thus be divided into a theoreti-

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

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

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

generally does so in actual operation. This means Electric circuit diagram
that the crane operator will often be able to give
valuable suggestions, e.g.: Electric circuit diagram
- Did the crane function fail without warning? Electric circuit diagram
- Was the operating speed first reduced, or did
the movement run irregularly?
- What manoeuvre immediately preceded the
failure?
Fig. 3.
1 (2)
SERVICE 6.005.10 E rev.: - 2007-03-23
As a first check always try to operate the crane and All important pressure adjusting devices are sealed.
at the same time check the status of the trouble- Breaking a seal voids the guarantee unless done with
shooting panel in the CT2 cabinet, according to error the explicit consent of MacGREGOR (SWE) AB.
list and signal overview list, (see instruction in section
6.3).
Check the control pressure at gauge outlet 1. Pressure

setting levels can be found in the pressure setting list
on the hydraulic circuit diagram.
When consulting MacGREGOR for service or advice,

always give the following information at once:
1. Is the fault electrical, electronic, hydraulic, or

mechanical in nature?
2. In which function does the fault appear:
- Hoisting circuit
- Luffing circuit
- Slewing circuit
3. Is the trouble limited to:
- Raising or lowering of the load
- Raising or lowering of the jib
- Slewing right or left
4. Special observations:
- Is the hoisting, luffing, or slewing capacity restricted?
- Do disturbances occur only at certain speeds?
- In the event of abnormal noise:
- To which of the main functions does the noise
pertain?
- Is the frequency of the noise high or low?
- Try to describe the noise (hissing, blowing,
humming, rasping etc.)
5. What is the status of the trouble-shooting panel in
CT2 cabinet?
6. Where have pressures been measured?
- Control circuit pressure, gauge outlet 1.
- Hoisting circuit pressure, 1662.
- Luffing circuit pressure, 2662.
- Slewing circuit pressure, 3662.
Analysis of information collected

By methodical trouble-shooting, it is often possible to
find, at an early stage, the defect producing the faulty
operation, thereby avoiding unnecessary waste of
time.
2 (2)
SERVICE 6.100.11 E rev.: a 2012-02-07
Measures Before Starting, During and After Completed

Service/Maintenance Work
WARNING ! 6. If some special arrangements to the crane are

When it is necessary to search for/or correct faults in the done for testing during the service/maintenance
crane's electrical, hydraulic or mechanical systems with work, these arrangements have to be removed at
the crane powered up, only authorized personnel may completion.
carry out such work.
7. Function test safety items i.e. limit settings, brakes
The following measures must be taken before any etc. must be placed back to their correct positions
service or maintenance work is started. after completion.
1. The jib must be secured preferably in the parking

8. Protections i.e. covers, rails etc. must be placed
support, (see separate instruction).
back to their correct positions after completion.
2. All lifting equipment must be parked/secured.
3. All power supplies to the crane must be isolated.
A. Isolate 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. Dangerous voltage, 700V DC, can remain

charged in the DC-bus for up to 5 min. after the
power switch Q1 is switched off.
WARNING!
Some components in the crane are still energized when
the main power switch is off. Refer to electric diagram for
information about energized components.
C. 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 can start the crane by mistake.
5. When special work has to be done see separate

instructions or contact Cargotec service division.
1 (2)
SERVICE 6.100.11 E rev.: a 2012-02-07
2 (2)
SERVICE 6.120.20 E rev.: - 2010-11-11
Slewing Gear
Assembly of slewing gear
- Install the slewing gear in the crane without using 1

force.
3
- Use the hand pump to release the disc brake
2 a
hydraulically. Input drive sleeve must turn easily.
- Measure the slewing gear backlash (pinion-to-
bearing gear). See description in paragraph
"Measurement and adjustment of slewing bearing
backlash". 5
- The gear backlash may be adjusted by rotating the
gear one or more screw hole divisions.
- Tighten the screws to torque recommended, secure
with Loctite 242 (or a similar compound). We
recommend that you apply a suitable sealing
compound, such as Loctite 640 on the mating
surfaces of the flanged connection.
- Remove the oil filling plug.
- After installation of the gear unit install supplied gear 4
ventilation valve at marked position "a" (optional to

install with a tube turn). See Fig. 1. 6
- If necessary, fill gear oil (see lubricating instructions
for appropriate type; the approximate quantity
needed is given on the name plate).
- Fill the brake disc chamber with hydraulic oil; e.g.
0.1 litre ATF-oil, type A.
Brake surface are sealed with Loctite type 573. Fig. 1. Slewing gear.
- Before the assembly of the electric motor, grease
shaft and gear teeth with a suitable grease for 1. Brake connection
protection against corrosion; we suggest 2. Oil filling plug
OPTIMOLY PASTE White T. 3. Gear ventilation valve
4. Oil inspection glass
- Do a functional test of the slewing gear with the 5. Oil level
electric motor running and pay particular attention 6. Oil drain with magnet plug
to the function of the brake.
Maintenance
Oil level check
Lubrication - Investigate the oil level when the gear is at rest
The slewing gear is splash lubricated. The output shaft and with the brake engaged.
roller bearing is ”for-life” lubricated with ball bearing - Examine the oil level on the oil inspection glass.
grease. - Fill oil if neccessary.
1 (4)
SERVICE 6.120.20 E rev.: - 2010-11-11
Oil changes Overall assessment

- Whenever practicable, let the oil drain while still The maximum permissible amount of foreign matter
hot. Remove also the oil filling plug(s). carried by the oil is some 0.15 per cent of the total
- For oil change open oil drain plug, see Fig. 1. mass of the oil in the gearbox. These impurities must
- At low ambient temperatures, flush the gearbox with be, exclusively, very fine abraded matter (max 25 µ).
a quantity of fresh oil to remove abraded matter If the contamination keeps within these limits,
and contamination products. continued operation of the gear is permitted after the
- Fill the correct amount of oil refer to Technical Data, oil has been changed.
section 2.
If coarser abraded matter (above 25 µ) or flake off
Gearcase and oil inspection material from the gear teeth is found, the gear must
be dismantled, irrespective of the actual amount of
foreign matter present, beginning at the input end of
Sampling oil
the gear.
Get a sample of the gearbox oil for analyse at intervals
as described in the "Maintenance Chart".
Hydraulic-Release Multiple-Disc Brake

To obtain a representative sample, drain the gearbox
during operation and with the oil at operating tempera-
ture. Technical description
The brake comprises the following major components:
Oil discoloration - Brake piston
- Brake cylinder
A darkish or black colour of the used oil suggests
- Disc carrier
that temperatures in excess of 100oC did occur in ope-
- Internal discs
ration, causing accelerated aging of the oil and
- External discs
impaired lubricating properties. In this case the oil
- Sealings
should be changed at shorter intervals.
- Thrust springs
If the oil sample displays a cloudy aspect, it may be

The brake housing is mounted on top of the gearbox,
that water has managed to seep into the oil. The oil
with long assembly screws through the motor adapter
must then be changed a t o n c e, and the gearbox
housing and both parts of the brake housing.
flushed out very thoroughly several times with fresh
oil.
The sleeve disc carrier, with the internal discs, is fixed
on the driven shaft with a shaft key or by splines.
The gearbox should preferably be dismantled for
inspection beginning at the input side, and the
The disc assemblies are pressed together by a set of
components examined for signs of corrosion.
thrust springs and the brake is disengaged by hydrau-
lic power.
Foreign solid matter
- As a first simple test, drop some of the used oil
Maintenance
onto the filter fleece specified. Coarse foreign mat-
The brake is self-adjusting.
ter, if present, will then show up on inspection,
preferably through a magnifying glass.
- A better test may be made by diluting an oil sample Troubleshooting
with n-heptane, passing it through a diaphragm a. Braking torque insufficient
filter, washing and drying it, and weighing it to
determine the mass difference.
2 (4)
SERVICE 6.120.20 E rev.: - 2010-11-11
Motor side
Thrust springs Brake piston Brake cylinder
Pressure oil
connection Sealing
Sealing
Total
thickness Leakage oil
of discs
Disc carrier
Internal discs
External discs
Gear side
Fig. 2. Disc brake.

Attention: Please select the requisite number of thrust springs from parts list "gear".
Test of brake torque may be done refer to below: Measurement of backlash

- Drive the hydraulic motors against closed brakes. The backlash should be measured by a dial gauge or
Brakes shall be able to withstand motor torque a feeler. When slewing the crane, the backlash may
without slipping. vary from one position to another due to some slight
excentricity of the slewing bearing. It is therefore
Note! Test procedure shall be done only for a short recommended to measure the backlash at four
period, a few seconds. positions of the slewing bearing.
- Inspect the brake discs and replace if excessively Proceed as follows:

worn. - Measure the backlash at one spot.
- If discs are coloured dark yellow to blue, the discs - Slew the crane 90 degrees and measure.
have been overheated. Replace discs and springs. - Proceed to measure the backlash at four 90-degree
- Inspect sealings for wear. If sealings are defect position in the bearing.
replace brake cylinder and piston with sealings to - Put the dial gauge on the tooth of the pinion. By
new ones. manual turning at the input, the pinion can be moved
in both directions up to contact with the teeth. Now,
b. Brake heats the tooth flank clearance can be exactly measured
Make sure that the hydraulic pressure is sufficient in on the dial gauge.
order to disengage the brake completely. - Measure the backlash at one spot
- Slew the crane 90°. measure again
- Proceed to measure the backlash at four 90-degree
Measurement and adjustment of slewing positions in the bearing
bearing backlash - Compare the four backlash values.
Backlash values: See drawing "Slewing
An oversize backlash between the pinion and the assembly".
slewing bearing will cause irregularities in the slewing
movement of the crane. Read this instruction carefully The backlash shall be adjusted at the position of the
prior to measurement or adjustment! slewing bearing with the lowest backlash value.
3 (4)
SERVICE 6.120.20 E rev.: - 2010-11-11
Adjustment of backlash
The backlash may be adjusted by turning the entire
gear one or more screw hole divisions.
Do below items:
1
- Slew the crane into the position with the lowest
backlash value.
- Remove all screws holding the gear to crane house
floor.
- Release the disc brake hydraulically by means of a
manual pump.
- Turn the entire gear one or more screw hole
to achieve the desired setting.
To turn the gear, remove the hydraulic motor and
turn the spline sleeve on top of the gear.
2
Note!
The turning of the entire gear may be restricted by the
hoses connected or by space limitations. To overcome
this problem, release the upper part of the gear by just
removing the holding screws, see Fig. 3.
3
Make sure that the upper part can be turned freely.
Turn the entire gear (except the upper part), until the
desired setting is achieved. Watch the hoses!
- Replace and tighten the screws holding the gear

to the crane house floor using ”Loctite 242” or a Fig. 3. Slewing gear.
similar compound.
If the upper part has been removed 1. Upper part.

2. Screws
If the upper part has been removed, clean its contact 3. Screws holding the gear to crane house floor.
surfaces and apply Loctite 640 Sealant or a similar
compound. Make sure not to strain the hoses. Apply
Loctite 242 on the screws holding the upper part, install
and tighten.
4 (4)
SERVICE 6.120.112 E rev.: b 2012-01-02
Winches, Hoisting/Luffing
General brake is automatically released by hydraulic pressure
when the winch rotates. See Fig. 3.
The luffing (upper) and hoisting (lower) winches is
operated by electric motors through a bevel gear and The gearbox is a planetary gearbox. It is filled with oil
an inner gearbox. See Figs. 1 and 2. and has splash lubrication. The gearbox is behind the
brake inside the winch.
The brake is a hydraulic release multiple disc brake. The bevel gear on hoisting and luffing winch has a
Springs keep the brake discs pressed together. The forced lubrication and is filled with oil from oil tank.
1 2
1. Journal bearing, grease nipple

2. Pressure relief valve of gearbox, 0.2 bar
3. Bevel gear
4. Thermo switch, 100°-95° (NC)
5. Oil filler inlet, bevel gear /
11 Pressure release of bevel gear, 0.2 bar
3 6. Oil tank, bevel gear
7. Oil drain, bevel gear
4 8. Oil heater with thermostat, bevel gear
9. Oil sight glass
10 10. Oil drain, gearbox
11. Oil filler inlet, gearbox / Oil dipstick
C-00101
9 8 7 6 5
Fig. 1. Luffing winch
1 2
1. Journal bearing, grease nipple

2. Pressure relief valve of gearbox, 0.2 bar
3. Bevel gear
4. Thermo switch, 100°-95° (NC)
5. Pressure roller
12 6. Oil filler inlet, bevel gear /
Pressure release of bevel gear, 0.2 bar
3
7. Oil tank, bevel gear
4 8. Oil drain, bevel gear
9. Oil heater with thermostat, bevel gear
11 5 10. Oil sight glass
11. Oil drain, gearbox
12. Oil filler inlet, gearbox / Oil dipstick
C-00100
10 9 8 7 6
Fig. 2. Hoisting winch
1 (4)
SERVICE 6.120.112 E rev.: b 2012-01-02
1 11 5. Remove the dipstick.

6. Note the oil level.
7. Put back the dipstick.
2 10
8. Put back the pressure relief valve
3
Replace oil, winch gearbox
Remove the inlet plug before the oil drain plug. Drain
oil while still hot. At low ambient temperature, flush
4 9 out the gearbox with clean pre-heated oil to remove
particles and sediment. See Figs. 1 and 2. Fill oil to
maximum oil level.
5
8 Oil level check, oil tank bevel gear
6 Check the oil level on the oil inspection glass. See
Figs 1, 2 and 4.
7
C-00173
MAX - oil level at top of the inspection glass.

1. Disc carrier MIN - oil level at the bottom of the inspection glass.
2. Inner discs
3. Arrangement of the brake discs
4. Gear side
5. Outer discs
6. Pressure valve / Air filter / Oil leak MAX. oil level
7. Pressure unit
8. Piston
9. Motor side
10. Pressure springs MIN. oil level
11. Connection, pressure oil
Fig. 3. Disc brake
C-00104
Maintenance Fig. 4. Oil sight glass, oil tank bevel gear
For maintenance intervals and number of grease nip-

Replace oil, oil tank bevel gear
ples refer to the "Lubricating Chart" and "Maintenance
Chart" in section 5. Replace oil in oil tank, bevel gear, see Figs. 1 and 2.
For type of oil and grease refer to "Lubricants for Deck Fill oil to maximum oil level, see Fig. 4.
Machinery" in section 5.
For oil volume refer to the "Technical data", section 2. Grease flange bearing
Grease flange bearing, see Figs. 1 and 2.
Oil level check, winch gearbox
Oil level can only be inspected when the winch not Brake
is in operation. Inspect brake for leakage. If leakage is detected in
1. Remove the pressure relief valve oil pressure unit, the complete pressure unit must be
2. Remove the oil dipstick. replaced.
3. Clean the dipstick.
4. Put back the dipstick.
2 (4)
SERVICE 6.120.112 E rev.: b 2012-01-02
Test brake torque by driving the motors against closed Check the hydraulic pressure to make sure that it
brake. is sufficient to open the brake completely. Refer to
On hoisting winch, close the stop cock 1663 for the hydraulic diagram.
pressure to the brake.
On luffing winch, close the stop cock 2661 for the
Adjustment of pressure roller (if applicable)
pressure to the brake.
After replacement of wire the pressure roller must be
Drive the motors only for a few seconds, the winch
adjusted. Refer to Fig. 5.
drum must not rotate.
1. Tighten adjusting nut carefully until the pressure

Inspect brake discs and replace if excessively worn.
roller touches the hoisting wire on the drum.
If brake discs are colored dark yellow to
2. Tighten adjusting nut 12 turns to get correct
blue, the discs have been overheated. Replace discs
spring force.
and springs.
3. Secure with the locking nut.
3 2
1. Adjusting nut
2. Locking nut
3. Pressure roller
Fig. 5. Hoisting winch with pressure roller
3 (4)
SERVICE 6.120.112 E rev.: b 2012-01-02
Gearbox oil test

Sampling oil
Take a sample of gearbox oil for inspection at inter-
vals as described in the "Maintenance Chart". The oil
temperature in the gearbox must be at least +40 0C.
Use special oil sampling bottles, you can get them
from oil companies. Take the oil sample from the oil
drain on the winch, see Figs. 1 and 2.
1. Drain 1-2 litres of oil into a bucket. Discard this oil.

2. Fill a oil sample bottle from the gearbox.
3. Send the oil sample to an oil company for analysis.
The oil company will be able to recommend if the oil

can be further used. Feedback on the oil analysis can
also be obtained from Cargotec Services Organisation .
Oil discoloration
A darkish or black colour of the used oil suggests that
temperatures in excess of 100°C did occur in opera-
tion, causing accelerated aging of the oil and impaired
lubricating properties. In this case the oil should be
replaced at shorter intervals.
If the oil sample displays a cloudy aspect, it may be
that water has managed to seep into the oil. The oil
must then be replaced at once, and the gear case
flushed out very thoroughly several times with clean oil.
Disassamble the gearbox for inspection, start at the
input side, and examine the components for signs of
corrosion and/or excessive wear.
Overall assessment
The maximum permitted amount of foreign matter in
the oil is some 0.15 per cent of the total mass of the oil
in the gearbox. These impurities must be, exclusively,
very fine weared of matter (max 25 microns). If the
contamination keeps within these limits, continued
operation of the gearbox is permitted after the oil has
been replaced with new oil.
If any material larger than 25 microns or flakes off
material from the gear teeth is found, the gearbox
must be disassambled.
4 (4)
SERVICE 6.142.5 E rev.: a 2002-01-09
Recommendation for Inspection and

Replacement of Hydraulic Hoses
Hydraulic hoses and couplings assembled

inside crane house
Hydraulic hoses assembled inside crane house If the rubber in the hose is damaged so that the steel
should be inspected for damage every five (5) years, core can be exposed to corrosion the hose should be
see Maintenance Chart in section 5. replaced.
If the rubber in the hose is damaged so that the steel The hose couplings should also be inspected for
core can be exposed to corrosion the hose should leakage and damage of the corrosion protective Den-
be replaced. syl tape. If the corrosion protection is damaged so
The hose couplings should also be inspected for that the coupling can be exposed to corrosion the
damage and leakage. If the coupling is damaged or corrosion protection should be removed and the
severely corroded the hose should be changed. coupling inspected for damage and severe corrosion.
If the coupling is leaking the coupling should be tighte- If the coupling is damaged or severely corroded the
ned at first. If tightening does not help, the hose and hose should be changed.
the mating couplings should be changed, see Fig. 1. If the coupling is leaking the coupling should be tighte-
If the coupling is of flange type the O-ring and screws ned at first. If tightening does not help, the hose and
should be changed, see Fig. 2. the mating couplings should be changed, see Fig. 1.
If the coupling is of flange type the O-ring and screws
Hydraulic hoses and couplings should be changed, see Fig. 2.
assembled on outside of crane house
Replacement of hydraulic hoses
Hydraulic hoses assembled on outside of crane house
should be inspected for damage every two (2) years, All hydraulic hoses assembled inside crane house
see Maintenance Chart in section 5. should be replaced after ten (10) years due to safety
reasons.
All hydraulic hoses assembled on outside of crane
house should be replaced after five (5) years due to
safety reasons.
Hose coupling
Mating coupling O-ring
Screw
Fig. 1. Hose coupling with O-ring. Fig. 2. Flange coupling with O-ring.
1 (2)
SERVICE 6.142.5 E rev.: a 2002-01-09
2 (2)
SERVICE 6.189 E rev.: f 2007-04-11
Hydraulic Piston Accumulators
Function Charging hydraulic accumulators with nitrogen (N2)

A hydraulic accumulator functions as a source of pres- All crane motors must be immobilized.
surized fluid. Conversely, when the pressure falls off,
the accumulator supplies oil to the hydraulic system. 1. Dismount valve guard and unscrew the
protective cap from gas valve.
Note! - Do not bleed hydraulic accumulators! 2. New design, see Fig. 1. Connect the three-way
valve to the gas valve of the accumulator. The
bleed valve should be tightly closed.
Charging equipment
2a. Old design, see Fig. 2. Connect the three-way
To charge hydraulic accumulators, art. nos. see
valve to the gas valve of the accumulator. The
below, MacGREGOR (SWE) AB supply a charging
filling screw of the three-way valve shall be
valve and associated equipment, Fig. 2, comprising:
backed out completely, and the bleed valve
- a three-way valve
tightly closed.
- a 0-25 bar pressure gauge
3. Connect the charging valve, see Fig. 3 to the
- a 0-60 bar pressure gauge
reducing valve at the nitrogen cylinder.
- a 1-metre hose with a W24 connector for nitro-
4. Back out the adjusting screw of the reducing
gen cylinder
valve on the nitrogen cylinder until the valve
- two reduction connectors, W24/32M and W24/14D.
spring is unloaded.
5. Open the nitrogen cylinder valve.
Charging pressure for 388 0362-801: 15 ±1 bar at 20°C.
6. Adjust the reducing valve to the correct charg-
ing pressure.
New design
Valve guard
Protective
Gas valve cap
Protective cap Gas valve Open/close
Valve guard hexagonal nut
Open/close
hexagonal nut
Fig. 1. New design. Piston accumulators.
1 (4)
SERVICE 6.189 E rev.: f 2007-04-11
7. New design, see Fig. 1. Open the hexagonal nut 10. Close the nitrogen cylinder valve.
on the gas valve counter-clockwise to stop, by 11. Open the bleed screw of the three-way valve to
using a 19 mm fork wrench. discharge the pressure in the filling hose.
7a. Old design, see Fig. 2. Screw in the filling screw 12. Adjust the reducing valve to zero.
of the three-way valve but not so tightly that the 13. Unscrew the charging equipment from the nitro-
gas valve of the accumulator is damaged. gen cylinder and from the accumulator.
8. Fill nitrogen. 14. Check tigthness of accumulator gas valve, us-
9. New design, see Fig. 1. Check the nitrogen ing soap water.
pressure when the temperature and the pressure Note! - The protective cap shall be fitted with an
of the gas become stable. When the correct O-ring which must fit correctly into its groove.
charging pressure has been obtained, close the 15. Screw on protective cap of the gas valve.
gas valve by turning the hexagonal nut clockwise 16. After charging the accumulator, fit a lable carry-
by use of the 19 mm fork wrench. ing the charging date and signed by the operator.
9a. Old design, see Fig. 2. Check the nitrogen
pressure when the temperature and the pressure Note! For charging, it is not necessary to install a
of the gas have become stable. When the correct reducing valve on the nitrogen cylinder.
charging pressure has been obtained, again
back out the filling screw of the three-way valve.
Old design
Valve guard Valve guard
Protective cap Gas valve Gas valve Protective

cap
Fig. 2. Old design. Piston accumulators.
2 (4)
SERVICE 6.189 E rev.: f 2007-04-11
Filling screw, to be
used for old design
Pressure gauge
Bleed valve connection
Connector for hose

Connector for accumulator coupling
gas valve
Hose
W24 connector for

nitrogen cylinder
Fig. 3. Charging equipment.
3 (4)
SERVICE 6.189 E rev.: f 2007-04-11
4 (4)
SERVICE 6.214.1 E rev.: a 2007-03-02
Tightening Torques
Studs/Screws and Bolts
Introduction
This instruction applies to studs, screws and bolts Note!

generally, if separate recommendations are not gi- Threads that have been rolled after hardening have a
ven. Apply Molykote R 1000 Lubrication on the threads lower surface notch indicating that the permitted ten-
and under the bolt head. For stainless elements and sion amplitude at fatigue can be about doubled
hydraulic pipe couplings apply Gleitmo paste. compared to threads that have been rolled before
hardening. If the screw has been loaded beyond the
Slewing bearing, studs/screws yield limit, this feature will disappear.
See drawings "Slewing bearing mounting" and

"Slewing bearing yard mounting" in Section 9.3.
Winch bolts
See spare part figure "Winch mounting set" (hoisting)
in Section 9.1.
Phosphatized bolts greased with Molykote R 1000 Untreated bolts greased with Molykote R 1000
(Also valid for bolts greased with Loctite 243 or oil.) (Also valid for bolts greased with Loctite 243 or oil.)
Thread Tightening torque in Nm Thread Tightening torque in Nm

10 Nm ≈ 1 kpm 10 Nm ≈ 1 kpm
M 8.8 10.9 12.9 M 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
14 110 156 187 14 128 181 217
16 169 238 286 16 197 277 333
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
27 826 1161 1393 27 961 1350 1620
30 1127 1582 1901 30 1310 1840 2210
33 1522 2133 2563 33 1770 2480 2980
36 1961 2761 3311 36 2280 3210 3850
39 2520 3543 4248 39 2930 4120 4940
42 3130 4395 5280 42 3640 5110 6140
1 (4)
SERVICE 6.214.1 E rev.: a 2007-03-02
As a rule, always change screws with specified tight- Stainless bolts and hydraulic pipe couplings
ening torque on cranes in operation if the joint has to greased with Gleitmo paste
be opened for some reasons.
Thread Tightening torque in Nm
If any joint has been opened apply Intertuf after tight- d 10 Nm ≈ 1 kpm
ening the joint to avoid rust damage. Austenite (A)
50 70 80
6 3.3 7 9.3
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
2 (4)
SERVICE 6.214.1 E rev.: a 2007-03-02
Strength of screws and bolts
Strength class Min. ultimate strength Min. tensile strength Corresponding strength
N/mm2 (kp/mm2) N/mm2 (kp/mm2) class of nuts
4.6 400 (40) 240 (24) 4

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

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

Forged
3 (4)
SERVICE 6.214.1 E rev.: a 2007-03-02
Tightening Torques
Hydraulic Couplings
The values below presume greasing of threads when

assembling.
Type of Thread Tightening Type of Thread Tiightening

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

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

Grease
O-ring sealed Sealing
4 (4)
SERVICE 6.215.21 E rev.: b 2007-06-08
Service Door (Opening and Closing)

Service and Lubrication of Door Hinges
Warning!
There is a risk of falling down when opening or
closing the service door. Always use a safety belt!
Note! Before opening the service door you should A. Procedure for opening
always check the condition of the door hinges. Also
make sure that the doors are secured before opening, 1. Put on safety belt.
see Fig. 1. 2. Loosen the two nuts (1) and the washer (2), see
Fig. 2.
3. Unhook the eye bolt (3).
4. Swing service door outward.
Note! Do not forget to secure yourself using safety
belt.
5. Release the locking rod (5) from its parking posi-
tion by loosening the chapel strop (6), see Fig. 3.
6. Remove the screw (7) from its bracket.
7. Swing the locking rod (5) and secure it by use of
the screw (7).
1
2
3
4
Fig. 1. Securing service door to top of crane. Fig. 2. Opening service door.
1 (2)
SERVICE 6.215.21 E rev.: b 2007-06-08
B. Procedure for closing
1. Put on safety belt.

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

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

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

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

questions.
2 (2)
SERVICE 6.216.116 E rev.: a 2012-02-16
Rope Reeving Diagram for Cranes Type GLBE-2
Caution!
Number of reeving parts:
It is of utmost importance to grease the wire thimble
Luffing: 5 parts
according to instructions "Lubricating Chart" and
Hoisting: 6 parts
"Lubricants for Deck Machinery".
Warning!
Note!
Make sure that the lockwashers for the wire thimbles
Before rigging slacken the pressure roller on the hois-
are correctly mounted. Risk of injury. see Fig. 2 on
ting winch. See Fig. 4.
page 2.
Note!
Securing of the luffing and hoisting wires, see instruc-
tion "Replacement of Wires, One or Two Fall Rigging",
in section 6.2.
Fig. 1. Rope reeving and securing wire rope thimbles.
1 (4)
SERVICE 6.216.116 E rev.: a 2012-02-16
Luffing wire rope
Hoisting wire rope
Fig. 2. How to secure the lock washers for the wires Fig. 3. Rope reeving for Slack wire safety switch,
and loadcell. hoisting and luffing showing correct wire position in
operation.
2 (4)
SERVICE 6.216.116 E rev.: a 2012-02-16
Adjustment of pressure roller on the - Tighten adjusting nut 12 turns to get correct spring
hoisting winch force. Adjustment shall be done at full drum condi-
tion.
After replacement of wire the pressure roller on the - Secure with the locking nut.
hoisting winch must be re-adjusted.
- Tighten adjusting nut carefully until the pressure

roller touches the hoisting wire on the drum.
- Check that the play (approx. 2 mm) between wire
and pressure roller corresponds to Fig. 4. Adjust if
necessary by changing location (rotation) of frame Full drum
Empty drum
bearings, see Fig. 4. Approx. 2 mm
Approx. 2 mm
Full drum
Empty drum
Pressure roller
Frame bearing Adjusting nut
Frame
Adjust play by rotating Frame bearing

the washer/bearing.
Locking nut
Fig. 4. Hoisting winch with pressure roller.
3 (4)
SERVICE 6.216.116 E rev.: a 2012-02-16
4 (4)
SERVICE 6.222.1 E rev.: a 1998-04-17
Handling, Installation and Maintenance

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

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

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

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

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

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

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

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

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

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

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

shown below.
The aluminum ferrule with mechanical splice.

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

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

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

cessary as to whether the wire rope should be pulled
through the whole reeving system or whether it
should first be wound from the coil or reel onto the
drum and afterwards be reeved into the system.
4 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
Here, special attention must be paid to the hook tional wire ropes one must at least make sure that
block. It must be secured in an upright position so they have the same direction of lay as rope to be
that the rope can be spooled without any fleet an- installed.
gles occuring between the rope and the block´s
sheaves. If the new rope is pulled in with help of the used
one, the two rope ends are often buttwelded to-
gether. A connection of that kind can transfer the
Winding the steel wire rope from the reel twist of the old rope, built up in the reeving system,
onto the drum into the new rope. By that method of installation the
new rope may be extremely damaged.
During the manufacturing process every steel wire
rope receives its preferred bending direction when There are even more reasons why that procedure
being drawn from the wire rope closer by means of is highly problematic: It is true, that when using spe-
a capstan. When delivered to the customer the rope cial electrodes the welded connection presents
is bent in that direction. Make certain that it bends acceptable results in a pull test with a straight rope;
in the same direction when it is wound from the reel but because of the great length of rigid connection
onto the drum. zone the very same connection could break due to
the enormous bending stresses when running over
sheaves.
If that connection is applied, its safety should be

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

size sheaves are used. Vibrations and torsional
stress loads in the rope accelerate fatigue rupture.
11 (12)
SERVICE 6.222.1 E rev.: a 1998-04-17
12 (12)
SERVICE 6.223.26 E rev.: b 2012-02-15
Replacement of Wires, Two Fall Rigging
General - Disengage the slack wire switch by blocking the

spring tensioned roller, which can be done with a
The procedure is general and should be seen as a piece of wood, see Fig. 4.
guidance only. It is important to read and understand - Loosen the hoisting wire rope socket attached to
the instructions below before replacement of wires. the load cell on crane house top with the help of
a shore crane or other suitable crane. Attach the
- Rope Reeving Diagram for Cranes Type GLBE-2, hoisting wire rope socket to the reel before the
section 6.2. hoisting winch wire is wind from the hoisting winch
- Preparation for Rig Mode, section 6.3. drum to the reel. See Fig.13.
- Handling, Installation and Maintenance of Steel - Run the hoisting winch to pay out the hoisting wire,
Wire Ropes, section 6.2. and at the same time pull on the loose wire end.
- Stop the winch just before it enters into the empty
WARNING! drum limit.
Rig mode will disable stop and overload limits. - Stop the crane. Use pushbutton S13 Start/Stop on
There is a risk of severe damage to the crane and the control panel in cabin.
personal injury. - Mark the position of the wire drum in relation to the
bracket, this to avoid setting of all hoisting limits
again after installing the new hoisting wire.
WARNING!
- Remove the cover from the limit switch box.
Jib must be supported, lifting of load is not permitted.
- Mark the position of the shaft in relation to the limit
There is a risk of severe damage to the crane and
switch box. See Fig. 8.
personal injury.
- Remove the limit switch box.
- Measure the empty drum measure AL. See Fig. 2.
Hoisting winch / wire
For cranes with two fall rigging proceed as follows: AL
- Place the jib in the jib rest.
If applicable, park the crane, slewing position locked
with cylinders, and the jib at maximum outreach.
If applicable see also special instruction "Parking
of Crane in Wires" in section 4.
- Place the lifting block in a position where the wire
runs freely in the lifting block, see Fig. 1. AL = Empty drum flange
side/ At least three locking
turns/Tank top
Fig. 2. Hoisting winch.
- Secure the wire so the wire can not pay out and
make sure that the wire clamps that holds the end
of the wire can be removed safely.
- Attach a long rope (longer than the wire rope) to
C-00262
the wire end and place it 4 to 5 turns around the

wire drum.
Fig. 1. Lifting block in right position.
1 (8)
SERVICE 6.223.26 E rev.: b 2012-02-15
WARNING! - Run the hoisting winch to pay out the old (damaged)
Rig mode will disable stop and overload limits. wire until it is on the deck.
It is not permitted to have any load in the hook. - Attach the new hoisting wire to the same rope by
There is a risk of severe damage to the crane and using tool 662 0754-000, see Fig. 5.
personal injury.
Preparation for Rig Mode

- Set the key switch RIG/OL Test (inside cabinet CT2)
in position RIG. See Fig.3.
Error
Input
07 18
MP SP
Output
27
Error
07
Input
MP
Output
33 36
SP Error MP
07
Input
SP
Output
33 36
Error
07
Input
MP
Output
33 36
SP Error
07
Input
MP SP
Output
33 36
Fig. 5 Tool, wire rigging sock, 662 0754-000.
08 19 28 39 43 39 43 39 43 39 43
09 20 29 34 37 34 37 34 37 34 37
08 08 08 08
10 26 30 40 45 40 45 40 45 40 45
11 49 31 09 31 09 31 09 31 09 31
30 30 30 30
12 51 32 10 32 10 32 10 32 10 32
13 56 33 19 Sw19 19 Sw19 19 Sw19 19 Sw19
14 57 34 20 Sw20 55 20 Sw20 55 20 Sw20 55 20 Sw20 55
15 58 35 11 14 Sw14 11 14 Sw14 11 14 Sw14 11 14 Sw14
16 59 36 56 Sw56 56 Sw56 56 Sw56 56 Sw56
17 60 37 12 15 Sw15 12 15 Sw15 12 15 Sw15 12 15 Sw15
24V 38 26 27 26 27 26 27 26 27
Com 39 58 59 58 59 58 59 58 59
40 49 17 29 49 17 29 49 17 29 49 17 29
- Attach the wire rope end to the wire drum with the
53 51 18 53 51 18 53 51 18 53 51 18 53
61 52 54 52 54 52 54 52 54
57 57 57 57
Com Com Com Com
SC
C3
IO
C3
SC Supervisory
A1 C1
HOHoisting
A1 C1
LU Luffing
A1 C1
SL Slewing
A1 C1
AU Auxiliary
A1 C1
IO
A1
Input/Output
C1
wire rope clamps and tighten the bolts. For tighten-
HO_C1
SC_C3
SC_C1
AU_C1
LU_C1
SL_C1
IO_C3
IO_C1
HO_A1
SC_A1
AU_A1
LU_A1
SL_A1
IO_A1
C4 C4 A2 C2 A2 C2 A2 C2 A2 C2 A2 C2 A2 C2
ing torques, see instruction "Tightening Torques..."

HO_C2
SC_C2
AU_C2
LU_C2
SL_C2
IO_C2
HO_A2
SC_C4
SC_A2
AU_A2
LU_A2
SL_A2
IO_C4
IO_A2
485.2 485.2 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1
HO_485.1
SC_485.1
AU_485.1
LU_485.1
SL_485.1
IO_485.1
SC_485.2
IO_485.2
HO_A3
SC_A3
AU_A3
LU_A3
SL_A3
IO_A3
485.3 485.3 Sp SSI Sp SSI Sp SSI Sp SSI Sp SSI Sp SSI

SC_485.3
IO_485.3
HO_SSI
SC_SSI
AU_SSI
LU_SSI
SL_SSI
IO_SSI
HO_Sp
SC_Sp
AU_Sp
LU_Sp
SL_Sp
IO_Sp
in section 6.2.
- Run the hoisting winch by pulling in the new hoist-
Key switch ing wire, so that the AL measure is the same as
RIG/OL Test noted earlier and that the winch corresponds to the
Fig. 3. RIG/OL Test key switch in cabinet CT2. position marked earlier.
- Stop the crane. Use pushbutton S13 Start/Stop on
- Start the crane again. the control panel in cabin.
- A login window will now appear on the cabin display. - Before operating the hoisting winch read prepara-
See Fig 3. tion for rig mode, page 2.
- Exit Rig mode. Set key switch in position Normal.
- Assemble the limit switch box in its proper place,
the marking on the shaft/box must correspond.
- Start the crane again.
- Run in the rest of the wire. Leave enough slack to
secure the wire rope socket.
- Secure the hoisting wire rope socket to the load
cell on the crane house top. See Fig. 15.
- Remove the wooden piece holding the slack wire
roller.
- Run the hoisting winch and check all limits and
examine that the limit switch settings are correctly,
If necessary, adjust the limits according to instruc-
tion "Limit Switches in..." in section 6.3, instruction
Fig. 4. Login window. "Technical Data" in section 2, and calibrate the
encoder according to instruction "Absolute Encoder
- Write the password to accept rig mode, use the Calibration" in section 6.3.
software keyboard on the cabin display.
Adjustment of pressure roller on the
Note! hoisting winch
The password is normally the last four digits of the See instruction "Rope Reeving Diagram for Cranes
Mfg No which can be found in the table of contents. Type GLBE-2" section 6.1
2 (8)
SERVICE 6.223.26 E rev.: b 2012-02-15
Luffing winch / wire - Mark the position of the wire drum in relation to the
- Place the jib in the jib rest or move the lifting block bracket.
up against the jib top. - Remove cover from the limit switch box.
- Disengage the slack wire switch by blocking the Note!
spring tensioned roller, which can be done with a Mark the position of the shaft in relation to the box.
piece of wood, see Fig. 6. See Fig. 8.
Piece of wood
100 x 200
Piece of wood
 100 x 200
Fig. 8. Marking inside limit switch box.
- Remove the limit switch box.

- Loosen the luffing wire rope thimble attached to the
crane house top or jib top with the help of a shore
crane or other siutable crane, and lower wire to
deck by means of a rope, see Fig. 11 or 16.
Fig. 6. Disengage of slack wire safety switch. - Secure the wire so that the wire can not pay out
and that the wire clamps that holds the end of the
- Pay out the luffing winch wire and stop just before wire can be removed safely.
it enters into empty drum limit. - Attach a long rope to the wire end (longer than the
- Stop the crane. Use pushbutton S13 Start/Stop on wire rope) and place it 4 to 5 turns around the wire
the control panel in cabin. drum.
- Note how many revolutions of the wire there are - Start the crane again.
left on the drum at this position. Make a mark on - Before operating the luffing winch read preparation
the drum. Measure the empty drum measure AT, for rig mode, page 2.
see Fig. 7. - Activate Rig mode.
- Run the winch to pay out the old luffing wire, and
Wire lock AT
side at the same time pull on the loose wire end until it
is on the deck.
- Attach the new luffing wire to the rope, by using
tool 662 0754-000, see Fig. 5.
- Run the winch by pulling in the wire so that the wire
rope end just enters into the crane house.
- Secure the luffing wire rope socket on crane house
AT = Empty drum flange top or jib top. See Fig.11,12 and 16.
side/ Stop lowest position/ - Run the winch by pulling in the wire, so that the
At least three locking turns empty drum AT measure is the same as noted
earlier and that the luffing winch drum corresponds
to the position marked when the limit switch box
Fig. 7. Luffing winch. was disconnected.
3 (8)
SERVICE 6.223.26 E rev.: b 2012-02-15
- Attach the wire rope end to the wire drum by the

wire rope clamps and tighten the bolts. For tighten-
ing torques see instruction "Tightening Torques..."
in section 6.2. Limit
switch box
- Stop the crane. Use pushbutton S13 Start/Stop on
the control panel in cabin.
- Exit Rig mode. Set key switch in position Normal.
- Assemble the limit switch box in its correct place.
- Start the crane again.
- Run in the rest of the wire.
Winch drum
- Remove the wooden piece holding the slack wire
roller.
- Run the hoisting winch and check all limits and ex-
Fig.9. Limit switch box, hoisting winch.
amine that the limit switch settings are correctly. If
necessary, adjust the limits according to instruction
in section 6.3 and calibrate the encoder according
to instruction "Absolute Encoder Calibration" in
Winch drum
section 6.3.
Limit switch
box
Tightening torque: See the winch part picture or in-
struction "Tightening torques, studs and screws" in
section 6.2 in the instruction and spare parts manual.
Fig. 10 Limit switch box, luffing winch.
4 (8)
SERVICE 6.223.26 E rev.: b 2012-02-15
Rigging of the luffing wire to crane

CAUTION!
house top
The wire rope thimble must be safely secured by
bending the lock washers, see Fig. 12.
NOTE!
Make sure to grease the wire rope thimble refer to
instructions "Lubricating Chart" and "Lubricants for
Deck Machinery" in section 5.
Luffing
Hoisting
Fig. 11. Example. Rigging of hoisting/luffing wire rope socket/ thimbles to crane house top.
Fig. 12. How to secure the lock washers for the wire Fig.13. How the wire is spooled from the winch drum
ropes and loadcell. on to the reel on deck.
5 (8)
SERVICE 6.223.26 E rev.: b 2012-02-15
Assembly of the hoisting wire/ load cell

on crane house top
It is important to install new split pins when they are

removed. See Fig. 15 and 17.
Fig.14. Example. Assembly of the load cell for hoisting wire.
Install a new split pin

when replacing wire
Hoisting wire rope socket
Fig.15. Example. Securing of the hoisting wire rope socket to the loadcell.
6 (8)
SERVICE 6.223.26 E rev.: b 2012-02-15
Securing of luffing wire rope thimble to

jib top.
Luffing wire rope thimble
Fig.16. Example. Securing of the luffing wire rope thimble to jib top.
Securing of the hoisting wire rope sock-

et to jib top, applicable to cranes with
load-cell.
Hoisting wire rope socket Load cell Install a new split pin
when replacing wire
Fig.17. Example. Securing of the hoisting wire rope socket to jib top with load cell
7 (8)
SERVICE 6.223.26 E rev.: b 2012-02-15
8 (8)
S E RV I C E I N F O R M AT I O N
625/1473 E rev.: c 2010-06-23
Indentation and Wear on Wire Sheaves
General
To ensure safe working conditions and long lifetime The wear, see Table 1, can certainly occur on every
of the wire rope it is important to inspect the condition spot where the wire rope is in contact with the wire
of the wire sheaves. sheave, not only on places shown in Fig. 1.
Wear criterias Indentation

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Class Working load limit Proof load
ABS PL = 2 x WLL
BV WLL < 25 T PL = 2 x WLL
25 T < WLL < 160 T PL = (0.933 x WLL) + 27
WLL > 160 T PL = 1.1 x WLL
DNV PL = 2 x WLL
GL WLL < 25 T PL = 2 x WLL
WLL > 25 T PL = (1.22 x WLL) + 20
LRS WLL < 25 T PL = 2 x WLL
WLL > 25 T PL = (1.22 x WLL) + 20
WLL = Working Load Limit (SWL)
T = 1 metric ton = 1000 kg
PL = Proof Load
2 (2)
625/1579 E rev.: k 2011-10-28
Measuring Procedure for Wear in Slewing Bearings
General at the reference point in the front of the crane and

"B, C" at the reference point at the back of the crane.
Below measuring procedure is valid for the crane Remove excessive wear (burr) from slewing gear teeth
types G, TG, GL, TGL, GLB, H, TH, L, and TL. before measuring.
Note! Measurements shall be taken at four positions of the

The procedure is not valid for measuring the slewing slewing bearing, if possible. With the jib pointing:
bearing under the twin platform. - Forward to the ship
- Starboard
The slewing bearing is an essential part of the crane - Aft
and must be well maintained. Over the years the slew- - Port side
ing bearing will have some wear, and to be able to It is important to use the same position for all further
know if there is a need for changing the slewing bear- measurements to be able to compare the measure-
ing records of the wear are needed. ments.
The initial measurements should be taken when With the jib at maximum outreach two measurements
the crane is installed at yard or within 2 months are to be taken, see Fig. 1.
from crane installation.
With the jib at minimum position one measurement is
If the wear measurement shows wear, grease samples to be taken, see Fig. 2.
can be taken for analysis.
Enclosed table can be used to record the measure-
For slewing bearing grease sampling procedure see ments.
inspection instruction 625/1651 E.
Allowed play for slewing bearing

Measurements should be recorded with an accuracy
Measuring
of 0.1 mm.
The measurements should be taken regularly, every

As a guidence the maximum allowed play is:
6 months. Measurements can be sent to Cargotec
- for roller bearings 1.5 mm
Service Organisation for evaluation.
- for ball bearings 3.0 mm.
Note!
Contact Cargotec Service Organisation for exact maxi-
When measurements are to be taken the ship shall
mum slewing bearing play for your crane.
have as little list/trim as possible.
See Slewing Specification spare part picture or Slew-

Neither a load nor cargo handling equipment should
ing Bearing drawing for type of bearing in your crane,
be attached to the hook.
section 9.3 in spare parts manual.
Procedure
Deviation
First time a measurement is to be taken two reference
The deviation is related to differences in production
points on the crane's bottom plate must be grinded
tolerances and material. For Cargotec a part for a more
and marked. These reference points shall then always
accurat evaluation of the bearing play.
be used at any future measuring, see Fig. 4. Write "A"
1 (4)
625/1579 E rev.: k 2011-10-28
Jib at maximum outreach
Empty hook
Jib direction Jib direction
Measurement B Measurement A
(back of crane) (front of crane)
Fig. 1. Jib in outer position.
Measurement C
(back of crane)
Jib direction
Min. outreach,
empty hook
Fig. 2. Jib at minimum outreach.
2 (4)
625/1579 E rev.: k 2011-10-28
Note!
If there is a machined surface this shall be used as
reference point. In other cases a reference point must
be grinded and marked.
Machined surface/ Machined surface/

reference point reference point
Jib
B,C A
Fig. 3. Machined surface on crane bottom plate.
Remove excessive
Reference point
wear (burr) from slew-
ing gear teeth before
measuring.
Reference point
A
B,C
Fig. 4. Reference points, how to measure
3 (4)
625/1579 E rev.: k 2011-10-28
Vessel name: ...........................................................

Fore Note!
IMO No.: ................................................................... - If B - C = 0 or negative the
Ps Stb measurement is wrong.
Date: ......................................................................... - B - A = deviation bottom plate
crane house + play in bearing.
Crane No.: 1 Aft
Measurement (accuracy 0.1 mm) Play Deviation Jib direction

Jib at max. outreach Jib at min. outreach
A (front of crane) B (back of crane) C (back of crane) B-C B-A
Fore
Stb
Aft
Ps
Crane No.: 2
Fore
Stb
Aft
Ps
Crane No.: 3
Fore
Stb
Aft
Ps
Crane No.: 4
Fore
Stb
Aft
Ps
4 (4)
INSPECTION INSTRUCTION
625/1651 E rev.: a 2012-01-04
Slewing Bearing Grease Sampling Procedure
General
One of the criteria's to evaluate a slewing bearing's - Clean up the seal and the surrounding areas where
condition is to analyse the grease samples. The other the sample will be taken. When cleaning the area
is to make play measurements. The grease analysis of the seal, prevent the cleaner from contacting the
can be done in two steps, simplified or in a laboratory. seals or from entering the raceway's system.
What method to be used must be decided after the - Push new grease into the grease nipples / bearing
play measurement is taken. It must be noted that a without rotation and collect the first used grease
single laboratory test of a grease sample gives very which will come out at the seal.
little information. Laboratory tests must be done on
regular basis to see trends. Attention: Do not take fresh grease for analysing!
The required quantity of grease for analysing is ap-
The play measuring normally tells more about the proximately 3 cm3.
bearing condition than a grease sample. Both methods
provide together the best basis for evaluation of the The normal interval for grease sampling is 6 months.
bearing condition.
If steel particles are seen when the simplified grease
analysis is done or if the laboratory grease analysis
Procedure of grease sampling shows a too high value the grease sampling period
should be increased to each 50 crane operating hours
Following information is necessary in order to give a or every two months.
correct statement and allow further advice:
1. Type of grease used at lubrication (manufacturer

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

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

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

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

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

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

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

SERVICE 6.303.61 E rev.: c 2011-07-14

Card front menus CT2, CC3000

General Depending of crane type there can be

This instruction describes how to use the additional cards. On the front of each card
display and buttons on the Micro Processor there is a display and three buttons: Select/
Cards (MC- and CC) placed inside the CT2- Info, Up and Down/Exit.
cabinet.
Each crane with CC3000 is equipped with at

Note! Depending on equipment or software
least one CC-card and three MC-cards.
versions the number of alternatives may vary.
ϭ
Ϯ
ϯ
ϰ
ϱ
ϲ
1. Error MP (Main Processor) and SP

4. Select/Info
(Safety Processor)
Push the button = Select.
• Flashing diode = there are active
Push and hold the button = Information
errors that have not been
will scroll by on the display.
acknowledged.
• The diode is on (fixed) = there are 5. Up button
active errors but they have been Browse upwards
acknowledged.
• The diode is off = there are no 6. Down/Exit
active errors. Push the button - Browse downwards.
2. Encoder Calibration button Push and hold the button - Exit, back to
top menu.
Used for calibrating encoders
3. Display
See below

ϭ;ϰͿ

SERVICE 6.303.61 E rev.: c 2011-07-14

Display
At “power on” the software version will appear. For more information about errors refer to
To view that in a later stage, see below Troubleshooting CC3000 in section 6.3 in
paragraph 6 VER. the Instruction Manual.
For each card there will be two letters
representing the card. When holding the Select
button the complete name will appear. 2. CAL - CALIBRATION MODE (LOGIN
REQUIRED)
Standard Complete Calibration mode makes it possible to
view name
calibrate one or several encoders and
Sc Supervisor other equipment depending of crane type.
Ho Hoisting Calibration can only be done if Rig-mode
Lu Luffing is on. For more information see Absolute
Sl Slewing Encoder Calibration in section 6.3 in the
Au Auxiliary Instruction Manual.
Cl Closing Each card will be calibrated at a time.
Ec Eccenter For twin cranes, when in twin mode and
Ll Lift Line from the master crane and from card Sc:
Tl Tag Line Left Ho Ll Tl Tr but not Lu will be calibrated.
Tr Tag Line Right
Io Input/Output 3. PLU – Plussing Adjustment
Only on Sc card
Menu tree
All errors must be acknowledged before you Only to be used during commissioning of
can move on to other modes. (Diode must not the crane.
be flashing). There are seven main modes.
Push Select/Info to enter menu tree. 4. CUT – Cut off valve Adjustment
Only on Sc card
1 ERR Error Mode
Only to be used during commissioning of
Calibration Mode (Login
2 CAL required) the crane.
3 PLU Plussing Adjustment
4 CUT Cut off valve Adjustment 5. VAL - VALUE MODE
5 VAL Value Mode
Value Mode makes it possible to monitor
6 VER Software Version
different values. How many values that
Manufacturing number appear is dependent on equipment and
7 MFG (from version ,Ϭϰ͘ϬϬͿ parameter settings.
• Push Select/Info to enter menu tree.
1. ERR - ERROR MODE • Push Down/Exit until the display shows
VAL
Error mode shows all active errors in the • Push Select/Info to select Value Mode
respective control card. • Push Down/Exit until the value is on
• Push Select/Info to enter menu tree. display.
• Push Select/Info to select Error Mode. • Push select to see the value.
• Push Down/Exit or Up to browse
between errors.

Ϯ;ϰͿ

SERVICE 6.303.61 E rev.: c 2011-07-14

Values
Sc Ho Lu Sl Au Cl Ec LL TL TR IO
JOY Joystick % ● ● ● ● ● ● ● ● ● ● ●
AN1 Jib angle degrees (360) ● ● ● ●
AN2 Winch angle degrees (360) ● ● ● ● ● ● ● ● ●
SP1 Speed rpm rpm
SP2 Speed mpm mpm ● ●
PRE Pushure bar
WE1 Weight Dynamic ton ● ●
WE2 Weight max ton ● ●
LIF Lift height m ● ● ●
OUT Outreach m m ●
FOR Hook to hook FOR m m ●
AFT Hook to hook AFT m m ●
AL1 ALM line voltage V ●
AL2 ALM line current A ●
AL3 ALM power kW ●
AL4 ALM DC voltage V ●
PW0 PWM0 mA ● ● ● ● ● ● ● ● ●
PW1 PWM1 mA ● ● ● ● ● ● ● ● ●
PW2 PWM2 mA ● ● ● ● ● ● ● ● ●
PW3 PWM3 mA ● ● ● ● ● ● ● ● ●
PW4 PWM4 mA ● ● ● ● ● ● ● ● ●
AI1 "Parameter" Parameter value ● ● ● ● ● ● ● ● ● ● ●
CAR Card Temperature Degrees ●
MFG.
6. VER - SOFTWARE VERSION
• Push Select/Info to see the MFG-
Software Version makes it possible to number
read the version of the software. This will
also appear at “ power on”.
• Push Down/Exit until the display shows
VER.
• Push Select/Info to select Version
Mode
7. MFG – MANUFACTURING NUMBER

From software version CC3K H04.00 it is
possible to see the manufacturing number
of the crane.
• Push Down/Exit until the display shows

ϯ;ϰͿ

SERVICE 6.303.61 E rev.: c 2011-07-14

d,/^W'/^/EdEd/KE>>z>&d>E<

ϰ;ϰͿ

SERVICE 6.303.66 E rev.: a 2012-01-10
Troubleshooting Crane Control System CC3000

Electric crane GLBE
CT2 Cabinet
Contents
1. Description of input and output signals ............................................................................................. 2
2. Control system input and output signal levels................................................................................... 6
3. Troubleshooting for the control system............................................................................................ 9
4. Spare parts ....................................................................................................................................... 11
1 (10)
SERVICE 6.303.66 E rev.: a 2012-01-10
Error MP SP
Display
Select / Info
Up
Down / Exit
Backplane
Fig 1. Crane Control System CC3000
1 Description of input and output signals

specifically to your crane, will be found in the
1.1 General instruction manual, section "Spare Parts", Group
The following description refers to the 9.5.
microcomputer based crane control system
CC3000 for MacGREGOR hydraulic deck cranes. 1.2 Power supply, Control system
operation
Minor variations in the use of control system input
The power supply transforms the input
and output signals due to differences in hydraulic
380/400/440V AC to 24V DC. See Fig. 2.
and electric system may occur, the objective of this
description is only to provide a general orientation
It consists of a three-phase power supply. The
concerning the principles of control system
output 24V DC is divided into two supplies, one for
interface signals and of troubleshooting.
the control system and its output signals (terminal
48) and one for the limit switches, pressure
For a general description of the principles of the
switches (terminal 42). There are fuses on each
Crane Control system CC3000 see "Function",
supply in the CT1 cabinet.
section 3. For detailed information about the control
system a complete electric circuit diagram, relating
2 (10)
SERVICE 6.303.66 E rev.: a 2012-01-10
The 0V level for 24V DC is grounded in power condensation heating in the crane. A separate
supply unit. power line feeds the power supply.
1.4 Control levers - potentiometers,

outputs to and inputs from
The control levers linear potentiometers are fed
with 0V, +6V and +12V from their appropriate MC
and CC card. The potentiometer output is approx.
+6V with the lever in neutral. The output signal is
controlled by the lever and is depending on the
direction of lever movement. The output signal is
increased to approx. +10.5V for maximum speed
hoisting, luffing in, and slewing left respectively.
The output signal is decreased to approx. +1.5V for
maximum speed lowering, luffing out, and slewing
right respectively.
1.5 Control levers - direction signal

inputs
Fig. 2. CC3000 Power supply principle.
The control lever for hoisting selects two out of four
24V direction signals, for selection of
1.3 Power supply, Control system anti- hoisting/lowering. See Fig. 2. The control lever for
condensation heating luffing/slewing gives two out of four 24V direction
The anti-condensation heating in CT2 cabinet is signals for selecting luffing in/luffing out and
powered with 24V DC when the control system is slewing left/slewing right.
switched off and the crane is not in operation. A
separate power supply is used for all anti-
Fig. 2. Control lever signals, hoisting movement
3 (10)
SERVICE 6.303.66 E rev.: a 2012-01-10
1.7 Lamp output "Control System Error

1.6 Brake release outputs in CT2"
Each MC card has an output driver for the brake The LED no 28 on the CC Card are wired to a lamp
release signal. The system is capable of detecting in crane operator's cabin. The first time an error
short-circuited output and then giving an error- occurs, the lamp flashes. When the error is
message, see sign ERROR MESSAGES. acknowledged by pushing the Select/Info push-
button on the appropriate MC or CC card the lamp
is on if the error remains or out if the error is not
present for the moment. See chapter 3.5 for
detailed information about error messages.
4 (10)
SERVICE 6.303.66 E rev.: a 2012-01-10
2 Control system input and output signal levels
Power for control system input and output CT2-X10:48

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

Outputs to control lever potentiometer
CT2-X10:302 Lu +6V from MC "Lu"
Luffing
CT2-X10:303 0V from MC "Lu"
Control lever potentiometer input signal luffing CT2-X10:304 Lu 10.5V with 6V in neutral
position.
Control lever direction inputs slewing 24V when control lever actuated
Luffing In CT2-X10:307 Lu luffing in
Luffing Out CT2-X10:308 Lu luffing out
CT2-X10:401 +12V from MC "SL"
Outputs to control lever potentiometer slewing CT2-X10:402 SL +6V from MC "SL"
CT2-X10:403 0V from MC "SL"
Control lever potentiometer input signal slewing CT2-X10:404 SL 10.5V with 6V in neutral
position.
Control lever direction inputs slewing 24V when control lever actuated
CT2-X10:407
Slewing Left SL slewing left
CT2-X10:408
Slewing Right SL slewing right
Brake #1 open
Ho
Hoisting CT2-X10:230 24V, max. 2A, open circuit gives
Lu
Luffing CT2-X10:330 error message.
SL
Slewing CT2-X10:430
Brake #2 open
Ho
Hoisting CT2-X10:231
Lu
Luffing CT2-X10:331
SL
Slewing CT2-X10:431
Limit switch inputs hoisting 24V at normal operation, 0V at
CT2-X10:214
Hoisting Ho limit. At limit movement is
CT2-X10:215
Lowering, slack wire stopped and brake closed.
Limit switch inputs luffing CT2-X10:314 Lu 24V at normal operation, 0V at
5 (10)
SERVICE 6.303.66 E rev.: a 2012-01-10
Luffing In CT2-X10:315 limit. At limit movement is

Luffing Out, slack wire stopped and brake closed.
Limit switch inputs slewing 24V at normal operation, 0V at
CT2-X10:414 SL
Slewing left limit. At limit movement is
CT2-X10:415
Slewing right stopped and brake closed.
CT2-X10:256 Ho
Slack wire
CT2-X10:356 Lu
24V outputs wired together to
Output “Error in control system CT2” CT2-X110:128 Sc
error lamp in driver’s cabin.
Ho 24V when the hoisting pressure
Output for "Hoisting Overload" indication lamp CT2-X10:255
Lu exceeds adjusted value.
Tilt switch, Jack-knife CT2-X11:351 Lu 24V (Optional)
CT2-X10:259 Ho
Klixon High Motor temperature CT2-X10:359 Lu 24V
CT2-X10:459 SL
Brake low oil temp CT2-X11:452 SL 24V
Brake low oil level CT2-X11:456 SL 24V
Overload test CT2-X10:107 Sc 24V
Rig mode CT2-X10:108 Sc 24V

Cooling fan #1 CT2-X11:354 Lu
24V
Cooling fan #2 (if needed) CT2-X11:454 SL
Brake failure lamp CT2-X10:138 Sc 24V
CT2-X10:217 Sc 24V
Derating (Limiting) of high speed movement for
CT2-X10:317 Sc 24V
hoisting, luffing and slewing
CT2-X10:417 Sc 24V
Backplane Card
Temperature Cabinet CT10 Sc:AI3
Temperature Cabinet CT13/ Ho:AI3
Temperature Cabinet CT14/ Lu:AI3
Temperature Cabinet CT2 Sl:AI3
Ho:SSI
Absolute encoder Lu:SSI
Sl:SSI
Ho:Sp
Incremental encoder Lu:Sp
Sl:Sp
Sc:C1
Ho:C1
FQC
Lu:C1
SL:C1
6 (10)
SERVICE 6.303.66 E rev.: a 2012-01-10
3 Troubleshooting the Crane Control system

or is not corrected by the listed corrective actions,
3.1 General notify your supervisor.
This section provides information for identifying and
correcting malfunctions, which may develop while When troubleshooting a malfunction: Locate the
operating the cargo crane. Before performing symptom or symptoms that best describes the
troubleshooting, read and follow all safety malfunction. If the appropriate symptom is not
instructions found in section "General", section 1, of listed, notify your supervisor.
this manual. This chapter cannot list all
malfunctions that may occur, nor all inspections Read this section in conjunction with the electrical
and corrective actions. If a malfunction is not listed, and hydraulic diagrams provided in Group 9.5 and
9.4.
3.2 Troubleshooting Chart
Troubleshooting the
Crane Control System
CC3000.
Crane movement Crane movements function but the lamp

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

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

supply, see chapter joysticks, see chapter
3.3. 3.4.
7 (10)
SERVICE 6.303.66 E rev.: a 2012-01-10
3.3 Checking Power supply 24V DC in With the crane still running, the following steps are
CT2 cabinet necessary to obtain the error code(s).
See chapter 1.2. for explanation of the power
supply function.
 Check over-current relay F3 in cabinet
CT1.
 Check fuse F16 in CT1 for 24V in terminal
48 in CT2 cabinet.
 Check fuse F17 in CT1 for 24V in terminal
42 in CT2 cabinet.
 Check relay K34 in cabinet CT1, see
electric circuit diagram.
 No LED and display readout on MC card
indicates missing 24V in terminal 48.
3.4 Checking Limit switches and

Joysticks
Check Limits
 No LEDs on and no display readout -

indicates missing 24V in terminal 48.
 Check for Red LEDs - indicating stop limits.
 Check for Yellow LEDs - indicating speed
reduces.
 Check electric cable connections for limit
switches.
 For checking and adjustment of limit
switches see instruction for “Limit Switches
in Hoisting …” in "Service", section 6.3.
Check control lever (joystick)
See chapter 1.4 for explanation of the control lever

functions.
 Check for missing Green input signal LEDs
- from joystick.
 Check electric cable connections to control
lever.
 Check analogue input signal from joystick
potentiometer.
 Check for missing Green output signal
LEDs: Exchange the MC card with other
movement MC card. Replace broken MC
card with a new one.
3.5 Error message codes from CC3000

If the error from the CC3000 has no influence on
the performance of the crane the “control system
error” lamp in the driver’s cabin will not flash.
8 (10)
SERVICE 6.303.66 E rev.: a 2012-01-10
4 Spare parts
4.1 MC card and CC card

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

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

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

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

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

To protect all types of electronic cards from
damages from ESD (Electro Static Discharge) it is
important to use pink anti-static plastic bags and
conductive transit boxes of the same type as used
for delivered original spare parts.
9 (10)
SERVICE 6.303.66 E rev.: a 2012-01-10
10 (10)
SERVICE 6.303.67 E rev.: - 2011-01-18
Absolute Encoder Calibration, CC3000
General Preparation of minimum outreach luffing
Absolute encoders are used for position control WARNING! Always use safety belt when measuring
purposes. Each encoder gives an accurate position the MV distance.
feedback to the control system.
To operate the crane in Rig mode see instruction
The encoder calibration has to be done when the wire "Preparation for Rig Mode" in section 6.3.
or the absolute encoder has been replaced.
WARNING!
Absolute encoders for hoisting and luffing winches When the crane is operated in Rig mode the crane has
are installed in the limit switch box or on jib bearing. no software limits.
It is not permitted to have any load in the hook.
For slewing motion the absolute encoder is mounted Inappropriate use may cause severe damage to the
under the crane towards the slewing bearing. crane and bodily injury.
Center line of crane house
MV
(m
m)
MV distance
First jib stay
Center line of jib profile

(calibration point)
There must be a distance

between the front of the
crane house and the first jib stay.
Fig. 1. Crane house top.
1 (4)
SERVICE 6.303.67 E rev.: - 2011-01-18
- Activate Rig mode.

- Carefully position the minimum outreach until the
MV distance is achieved.
Caution! Do a visual inspection of the distance
between the front of the crane house and the first
jib stay on jib. AL
- Measure the MV distance on top of the crane
house, see Fig. 1, refer to table in Technical Data,
section 2.
- Calibration of the encoder in cabinet CT2, see
Table 1, page 4.
- Adjust the limit switch for "Min Outreach", see
instruction "Limit Switches and Software Limits
..." in section 6.3 and table "Limit switches -
luffing winch" in Technical Data, section 2. Fig. 2. Definition of "AL" hoisting winch.
- Luff out a few meters and stop.
- Exit Rig mode by stopping the crane and switch
the key switch to Normal.
- Luff in until the jib stops at "Min Outreach".
- Recheck the MV distance.
Preparation of hoisting

- Start to operate the crane to definition "AL"
(hoisting winch), see Fig. 2, refer to table "Limit
switches - hoisting winch" in Technical Data,
section 2.
- Measurement to be done in front of the hoisting
winch, from the empty drum flange to the side of
the wire.
- Adjust the limit switch for empty drum. Hoist the
hoisting wire a few meters and stop. Lower the
wire until it stops at position empty drum, i.e. at
least three locking turns or tank top.
Table 1, page 4.
- Exit Rig mode by stopping the crane and set the
key switch to Normal.
2 (4)
SERVICE 6.303.67 E rev.: - 2011-01-18
Preparation of slewing
- To calibrate the absolute encoder for slewing aim

the crane jib straight ahead, i.e. 0°, see Fig. 3.
Table 1, page 4.
0°
Fig. 3. Reference points.
3 (4)
SERVICE 6.303.67 E rev.: - 2011-01-18
Calibration of encoders in cabinet CT2
Hoisting Luffing/slewing
Operation of rig mode see instruction "Preparation for To calibrate the encoder on the other cards proceed in
Rig Mode" in section 6.3. the same way as in items 1, 2, 3, and 4 in above
paragraph except for choosing the corresponding card.
1. Push the "Select/Info" button on the front of the
MC-card which you want to calibrate, for example
Ho-card. The display on the Ho-card shows
"ERROR".
2. Push the "Down/Exit" button on the Ho-card
front. The display on the Ho-card shows "CAL".
3. Push the "ENCODER CALIBRATION" button in
cabinet CT2. The display in the Ho-card then
flashes and shows "ANG".
4. Push the "Select/Info" button on the Ho-card.
Angle encoder is calibrated in this position.
Table 1. Encoder calibration modes
Function/ Purpose Calibration position

Mode
Ho Zero position of hoisting winch Empty drum, at least three locking turns (AL).
Lu Zero position of luffing winch Full drum, min. outreach, MV distance.
SL Zero position of slewing Aim crane jib straight ahead for 0°.
Display
ENCODER
CALIBRATION
button
Select/Info
button
Up button
Down/Exit
button
Fig. 4. Cabinet CT2, CC3000.
4 (4)
Page Date
SIGNAL OVERVIEW 1 (2) 2011-11-30
No Revision
Crane Control System CC3000 E
424 0738
LEDs - 24V Input/Output signals are indicated with coloured LEDs
.Colour Indicating LEDs on External communication
when LEDs within the COM box are external communication and
communication with Main Processor (MP).
Green Normal inputs and outputs +24V
The external communication LEDs are blinking when
Yellow 11,12 Speed reduce limits 0V transmitting data in one direction and is lit when data is
transmitted both ways. The MP LED must always be lit.
Yellow 17,18 Speed reduction switches +24V
Software
Red Limit switches, low pressure, 0V Sw before “LED No” means the software (orange means
slack wire and overload that the motion is blocked).
SC – Supervisory Ho – Hoisting
CC Card MC Card
LED Plinth LED Plinth
Signal Description Signal Description
No No No No
07 Overload test 107 07 Hoisting, input 207
08 Rigging mode 108 08 Lowering, input 208
09 Parking of jib 109 09 Low speed, input 209
Hardware
324 1670-901 10 110 Hardware
324 1665-901
10 High speed, input 210
11 Mode A (Container) 111 11 Speed reduce hoisting 211
12 Mode B (Grab) 112 12 Speed reduce lowering 212
13 Mode C (Hatch C.) 113 14 Limit switch hoisting 214
16 116 Sw14/15 Speed reduce, stop, block
17 Pump Unit 1/ RBTS 117 15 Limit switch lowering 215
18 Pump Unit 2 118 17 Speed reduction, ext1 217
19 119 18 Speed reduction, ext2 218
20 120 19 Low pressure switch 219
26 Run enable in 126 20 Overload switch input 220
27 Run enable out 127 Sw20 Overload load cell/pressure
28 Alarm (error in CT2) 128 26 Run enable in 226
29 Ready to run 129 27 Run enable out 227
Indication Speed
30 Twin not synch. 130 29 229
reduce/stop
31 131 30 Hoisting brake, output 230
32 132 31 Low speed, output 231
33 ARC Cabin A Lamp 133 32 High speed, output 232
34 ARC Cabin B Lamp 134 33 Pump1 hoisting, output 233
35 ARC 180 deg. rotation 135 34 Pump1 lowering, output 234
36 ARC Run enable out 136 36 Pump2 hoisting, output 236
37 137 37 Pump2 lowering, output 237
38 Brake Failure lamp 138 39 Pump3 hoisting, output 239
39 139
49 149 43 Pump4 hoisting, output 243
53 153 49 Angle Check Cam 249
56 Twin on 156 51 251
57 Calibration 157 52 252
58 Twin reset 158 53 VFD Run enable out 253
59 159 54 254
60 Em. op. request 160 55 Indication Overload 255
61 Em. op. activated 161 56 Slack wire 256
24 V Power supply +24V Sw56 Slack wire from LU
C1 CAN1 (ALM) Sc_C1
Software
57 Brake Open Indication 257
Software C2 CAN2 (Cabin display) Sc_C2 CC3K H01_00 58 Ext stop 1 258
CC3K H01_00 Rev B
Rev B Ext stop 2
C3 CAN3 Sc_C3 59 259
El.motor high temp
C4 CAN4 Sc_C4 C1 CAN1 (VFD) Ho_C1
R1 RS485_1 (Remote) Sc_R1 C2 CAN2 Ho_C2
R2 RS485_2 (Twin) Sc_R2 R1 RS485_1 Ho_R1
R3 RS485_3 Sc_r3 MP Internal communication
MP Internal communication
Page Date
SIGNAL OVERVIEW 2 (2) 2011-11-30
No Revision
Crane Control System CC3000 E
424 0738
LEDs - 24V Input/Output signals are indicated with coloured LEDs
.Colour Indicating LEDs on External communication
when LEDs within the COM box are external communication and
communication with Main Processor (MP).
Green normal inputs and outputs +24V
The external communication LEDs are blinking when
Yellow 11,12 speed reduce limits 0V transmitting data in one direction and is lit when data is
transmitted both ways. The MP LED must always be lit.
Yellow 17,18 Speed reduction switches +24V
Software
Red limit switches, low pressure, 0V Sw before LED No means the software (orange means
slack wire and overload that the motion is blocked).
Lu - Luffing Sl - Slewing
MC Card MC Card
LED Plinth LED Plinth
Signal Description Signal Description
No No No No
Hardware 07 Luffing in, input 307 07 Left, input 407
324 1665-901 Hardware
08 Luffing out, input 308 324 1665-901 08 Right, input 408
11 Speed reduce luffing in 311 11 Speed reduce left 411
12 Speed reduce luffing out 312 12 Speed reduce right 412
14 Limit switch luffing in 314 14 Limit switch left 414
Sw14/15 Speed reduce, stop, block Sw14/15 Speed reduce, stop, block
15 Limit switch luffing out 315 15 Limit switch right 415
17 Speed reduction, ext1 317 17 Speed reduction, ext1 417
18 Speed reduction, ext2 318 18 Speed reduction, ext2 418
19 Low pressure switch 319 19 Low pressure switch 419
20 Overload switch input 320 20 320
26 Run enable in 326 26 Run enable in 326
27 Run enable out 327 27 Run enable out 327
29 Indication Speed 29
329 329
reduce/stop
30 Luffing brake, output 330 30 Slewing brake, output 430
31 Unloading, output 331 31 431
32 32 432
33 Pump1 luff in, output 333 33 Pump1 left, output 433
34 Pump1 luff out, output 334 34 Pump1 right, output 434
36 Pump2 luff in, output 336 36 Pump2 left, output 436
37 Pump2 luff out, output 337 37 Pump2 right, output 437
39 Pump3 luff in, output 339 39 Pump3 luff in, output 439
40 Pump3 luff out, output 340 40 Pump3 luff out, output 440
43 Pump4 luff in, output 343 43 Pump4 luff in, output 443
45 Pump4 luff out, output 345 45 Pump4 luff out, output 445
49 Angle Check Cam 349 49 Angle Check Cam 449
51 Jack-knife 351 51 Remote on 451
52 352 52 Brake low oil level warning 452
53 VFD Run enable out 353 53 VFD Run enable out 453
54 Cooling fan #1 354 54 Cooling fan #2 454
55 Indication Overload 355 55 455
56 Slack wire 356 56 Brake low oil level stop 456
57 Brake Open Indication 357 57 Brake Open Indication 457
58 Ext stop 1 (Jack knife) 58 Ext stop 1
358 458
Software
(Luffing Slewing limit off)
Software
CC3K H01_00 Ext stop 2 (High hook) CC3K H01_00
Rev B
59 Ext stop 1
Rev B 59 (El.motor high temp Klixon) 359 (Luffing Slewing limit off) 459
(El.motor high temp Klixon)
C1 CAN1 (VFD) Lu_C1
C2 CAN2 (ARC angle swivel) Lu_C2 C1 CAN1 (VFD) Sl_C1
R1 RS485_1 (ARC gyro) Lu_R1 C2 CAN2 (ARC Angle Cabin) Sl_C2
MP Internal communication R1 RS485_1(Outdoor display) Sl_R1
MP Internal communication
Page Date
ERROR MESSAGES
1(2) 2011-11-27
No Revision
424 0739 F
Error message codes from CC3000 Note!

If the error from the CC3000 has no influence on the performance of the Before reporting to Cargotec (MacGregor) in Örnsköldsvik, please look
crane the ”control system error” lamp in the driver’s cabin will not flash. for the error code in the display of the MC or CC card and use the
With the crane still running, the following steps are necessary to obtain “select/info” button to view all error codes. It is essential that all faults to
the error code(s). be corrected to allow the crane to function correctly.
 Open the control system cabinet and look for the Sc-card (the
lestmost card in the rack). LED 28 is now flashing. Then look for the Abbreviations: VFD = Variable Frequency Drive
card with the flashing LED “error MP” or “error SP” on top of the ALM = Active Line Module
cards. Error code Description
Green LED 28 on the Sc-card Indicate error status in the
01 S ys t e m E r r o r s
whole system (All cards)
Red LED “Error MP” Indicate error status from MP in
01_01 to 01_15  Contact Cargotec in Örnsköldsvik
the local card 01_12 System Software version mismatch
Red LED “Error SP” Indicate error status from SP in  Check the software version in the cards
the local card 02 MC or CC Card
 Push the “Select/Info” button once on the card with error LED 02_01 to 02_61  Restart system or replace the card
flashing. An error code (e.g. E51_11) is shown on the display on the  Contact Cargotec in Örnsköldsvik
card. 03 Safety processor
 Hold on pressing “Select/Info” button, the description of this error will 03_01 to 03_91  Contact Cargotec in Örnsköldsvik
be rolling on the display. Release the button, the description
disappears and the error code is shown. 10 MEM card
 Continue to press “Select/Info” or “Down/Exit” button once to see the 10_10  Replace the MEM card
next error and so on.  Contact Cargotec in Örnsköldsvik
 Pressing “Up” button once to show the previous error and so on. 11 Parameters
 When there are no more error messages, the display shows three 11_01 to 11_30  Contact Cargotec in Örnsköldsvik
hyphens “---”. When all errors have been shown on the display, the 24 24V Suppl y Voltage
error LED is either on or off. 24_01 to 24_04  Check 24V supply
 All errors can be shown round and round if you continue pressing
30 J o ys t i c k
“Select/Info” or “Down/Exit” button or “Up” button.
30_01 Joystick level, normally 1.25 V to 11.75 V.
LED flashing New error, not acknowledged
 Check connection to joystick
LED on Error remains, now acknowledged
 Check switches/cam in joystick
LED off No error present at the moment
 Measure potentiometers in joystick
 The display returns to normal mode (Sc, Ho, Lu, Sl, Cl, Au, Ec, Tl,
Tr, Li, Io) fifteen seconds after one of the three buttons was last 30_02 Joystick logic error for “Lowering”, “Luffing Out” or
pressed, or holding on pressing “Down/Exit” button longer than one “Slewing Right” movement.
second. 30_03 Joystick logic error for “Hoisting”, “Luffing In” or
 If the system is restarted (i. e. 24V power supply is switched off for a “Slewing Left” movement.
short time) all alarms disappear and only reappear when the error 30_04 Joystick is not in zero position when system starts.
recurs. 31 An g l e E n c o d e r
How to see the remaining errors after acknowledging (i.e. error LED is 31_01 Angle encoder communication error
on)?  Check angle encoder connection
 Errors can be shown again from normal mode when pressing  Replace the angle encoder
“Select/Info” twice.
31_02 Angle shaft coupling
 Pressing “Up” or “Down/Exit” button to see the previous respective
 Check angle encoder connection
next error, following the same instruction above.
 Replace the angle encoder

31_03 Angle encoder or speed encoder error
Hardware
324 1670-901
Hardware
324 1665-901
Hardware
324 1665-901
Hardware
324 1665-901  Replace the angle encoder or speed encoder
 Contact Cargotec in Örnsköldsvik
Encoder
Calibration Error MP SP 31_04 Angles at CAM control place mismatch.
 Check angle encoder cable and connection
 Replace the angle encoder
 Calibrate encoder again.
 Contact MacGREGOR Cranes in Örnsköldsvik
31_05 Shaft not connected
31_11 Different angle values when more than one encoder
31_12 for luffing.
31_13 (Only on Sc-card).
Display 31_51 to 31_53 Power Swivel angle encoder
31_54 to 31_57 ARC angle encoder in cabin
32 Speed Encoder
Select/Info button 32_01 No data from speed encoder
Up  Check speed encoder cable and connection
Down/Exit  Replace a new speed encoder
Software
CC3K H01_00
Rev B
Software
CC3K H01_00
Rev B
Software
CC3K H01_00
Rev B
Software
CC3K H01_00
Rev B
 Exchange cards
32_02 VFD or CC3000 encoder
Page Date
ERROR MESSAGES
2(2) 2011-11-27
No Revision
424 0739 F
32_03 Wrong speed direction 49 External analogue in

 Change speed encoder direction or shift cable 49_01 to 49_07 A1, A2, A3, A4, A5, A6, A7
connection (switch A and B)  Check cable, connection
 Replace the speed encoder  Check encoder
 Exchange cards  Replace the MC or CC card
 Contact Cargotec (MacGregor) in Örnsköldsvik 50 Displacement
32_04 VFD encoder 50_11, 50_21 Open circuit (Low speed, high speed, unloading,
32_05, 32_06 Encoder error 50_31, 50_41 plussing valve [LC])
32_10 No data from speed encoder  Check cable and connection
33 Weight 50_12 Short circuit (Low speed, high speed, unloading,
33_01 Loadcell 50_22, 50_32 plussing valve [LC]))
 Check loadcell cable and connection 50_42  Check output cable is not connected to 0V(ground)
 Replace the loadcell  Replace the MC or CC card
 Contact Cargotec in Örnsköldsvik 50_13, 50_23 Transistor (Low speed, high speed, unloading,
33_02 Pressure 50_33, 50_43 plussing valve [LC]))
33_03 Loadcell Check  Check cable and connection
33_04 Torque  Replace the MC or CC card
33_07 Load system, in EO 50_24 High speed valve
33_11 Difference Loadcell 50_34 No plussing pressure
33_12 Difference Pressure 51 Brake
33_13 Difference Loadcell check 51_11, 51_21 Open circuit
33_14 Diffeerence Torque  Check cable and connection
33_31 Outreach, angle Lu 51_12, 51_22 Short circuit
33_32 Outreach, angle Sc  Check output cable is not connected to 0V(ground)
33_33 Outreach, angle Sc speed  Replace the MC card
33_37 Outreach, in EO 51_13, 51_23 Transistor
33_41 Change to Main not possible  Check cable and connection
33_42 Change to Whip not possible  Replace the MC card
35 Temperature 51_14, 51_24 Control Circuit
35_01, 35_02 MC card temperature is too high 51_15, 51_ 25 VFD Brake output
 Power off system 51_31 Read back (pressure or switch)
 Contact Cargotec in Örnsköldsvik 51_32 Closed (pressure or switch)
35_11 ALM high temp 51_33 Closing failure
35_12 VFD high temp 51_34 Slip
35_13, 35_41 Electric motor high temp 51_50 to 51_52 Low oil level or temp error
35_14, 35_42 Hydraulic oil high temp 52 Pump
35_15, 35_43 High temp 51_01 to 51_05 Pump PWM current
35_16 Air intake high temp 51_11 to 51_14  Check that PWM output is not connected to
35_44 Winch oil high temp 0V(ground)
35_45 Braking resistors overheated  Check that cable is not broken
36 Power  Replace the MC card
36_01, 36_02 High current 53 VFD
36_03 No data from power sensor 53_01 to 53_50 VFD
37 Limit 54 AL M
37_01 to 37_06 Limit error at stop cam 54_01 to 54_06 ALM
 Check stop cam connection or switch 55 Stab Winch
37_10 Limit: Software limits 55_01 to 55_04 Stab winch
37_21 Limit: Luffing Slewing 56 Power Swivel
37_22 Limit: Anticollision 56_01 to 56_23 Power Swivel
38 Run Enable 62 Twin
38_01 Run enable: No input on terminal X26 62_01 No data from Slave
38_02 Run enable: Terminal X26 is always set 62_02 Error in Slave
38_03 Run enable: No run enable in 62_10 to 62_14 Angle error Master Ho, Lu, Ll, Tr
38_04 Run enable: Team 62_20 to 62_24 Angle error Slave Ho, Lu, Ll, Tr
39 Low feed pressure 63 Team
39_01, 39_02 Low feed pressure 63_01 to 63_05 Team
40 Lubrication 70 Speed
40_01, 40_02 Lubrication 70_10 Speed control deviation
41 Power limitation 70_20 Variable Frequency Drive zero speed timeout
41_01 to 41_03 Power limitation
45 External IO
45_01 to 45_36 External IO
48 Motion Sensor
48_01, 48_02 Power swivel
48_11, 48_12 Swing
48_21, 48_22 Ship
INSTRUCTION
INSULATION TEST
ELECTRICAL CRANE
1 PREPARATION LIST
Before applying high voltage anywhere in the electric system, all electronic systems need to be
prepared according to the preparation list below.
1.1 CT1 Cabinet
 Switch off all circuit breakers.
 Transformers (T1, T2, T3 a.s.o.)
Disconnect all kind of fuses.
Disconnect all earthing cables.
 Power supplies (U1, U2, U3 a.s.o.)
Disconnect all earthing.
 Safety relay (K99)
Disconnect earthing cable.
1.2 CT2 Cabinet
Disconnect (pull out) all MC- and CC-cards on the CC3000 19" rack.
Disconnect the cables from terminal X10:48 & 50 (internal side) up to backplane card (Two red and
2
two black 2,5 mm ).
Disconnect all cables connected on the backplane card (used for different encoders).
Disconnect (pull out plinth, Se picture 1) X122, X132 and X124 from UZ1, UZ2, UZ3 a.s.o)
Disconnect (pull out plinth, Se picture 2) X521, X531 and X524 from BU1, BU2, BU31 a.s.o)
Check that there is no connection between terminal X10:42 and X10:48.
Check that there are no short circuit between X10:42 and X10:50.
Check that there are no short circuit between X10:48 and X10:50.
Disconnect the small capacitor connected between terminal X10:50 and X10:PE.
Disconnect all cables from X2:243 to prevent megger to destroy electronic components.
Disconnect all cables from X2:244 to prevent megger to destroy electronic components.
Picture 1. Remove X122, X132 and X124. Picture 2. Remove X524, X521 and X531
1.3 CT13/16 Cabinet

Verify that motor cables from frequency converters are not connected to converter.
1.4 CT14/17 Cabinet
Verify that motor cables from frequency converters are not connected to converter.
This document remains our property. It must not be reproduced or made accessible to our competitors or others who could make undue use of it, without our written permission.
Rev ind Revision Appd Year Week

Description (English) Drawn by Year Week
Insulation test (megger) Electrical crane C Hörnfeldt 10 40
Deescription (own language) Drawing No Rev ind Sheet
Isolationstest (megger) Elkran 1000004064 B 1(2)
INSTRUCTION
INSULATION TEST
ELECTRICAL CRANE
1.5 Crane Computer
Disconnect all cables from the computer.
2 PROCEDURE
2.1 Resistance check after preparation
Check with an Ohm-meter that there is no connection between following terminals:
 In CT1 cabinet:
X2:127 and earth
X2:274 and earth
 In CT2 cabinet:
X10:50 and earth
X11:50 and earth
2.2 Megger test 500 V
Test all cables in the 24V circuits on X10 plinth with 500 VAC. Apply test probes between mounting
plate and X10 plinth. IT IS ABSOLUTELY FORBIDDEN TO USE THE MEGGER ON X11 PLINTH.
2.3 Megger test 1000 V
CT1. Test electric motors and cables. Apply test probes between mounting plate and X2 plinth.
Test motor circuits by applying test probes between mounting plate and contactor.
CT13/16. Test electric motors and cables. Apply test probes on motor cables.
CT14/17. Test electric motors and cables. Apply test probes on motor cables.
2.4 Test results
Results to be higher than 5 MOhm. Note! If the humidity in the air is high a result between 1 and 4
MOhm is acceptable.
This document remains our property. It must not be reproduced or made accessible to our competitors or others who could make undue use of it, without our written permission.
Rev ind Revision Appd Year Week

Description (English) Drawn by Year Week
Insulation test (megger) Electrical crane C Hörnfeldt 10 40
Deescription (own language) Drawing No Rev ind Sheet
Isolationstest (megger) Elkran 1000004064 B 2(2)
SERVICE 6.305.19 E rev.: - 2010-12-03
Electrical Equipment, General Maintenance
Introduction Portable control boxes

General maintenance of the electric equipment of Control panels and remote control boxes may be sub-
the crane is important in order to prevent unexpected jected to abuse an abnormal wear, and should be
breakdowns. The following general advice may be inspected after every use. The control boxes must be
useful. Relevant electrical system is placed in section stored in a compartment that is well protected against
9, SPARE PARTS. moisture. Remove moisture that may have collected
in the boxes, and find out how it entered.
Start the crane and try out all combinations of move-
ments that are practicable. This will show if the electric
functions are satisfactory.
Inspect all electrical equipment cabinets, and com-

ponents. Any defective component must be repaired
or replaced without delay. A detailed inspection and
overhaul at two-year intervals is recommended. Check
that all screws and nuts are securely tightened in the
contactor cabinets, that all switches and pushbuttons
operate correctly, and that cable connections are per-
fectly tight and all insulating parts intact. Make sure
that inspection door gaskets seal perfectly.
Dangerous voltage, 700V DC, can remain charged in

the DC-bus up to 5 min. after the power switch Q1 is
switched off.
C-00108
Danger!
Fig.1. Electric Cabinet CT1/CT2
Electrical equipment can be alive unless the main
switch and the separate supply is disconnected in
cabinet CT1 and CT2.
Earth connection, hull

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

Check crane system earth connections, and clean
contact surfaces as required.
1 (2)
SERVICE 6.305.19 E rev.: - 2010-12-03
General maintenance Oil level/temp

- Change filter to the ventilation fan in cabinet CT1,
See instruction "Control and Indicators" in section 4.
if necessary, see Fig. 1.
- Clean contacts, insulating parts, cams, contact rolls,
and rotary potentiometers.
- Make sure that all cable connnections are clean
and securely tightened.
- Clean the control levers, and grease their sliding
surfaces.
- Examine the return springs and grease lightly so
that no grease transfers to the contacts.
- Replace the filters of the airflow fans in cabinets
CT2, CT10, CT13 and CT14. See instruction "Hea-
ting and Cooling of Cabinets in Electric Cranes" in
section 3.
Jib flood light

Make sure that connections in the junction box are
clean and well tightened.
- Remove moisture and dirt.

- When necessary, clean contact surfaces of terminal
strips and of lamp holder.
- Make sure that lamp holder gasket seals correctly.
- Make sure that the work light can be rotated.
Slip-ring unit
Danger!
Before opening the slip-ring unit, make sure that po-
wer supplied by separate transformers is switched off
in the ship's engine room. Also check by means of a
voltmeter that the slip-ring unit is not alive.
- Verify that slip-ring contact surfaces are smooth

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

subject of a separate description.
2 (2)
SERVICE 6.306.7 E rev: a 2011-10-27
Installation of Power Supply Cable

and
Cable for "Grab Control Equipment", Interlock
General Installation of power supply cable for

"grab control equipment"
Preparations for installation of the "grab control equip-
ment", are made in all cranes to get an interlock con- The power supply cable to the "grab control equip-
nection between the external mounted "grab control ment" needs to be connected as shown in Fig. 1. To
equipment" and MacGregor Cranes' safety functions. protect the "grab control equipment" we recommend
Some preparations are done in the cabinet CT1 and that the power supply cables are connected after the
on control panel (CT3) in cabin. The two-position key main switch Q1 and fuse switch disconnector F1 in
switch "Cargo/Grab Handling" which is adaptable to the cabinet CT1, see Fig. 1.
the "grab control equipment", see instruction "Controls
and Indicators", section 4.
K59
Connection of the power supply cables.
Main switch Q1 Fuse switch disconnector F1
Fig. 1. Cabinet CT1.
1 (2)
SERVICE 6.306.7 E rev: a 2011-10-27
Contactor relay K59
To energize the contactor relay K59 in cabinet CT1,see

Fig. 1, the two-position key switch "Cargo/Grab Hand-
ling" must be in position 2, "Grab", to get reduced SWL
for operation with grab. See instruction "Controls and
Indicators", section 4.
Grab control equipment
When the cranes have a "grab control equipment"

make sure that:
- The electrical installation is done refer to the elec-
trical circuit diagram valid for the crane
- The two-position key switch "Cargo/Grab Handling"
is in position 2, "Grab", to reduce SWL for operation
with grab.
See instruction "Controls and Indicators", section 4.
2 (2)
SERVICE 6.307.11 E rev.: b 2003-01-08
Slip-Ring Unit
Danger! Use only insulated tools and original spare parts.

Before opening the slip-ring unit, make sure that
power supplied by separate transformers is No responsibility will be assumed for damage to
switched off in the ship's engine room. Also check property or injury to persons caused by improper
by means of a voltmeter that the slip-ring unit is not use of the slip-ring assembly.
alive. Make sure that the current can not be switched
on again during the maintenance operation. Removal
Work on a slip-ring assembly may only be carried 1. Park the jib in a suitable manner.
out by a qualified electrician or by persons under 2. Disconnect the ship's power supply at all points
the supervision of a qualified electrician and only of feed.
according to accepted electrical safety procedures. 3. Disconnect all the cables connection from crane-
and ship supply.
The function of the slip-ring assembly may not be 4. Remove the driver connecting the slip-ring unit
changed in any way. Especially safety devices must and the foundation. Note the cables mounting
not be made ineffective. Other than during mainte- sequence.
nance and inspection work the housing must always 5. Remove mounting screw holding the slip-ring unit
remain closed. on cranehouse bottom. See Fig. 1.
6. Remove the slip-ring unit.
Mounting screws
Connection crane
Slip-ring unit
Connection ship Connection box

power
Guide pins
Driver
Rubber protection
Note! Must be
tightened.
Fig. 1. Slip-ring unit.
1 (2)
SERVICE 6.307.11 E rev.: b 2003-01-08
Any extra equipment such as extra limit switches Carbon brushes

fitted on top of the slip-ring unit are removed prior - The carbon brushes must never wear down so
to removal of the entire slip-ring unit. far that metal parts of the brush holder come into
contact with the slip-ring.
The carbon dust is to be removed with dry, oil
Installation free, compressed air or with a vacuum cleaner.
No substance containing oil or grease may come
Clean all contact surfaces between slip-ring unit into contact with the brushes or the slip-rings.
and cranehouse bottom. Tighten all screws prop-
erly. See instruction "Tightening torque".
Wire brushes
- Assemble the slip-ring unit under crane bottom - Check wire brushes.
- Assemble the driver to the bottom of the founda- Debris caused by wear is to be removed with dry,
tion oil free, compressed air or with a vacuum cleaner.
- Remove the cover around the slip-ring unit Afterwards the slip-ring ways and wire brushes
- Fit the slip-ring unit guide pins to the driver's slot- should be lightly sprayed with "Cramolin B" or
ted holes by pulling apart the driver and lock it equivalent contact spray.
with help of the through bolt
- Install the cables against the driving bar Others
- Connect the crane cables from the crane on cor- - Check tightness of electric and mechanical
rect mounting sequence fasteners.
- Remove the connection box plates - Check gaskets and cable glands for tightness.
- Connect the cables to the plinths
Keep grease and oil products away from the plastic
insulating parts in the collector.
After installation
- Check tightness of all electric and mechanical
fasteners regularly for the first working period.
- Check alignment. The slip-ring unit must not be
allowed to slope in relation to the driver.
- Rotate the crane ensure that no mechanical side
forces are transferred to the unit.
- Tighten the rubber protection , see Fig. 1.
Maintenance
Always cut current before accessing the collector

for inspection or maintenance. Make sure that the
current can not be switched on again during the
maintenance operation.
At regular intervals
- Check collector for damaged parts
- Check contact pressure of brushes
- Check brush holders
2 (2)
SERVICE 6.311.14 E rev.: - 2012-01-25
Oil Level/Temperature Sensor, Brake unit
General Sensor display
To prevent operation of the crane with too little oil in The display on the sensor shows the oil level in cm.
the brake unit oil tank, an oil level/temperature sensor The display can also show oil temperature. If you push
is installed, see Fig. 1. the arrow to the right the display shows, in this order:
The sensor controls an indicator lamp on the control 1. Max value for oil level
panel in the cabin, see fig. 2. 2. Min value for oil level
3. Oil temperature
4. Max value for oil temperature
5. Min value for oil temperature
6. Oil level
If no arrow is pushed for five seconds the display will

1 show the oil level again.
C
C-00258
cm
mode
C-00257
1. Oil level/temperature sensor

Fig. 3. oil level/temperature sensor with display
Fig. 1. Brake unit

If the oil level is under or above measureable area for
the sensor the display will flash.
1. Indicator light "BRAKE, LOW OIL LEVEL"
Fig. 2. Control panel in cabin
1 (2)
SERVICE 6.311.14 E rev.: - 2012-01-25
2 (2)
SERVICE 6.320.386 E rev.: c 2012-02-09
Limits in Hoisting and Luffing Winch Systems

CC3000
General CAUTION!
Store Keys Safely

The motion and outreaches of the crane jib and hois-
When the crane is rigged ready for operation, all keys
ting block are controlled by software limits in the crane
for all lockable switches must be stored in a safe place
control system CC3000 with limit switches as a safety
by the responsible officer on board.
system.
At large outreaches there is a risk that hook block and
jib will meet and that is taken care of by the crane's
safety system. See paragraph "Jib top and hook block
functions at large outreaches".
Some cranes have extra limit svitches to prevent this,
Check cam
see paragraph "Limit switches, high hook (optional)".
To verify that the encoders for luffing outreaches and
hoisting are working.
Software Limits
The software are controlled by angle encoders in the

limit switch boxes on the luffing and hoisting winch and/
or on the jib bearing. The system gives automatically
the correct hoisting speed and jib outreach correspon-
ding to the load. In addition to the software there are
safety cams installed.
Safety limits
The safety limit switches are contained in the limit

switch box on each winch. Every switch function is set
separately by means of a rotating cam which controls
a microswitch. The winch operates the cams through
the limit switch gearbox.
The safety cams in the hoisting winch limit box are

marked BH1, BH4 and a check cam BH(X) etc.
The safety cams in the luffing winch limit box are

marked BL1, BL3, BL5 and a check cam BL(X) etc.
1 (14)
SERVICE 6.320.386 E rev.: c 2012-02-09
Setting limit switches Measure references
Back off the lockscrews of the switch cams in the limit Below measures are stated in the document "Technical
switch boxes, with a 10 mm articulated wrench; the Data" in section 2.
cams are then easily rotated to their proper settings.
Min Outreach Lu (m)
- Use the cam end as measure line when you adjust MV distance (mm)
the cam(s), see Fig. 1 and 2. The measure between Check cam, Lu (m)
each hole is 5°. Max Outreach Lu (m)
- Adjust the cam(s) according to the table in "Tehnical High Hook (optional) (m)
Data", section 2. Force Limitation Parking Position Lu (m)
Empty Drum Lu (parking position) (degrees)
Software Limit Lu (m)
Lifting height, H (m)
Lifting height, K (m)
Measure line Check cam, Ho K (m)
Jack-Knife Lu, Min Outreach (optional) (m)
5°
Adjustment screw
Note that the jib outreach measures refer to the crane
house slewing centre (Not to the jib bearing centre!).
The measures H and K refer to the jib bearing centre.
30° 55°
Lock screw
Fig. 1. Cam.
H
K
Center line
Jib radius
5°
Measure line Measure line
Lock screw K
Jib radius
Adjustment
Adjustment screws
screws 100° 245°
Fig. 3. Min Outreach and lifting height H and K.
Fig. 2. Cam.
2 (14)
SERVICE 6.320.386 E rev.: c 2012-02-09
Adjustments of outreaches and hook po- BT and BL measures - second layer, from the side of
sition the full drum flange side to the wire, see Fig. 5 and 6.
- AT and BT - luffing winch Values of AT, BT (luffing) and AL, BL (hoisting) can be
- AL and BL - hoisting winch found in the "Technical Data", section 2. See tables for
hosting and luffing winches.
Measure AT, BT, AL, and BL on the front side of the
winch.
AT and AL measures (wire lock side), - from the

side of the empty drum flange side to the side of the
wire, see Fig. 4 and 5.
AL - Empty drum
flange side/ At least
AT - Empty drum flange side/
three locking turns/
Stop lowest position/ At least
Tank top
three locking turns
BL - Full drum flange
BT - Full drum flange side/second layer Wirelock
Wirelock
side/second layer side
side
BT BL
AT AL
Fig. 4. Luffing winch. Fig. 5. Hoisting winch.
3 (14)
SERVICE 6.320.386 E rev.: c 2012-02-09
Limit switches - luffing winch How to adjust cams
Adjustments of values, see "Technical Data", section 2. Adjust the cam until there is a "click". The cam is
activated. See Fig. 7.
After the cam adjustments are done, tighten the lock
screws and operate the luffing movements to measure Move the cam backwards until there is another "click"
the cam adjustments on the luffing winch. Begin at and the cam is now deactivated. (Approximately 1°
minimum outreach and luff out to maximum outreach. except for minimum outreach 0.5°.) See Fig. 8.
Measure of the "MV distance", see Fig.10. Tighten the cam.
When you replace the wires it is important that you

obey the procedure in instruction "Replacement of
Wires" in section 6.2, thus to avoid adjustments of
limits again.
KLICK!
BL1
BL3 Lock screw
BL5
Fig. 7. Cam is activated.
BL7 KLICK!
Fig. 6. Limit switch box on the luffing winch.
Lock screw
Fig. 8. Cam is deactivated.
4 (14)
SERVICE 6.320.386 E rev.: c 2012-02-09
BL5 Safety Cam, Min Outreach Lu, Stop

Min Outreach Lu, Stop
MV distance
SW BL(X) Check Cam, Lu
SW Max Outreach Lu, Stop
BL3 Safety Cam, Max Outreach Lu, Stop
SW A - Empty Drum Lu, Stop

(Parking position)
BL1 Safety Cam, Empty drum Lu, Stop
(Stop lowest position
at least three locking turns).
= Software limits.
= Stop position.
= Software stop.
= Check Cam, Lu.
= Speed reduce.
= Safety Cam Max Outreach Lu, Stop. To by-pass

this position, correct operation mode has to be
selected by help of the key switch "Parking of
jib" in cabin. The speed is reduced.
= Force Limitation Parking Position Lu.

Fig. 9. Luffing winch - limit switches.
5 (14)
SERVICE 6.320.386 E rev.: c 2012-02-09
How to adjust cams and software limits Parking position

for luffing winch - Set the key switch "Parking of Jib" in position 1 -
Parking. See "Control and Indicators", section 4.
WARNING! Luff out to "Empty Drum, Lu Stop".
When the crane is operated in Rig mode the crane - Adjust the cam refer to Fig. 7 and 8.
has no software limits. - Luff in from the parking area.
It is not permitted to have any load in the hook. - Activate Rig mode.
Inappropriate use may cause severe damage to the - Luff out to make sure that safety cam stops the
crane and bodily injury. parking motion. Make sure that there is at least
"Three locking turns" of the wire on the drum.
To operate in Rig mode see instruction "Preparation
for Rig Mode", section 6.3. - Push stop button to stop the crane and set the key
switch in position Normal = Exit Rig mode.
- Push start button to start the crane.
Min Outreach - Luff in from the parking area and then luff out to
- Activate Rig mode. make sure that software limit stops the parking
- To calibrate the angle encoder see instruction motion.
"Absolute Encoder Calibration", section 6.3.
- Adjust the cam refer to Fig. 7 and 8.
- Luff out to come out from minimum outreach area
and then luff in, to make sure that the safety cam
stops the luffing in motion. Make sure it stops before
it is touching the front side of the crane.
- Push stop button to stop the crane and set the key
switch in position Normal = Exit Rig mode.
- Luff out to come out from minimum outreach area
and then luff in, to make sure that the software limit
stops the luffing in motion. Make sure it stops before
it is touching the front side of the crane.
Adjust Check Cam

- Luff out to check cam position see "Technical Data",
section 2.
- Adjust the Check Cam refer to Fig. 7 and 8.
Maximum Outreach
- Luff out to maximum outreach, software limit.
- Luff in to come out from maximum outreach area
and then luff out, to make sure that the SW limit
stops the luffing out motion.
- Luff in to come out from maximum outreach area
and then luff out, to make sure that the safety cam
stops the luffing out motion.
6 (14)
SERVICE 6.320.386 E rev.: c 2012-02-09
Measurement of the minimum jib out-

reach, CC3000
See also instruction "Absolute Encoder Calibration",

section 6.3.
Center line of crane house
MV
(m
m)
First jib stay
MV distance
Center line of jib profile

(calibration point)
There must be a distance

between the front of the
crane house and the first jib stay.
Fig. 10. Crane house top.
7 (14)
SERVICE 6.320.386 E rev.: c 2012-02-09
Extra Min Outreach - "Jack-knife" (op-

tional)
To adjust the tilt switch and the safety cam values read
"Technical Data", section 2.
Read instruction about "Jack-knife" in section 3 in the

Instruction and Spare Parts Manual.
BL(X)
"Jack-knife" (m)
Tilt switch
= Stop position (safety cam).
Fig. 11. Extra Min Outreach - "jack-knife".
8 (14)
SERVICE 6.320.386 E rev.: c 2012-02-09
Limit switches - hoisting winch How to adjust cams
Adjust the cam until there is a "click". The cam is

Adjustments of values see "Technical Data", section 2.
activated. See Fig. 13.
Raise the jib into the Min Outreach Lu, Stop, which is
Move the cam backwards until there is another "click"
the correct jib position for adjustment of the limit switch
and the cam is now deactivated. (Approximately 1°.)
refer to Fig. 12. Note that the speed reduce switches
See Fig. 14.
are software and operate the speed reduction of the
crane hook.
Tighten the cam.
BH1
KLICK!
BH4
BH5
Lock screw
Fig. 13. Cam is activated.
Fig. 12. Limit switch box on the hoisting winch.

KLICK!
Lock screw
Fig. 14. Cam is deactivated.
9 (14)
SERVICE 6.320.386 E rev.: c 2012-02-09
BH4 Safety Cam Full Drum Ho, Stop.
SW Full Drum Ho, Stop.
H (m)
K (m)
K (m)
BH(X) Check Cam, Ho
SW Empty Drum Ho,Stop.
BH1 Safety Cam, Empty Drum Ho, Stop.

(At least three
locking turns or tank top.)
= Software limit.
= Software stop.
= Stop position.
= Check Cam, Ho.
Fig. 15. Hoisting winch - limit switches.
10 (14)
SERVICE 6.320.386 E rev.: c 2012-02-09
How to adjust safety cams and software Full drum

limits for hoisting winch - Luff in to minimum jib outreach.
- Hoist the hoisting wire to full drum (software stop).
WARNING! - Adjust the cam refer to Fig. 13 and 14.
When the crane is operated in Rig mode the crane - Lower the hoisting wire to come out from the full
has no software limits. drum area.
It is not permitted to have any load in the hook. - Activate Rig mode.
Inappropriate use may cause severe damage to the - Hoist the hoisting wire to full drum to make sure
crane and bodily injury. that the safety cam stops the hoisting motion of the
hoisting winch.
To operate in Rig mode see instruction Preparation - Lower the hoisting wire to come out from the full
for Rig Mode, section 6.3. drum area.
- Push the stop button to stop the crane and set the
key switch in position Normal = Exit Rig Mode.
Empty drum - Push the start button to start the crane.
- Activate Rig mode. - Hoist the hoisting wire to make sure that the soft-
- Luff in to minimum jib outreach. ware limit stops the hoisting motion of the hoisting
- Lower the hoisting wire to empty drum, at least winch and not the cams.
three locking turns.
- To calibrate the angle encoder see instruction "Ab-
solute Encoder Calibration", section 6.3.
- Hoist the hoisting wire to come out from the empty
drum area and then lower the hoisting wire to make
sure that the safety cam stops the lowering motion
of the hoisting winch.
- Push stop button to stop the crane and set the key
switch in position Normal = Exit Rig Mode.
- Hoist the hoisting wire to come out from the empty
drum area and then lower the hoisting wire to make
sure that the software limit stops the lowering mo-
tion of the hoisting winch.
Adjust Check Cam

- Lower the hook to check cam position see "Techni-
cal Data", section 2.
- Adjust the Check Cam refer to Fig. 13 and 14.
11 (14)
SERVICE 6.320.386 E rev.: c 2012-02-09
Jib top and hook block functions at large A slacking luffing or hoisting wire rope should stop
outreaches the luffing out and hoisting movements by use of the
slack wire switch BWL1.
Note!
If the crane is equipped with a high hook function, this Hook block hoisting the jib:
is not applicable. - This actuates the slack wire switch BWL1 and the
hoisting movement stops.
In a certain area there is a possibility that hook block
and jib top will meet. See Figs. 16 and 17. This will Jib landed on the hook block:
not cause any problem as the cranes safety system - Luffing wire slackens and the slack wire switch
takes care of it. BWL1 actuates. The luffing out movement stops.
It is only possible for the hook block to reach jib top

at large outreaches.
The hook block and the crane jib is designed and

calculated to take care of the forces which occur when
the hook block is hoisting the jib top or the jib top lands
on the hook block.
At small outreaches the full drum limit, BH4, on the

drum will be in operation.
The cranes are designed, calculated and manufactu-
red in accordance with and approved by classification
societies.
Area for large outreaches where hook block

and jib top will possibly meet.
Fig. 16. Large outreaches.
12 (14)
SERVICE 6.320.386 E rev.: c 2012-02-09
Hook way (full drum) limit BH4
Lifting height
H (m)
Block touches
jib top
jib
c/c
Jib bearing
centre Outreach (m)
Min. jib Max. jib

outreach outreach
Fig. 17. Hook way.
Hook stop
Hook stop
Fig. 18. Jib top.
13 (14)
SERVICE 6.320.386 E rev.: c 2012-02-09
14 (14)
SERVICE 6.321.18 E rev.: - 2007-04-10
Slack Wire Safety Switch,

Hoisting and Luffing Winches
Function Functional test, luffing

A slacking luffing or hoisting wire rope shall stop the Run the hoisting wire block/swivel slowly against the
respective winch movement before the spooling of jib top and lift the jib, to cause the luffing wire to slacken.
the rope on the drum has been damaged. The The hoisting winch shall then stop. Some cranes are
adjoining figures show the arrangement of the wire equipped with safety switches to prevent the block
sensing device with built-in switch. When the wire from touching the jib. This safety switch must be made
slackens the motion is stopped by means of a short inoperative. Lower the hoisting wire block/swivel so
ramp time. The spring-loaded pressure roll forces the that the luffing wire rope is taut. Check that the switch
wire towards the wire drum, at the same time swinging returns properly.
the arm to actuate the built-in switch.
Note! The slackwire device is not designed to detect
The slack wire function is approved as long as the slack in the rope at the position of the lifting block. It
wire is spooling properly on the drum. will only detect slack at winch.
The lifting block may lay flat on the ground/deck and

Functional test, hoisting
the slack wire device may still not be activated.
Lower the hook block on to the deck to slacken the
hoisting wire rope. Hoist the hook in order to check
This is most evident at minimum outreach. In these
that the switch returns properly.
cases there will probably never be a slack at the winch
and therefore never an automatic stop of the lowering
motion.
Wire rope
Wire rope slack
Switch
Arm
Slack wire safety switch. Normal condition. Slack wire safety switch. Slack wire condition.
1 (2)
SERVICE 6.321.18 E rev.: 2007-04-10
2 (2)
SERVICE 6.324.1 E rev.: b 2010-11-02
Preparation for Overload (OL) Test Mode
WARNING!
Overload test is only permitted when requested by
the classification society. A classification surveyor
must be present during the overload test. Key switch
Note! The surveyor has to fill in and undersign the
form on page 2.
WARNING! Error
Input
07 18
08 19
09 20
10 26
11 49
12 51
13 56
14 57
15 58
16 59
MP SP
Output
27
28
29
30
31
32
33
34
35
36
Error
07
08
09
10
19
20
11
Input
31
32
Sw19
MP
33
39
34
40
30
Sw20 55
14 Sw14
56 Sw56
SP
Output
36
43
37
45
Error MP
07
08
09
10
19
20
11
Input
31
32
Sw19
33
39
34
40
30
Sw20 55
14 Sw14
56 Sw56
SP
Output
36
43
37
45
Error
07
08
09
10
19
20
11
Input
31
32
Sw19
MP
33
39
34
40
30
Sw20 55
14 Sw14
56 Sw56
SP
Output
36
43
37
45
Error
07
08
09
10
19
20
11
Input
31
32
Sw19
MP
33
39
34
40
30
Sw20 55
14 Sw14
56 Sw56
SP
Output
36
43
37
45
17 60 37 12 15 Sw15 12 15 Sw15 12 15 Sw15 12 15 Sw15

24V 38 26 27 26 27 26 27 26 27
Com 39 58 59 58 59 58 59 58 59
During the overload test the load limits increase and

40 49 17 29 49 17 29 49 17 29 49 17 29
53 51 18 53 51 18 53 51 18 53 51 18 53
61 52 54 52 54 52 54 52 54
57 57 57 57
Com Com Com Com
the crane can lift a specified per cent more than the SC
C3
IO
C3
SC Supervisory
A1 C1
HOHoisting
A1 C1
LU Luffing
A1 C1
SL Slewing
A1 C1
AU Auxiliary
A1 C1
IO
A1
Input/Output
C1
HO_C1
SC_C3
SC_C1
AU_C1
LU_C1
SL_C1
IO_C3
IO_C1
HO_A1
SC_A1
AU_A1
LU_A1
SL_A1
IO_A1
safe working load. Inappropriate use may cause severe C4 C4 A2 C2 A2 C2 A2 C2 A2 C2 A2 C2 A2 C2
HO_C2
SC_C2
AU_C2
LU_C2
SL_C2
IO_C2
HO_A2
SC_C4
SC_A2
AU_A2
LU_A2
SL_A2
IO_C4
IO_A2
485.2 485.2 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1
HO_485.1
SC_485.1
AU_485.1
LU_485.1
SL_485.1
IO_485.1
SC_485.2
IO_485.2
HO_A3
SC_A3
AU_A3
LU_A3
SL_A3
IO_A3
485.3 485.3 Sp SSI Sp SSI Sp SSI Sp SSI Sp SSI Sp SSI
SC_485.3
IO_485.3
HO_SSI
SC_SSI
AU_SSI
LU_SSI
SL_SSI
IO_SSI
HO_Sp
SC_Sp
AU_Sp
LU_Sp
SL_Sp
IO_Sp
damage to the crane and bodily injury.
- Start the crane with pushbutton S13, START/STOP.

Fig. 1. Key switch in cabinet CT2.
- Wait until pilot light H1, "DO NOT OPERATE", goes
off.
- Wait until the display comes on.
- Set the key switch in position OL test. See Fig. 1.
NOTE! The key switch has to be set within 4 minutes
after the pilot light H1 goes off.
- A login window shows on the display. See Fig. 2.
- Write the password to accept overload test mode.
Use the software keyboard on the display.
NOTE! The password is the last four digits of the
manufacturing No., which can be found in the
instruction manual or at the sign in the cabin. The
password must be written within 5 minutes after
the key switch has been turned.
- The display should now show "OVERLOAD TEST" Fig. 2. Login window overload test.
and the diagram for load/outreach should have an
additional red area on top of the normal green area.
See Fig. 3.
- Overload test can now be done refer to MacGregor
Cranes' procedure. Contact MacGregor Cranes for
further information.
NOTE! Motions are speed reduced in overload test

mode. When the test is finished, the crane has to
be stopped to exit the overload test mode.
Fig. 3. Example of display in overload test mode.
1 (2)
SERVICE 6.324.1 E rev.: b 2010-11-02
Overload test report
Cause Date Classification Signatur Clarification of signature
2 (2)
SERVICE 6.324.2 E rev.: - 2010-11-10
Preparation for Rig Mode
WARNING! NOTE! The password is the last four digits of the

When the crane is operated in Rig mode the crane crane's manufacturing No., which can be found in
has no software limits. the instruction manual or on the sign in the cabin.
It is not permitted to have any load in the hook. The password must be written within 5 minutes after
Inappropriate use may cause severe damage to the the key switch has been turned.
crane and bodily injury.
- The display should now show "RIGGING" and the
WARNING! diagram shows only a red line. See Fig. 3.
Operation in Rig mode is only permitted together with NOTE! Motions are speed reduced in Rig mode. To
below intructions: exit Rig mode the crane has to be stopped and the
- Absolute Encoder Calibration, CC3000 key switch must be set to position "Normal".
- Rope Reeving Diagram
- Limit Switches and Software Limits
- Replacement of Wires
Procedure
- Set key switch in position Rig. See Fig. 1.

- A login window shows on the display. See Fig. 2.
- Write the password to accept Rig mode. Use the
software keyboard on the display.
Fig. 2. Login window.

Key switch
Fig. 1. Key switch in cabinet CT2. Fig. 3. Example of display in Rig mode.
1 (2)
SERVICE 6.324.2 E rev.: - 2010-11-10
2 (2)
SERVICE 6.990.61 E rev.: c 2012-01-02
Emergency Operation in Case of Complete Power Failure

Operation with a Hand Pump (Optional)
WARNING!
For reference see hydraulic circuit diagram in section
Make sure that no persons are within the working
9.4 in the parts manual. All hydraulic components in
area of the crane when the crane is emergency
this instruction can be found in the diagram.
operated.
The brake opens at approximately 6 - 13 bar (0.6 - 1.3

MPa). The pressure is changing because of the load
WARNING! in the hook.
You must only use the specified emergency hand
pump.
3 4
2 5
CAUTION!
After an emergency operation, slewing motion, hoist-
1
ing and/ or luffing lowering, examine the brake discs
inside the drive in unit and replace them if they:
- Are excessively worn
- Coloured dark yellow to blue
- Have been overheated in any other way than emer-
gency operation.
6
IMPORTANT!
- This work has to be done with great care by skilled 9 7
personnel. 8
- You can only operate one motion at a time.
- Valves 1663, 2661 and 3661 must not be operated 1. Handle
except in an emergency brake release situation. 2. Pressure relief valve
3. Safety valve
4. Air filter, oil filling
Introduction 5. Pressure gauge
6. Oil tank
This instruction describes how to do an emergency 7. Plug with o-ring, in holder
operation in case of a complete power failure. The 8. Pressure relief valve (must be closed)
slewing, luffing and hoisting motion may be operated 9. Quick coupling
to a limited extent by releasing their respective brakes
with the hand pump. Fig. 1. Hand pump, assembled for operation.
If the crane is in a good position to lower the load, start

with the emergency coupling of the hoisting circuit.
If the crane is not in position to lower the load, start
with the emergency coupling of the slewing or luffing
circuit. Move the crane into a position where the load
can be lowered.
1 (6)
SERVICE 6.990.61 E rev.: c 2012-01-02
Before operation Risk of overheating the brake discs
Before operation with the handpump the plug with the When lowering with hand pump there is risk for
o-ring must be removed from the oil filling connection overheating the brake discs. That can cause loss of
and be replaced by the plastic air filter from holder, brake force. The winch drums must not be turned
see Fig. 1. The plug with the o-ring can be placed in more than one revolution in one minute.
the holder. Wait for five minutes for the brake discs to cool down
before starting the next turn of the winch drum.
During transportation the plastic air filter must be re- To have control of the turn of the winch drum, the
placed with the plug with the o-ring and installed at winch frame and drum flange can be marked with
oil filling connection to avoid oil leakage and filter tape, see Fig. 2.
contamination.
2
The pressure relief valve must be closed during
emergency operation, see Fig. 1. If the valve is open 1
it is not possible to get hydraulic pressure to open
and close the brakes during the emergency opera-
tion.
Function test of the hand pump
Do a function test of the hand pump before operation.

- Push the safety valve button and operate the pump
with the handle, See Fig 1
- Between each pump stroke the pressure will de-
crease. Continue with pump strokes until the pres-
sure reaches 20-25 bar (2-2.5 MPa) on the pressure
gauge.
- Release the safety valve button. Then the pressure
must decrease rapidly.
- The emergency hand pump is ready for emergency
operation.
C-00253
1. Drum flange
2. Winch frame
Fig. 2 Put marks on the winch frames and drum

flanges.
2 (6)
SERVICE 6.990.61 E rev.: c 2012-01-02
Slewing circuit Operation

- Push safety valve, see Fig. 1. Release the safety
valve to quickly brake the slewing gears at any time.
WARNING!
- Release the brake by pumping oil from the hand
Risk of bodily injury. May only be operated by author-
pump. The crane may now be slewed to position
ized personnel. Operate with great care.
with the help of another crane. Be careful.
CAUTION! After operation

If the crane tilts, release the brakes with great caution. - Open ball valve 3661 and remove the hose from the
- Turn the crane in low speed. quick coupling 3662.
- Make sure that the brake closes between each
pump stroke.
Connection
- Connect the hose from the hand pump to quick
coupling 3662. See Fig. 3.
- Close ball valve 3661.
2
1
C-00250
1. Ball valve 3661

2. Quick coupling 3662
Fig. 2. Connection of hand pump, slewing circuit.
3 (6)
SERVICE 6.990.61 E rev.: c 2012-01-02
Hoisting circuit force the emergency lowering of the load must be

stopped in intervals of five minutes.
WARNING! In tropical conditions the stops must be longer than
Risk of bodily injury. May only be operated by author- five minutes. The brake discs can be cooled down with
ized personnel. Operate with great care. compressed air.

WARNING! valve to quickly brake the winch at any time.
The hoisting winch drum must only be emergency - Carefully pump with the handle until the hoisting
operated/lowered for one minute, then it must be winch drum moves. The load must be lowered slow-
stopped for five minutes. The brake discs can be ly and the brake must close between each pump
overheated and loss of brakeforce can cause load stroke.
drop. - Lower the load by turning the hoisting winch drum
one revolution during minimum one minute, see Fig.
2.
Connection - After one revolution wait for five minutes for the
- Connect the hose from the hand pump to quick brake discs to cool down, then continue lowering.
coupling 1662 on the hoisting winch, see Fig. 4.
After operation
- Open ball valve 1661.
Lower the load - Remove the hose from the quick coupling 1662.
To prevent overheated brake discs and loss of brake
2
1
C-00251
1. Ball valve 1661

Fig. 3. Connection of hand pump, hoisting winch.
4 (6)
SERVICE 6.990.61 E rev.: c 2012-01-02
Luffing circuit force the emergency lowering of the load must be

stopped in intervals of five minutes.
In tropical conditions the stops must be longer than
WARNING!
five minutes. The brake discs can be cooled down
Risk of bodily injury. May only be operated by author-
with compressed air.
ized personnel. Operate with great care.

WARNING! valve to quickly brake the winch at any time.
The luffing winch drum must only be emergency - Carefully pump with the handle until the luffing
operated/lowered for one minute, then it must be winch drum moves. The load must be lowered
stopped for five minutes. The brake discs can be slowly and the brake must close between each
overheated and loss of brakeforce can cause load pump stroke.
drop. - Lower the load by turning the hoisting winch drum
one revolution during minimum one minute, see
Fig. 2.
Connection - After one revolution wait for five minutes for the
- Connect the hose from the hand pump to quick brake discs to cool down, then continue lowering.
coupling 2662 on the luffing winch, see Fig. 5.
After operation
- Open ball valve 2661.
Lower the jib - Remove the hose from the quick coupling 2662.
To prevent overheated brake discs and loss of brake
1
2
1
C-00252
1. Ball valve 2661

Fig. 4. Connection of hand pump, luffing.
5 (6)
SERVICE 6.990.61 E rev.: c 2012-01-02
6 (6)
7.075.11 E rev.: - 2010-11-10
MacHeavyvisor Release 3.3
General
The MacHeavyvisor software is a part of the

logging and information system delivered by
MacGregor Cranes. The application is installed on
a dedicated display inside the crane cabin.
MacHeavyvisor communicates with the crane
control system (CC3000) via a data communication
cable. The display is automatically started and
stopped when the electric power of the crane
system is switched on/off.
MacHeavyvisor has two main purposes:
- Displays real-time information about current

properties of the crane such as jib outreach,
load in the hook and hoisting speed. Three examples of different cranes and
equipments.
- Log information about crane operations,
allowing future analysis.
Load diagram
The centre part of the screen shows a diagram,
which visualize the current load in the hook and jib
outreach in addition to the text values displayed in
the blue boxes. The current values are indicated
by a white “ball” with a black circumference. The
areas displayed in the diagram are defined by
CC3000.
A horizontal black line indicates the area with low

speed only.
Note! This view changes depending on the crane's

different load areas and on the extra equipment
delivered with the crane.
1 (6)
7.075.11 E rev.: - 2010-11-10
Icons If an arrow goes yellow the motion is speed

reduced by CC3000.
Standard crane The small white “ball” on the hoisting joystick

indicates the speed of the hoisting winch. During
GLH crane operating Main operation, the “ball” will move along the hoisting
Hoist circle, to indicate the direction and movement when
hoisting or lowering. Hoisting is indicated by a
GLH crane operating Whip clockwise rotation and lowering by a
Hoist
counterclockwise rotation.
Crane with ELCCL
Different modes depend on type of crane and

equipment. If there is a mode it shows centered on Ton in hook
top level of the screen.
The current load in the hook. If the value exceeds

The current date and time is displayed in UTC the overload limit the box background will flash in
time. red and an audio warning is also given. The
overload information is indicated by CC3000.
Optional
The MacGREGOR logo is displayed. When Visual warning with or without alarm sound can be
touching the logo, version information will be configured by CC3000 parameter. This warning
displayed. can be set to be triggered between 1-99% of
maximum load (at current outreach). The box will
flash in yellow colour when this warning is on.
If there is no communication with the CC3000

system, the message “Disconnected!” on the
screen. The current jib outreach
Joystick, hoisting with high and low

speed When reached the limit the box will flash in yellow.
The current
Joystick, hoisting hoisting/lowering speed
The current lifting height

Joystick, luffing/slewing
Above circles represent the joysticks used when

operating the crane. When an operation is not The current
hoisting/lowering speed
permitted by CC3000 a white cross will over cross
together with current
the corresponding arrow. lifting height
2 (6)
7.075.11 E rev.: - 2010-11-10
List When tapping the “System Error” box below

error log shows.
The list of the ship in degrees. When this value

exceeds an adjustable warning level, the
background in the box starts to flash yellow.
Exceeding the alarm level the background starts to
flash red and an audio warning sounds.
Trim
The trim of the ship in degrees. When this value

exceeds an adjustable warning level, the
background in the box starts to flash yellow.
Exceeding the alarm level the background starts to
flash red, and an audio warning sounds.
ELCCL mode
Jack-knife
When jack-knife limit is reached this icon shows on

the screen.
Standard mode
Buttons to switch different modes.

Anti-collision (optional)
If the crane has anti-collision system an indication

shows the status of the system
Twin platform (optional)
If the crane is a twin crane with anti-collision an

indicator helps the crew to position the twin
platform into “single position” and operate the anti-
collision system in single mode.
3 (6)
7.075.11 E rev.: - 2010-11-10
1. Admin (top left corner)

This manual does not cover this menu alternative,
which is protected by an administrator password.
The functions are intended for MacGregor Cranes’
personnel.
To get access to the Admin dialog box tap the top

left corner of the screen. A password dialog box
shows. Enter admin password and push OK.
If correct password is entered then the Admin

dialog box shows.
Rig mode.
First button:
Overload test.
Dialog alternatives
The program is controlled through a dialog box
system and you get access to it by touching the
background of the display. If the user stays idle
(does not push the screen) for a while (1-2
minutes) any entry will be ignored and the dialog
box closes. There are three areas to get access to
the functions and settings:
Software keyboard
Date, time and the copy logs. This is the same
When a dialog box needs input, a keyboard shows diaolog box that shows for users.
on the screen.
Second button
4 (6)
7.075.11 E rev.: - 2010-11-10
Eighth button
2. User (bottom left corner)

Tap the bottom left corner and a password dialog
box shows. Enter the user password (set to 1111)
Third button and push OK. Input of an incorrect password is
notified by a warning message, push OK to close.
Fourth button:
Fifth button:
Sixth button:
Seventh button
5 (6)
7.075.11 E rev.: - 2010-11-10
3. Offset (weight box)
To change the weight offset tap the box which

displays the weight in the top centre of the screen.
The weight offset dialog box shows on the screen.
The “Use Current” button will set the offset to the

current weight. To enter an own value just type it in
the box in the “Manual Offset” and push “Use
Manual” button. To discard any changes or just
quit the dialog box push “Cancel (No Change)”.
6 (6)
7.076.2 E rev.: c 2009-06-29
USER MANUAL
DISPLAY
CC Pilot XS
1 COMPATIBILITY .............................................................................................................................................. 2
2 THE INSTALLATION AND SERVICE .............................................................................................................. 2
3 THE CONNECTION OF PERIPHERAL DEVICES........................................................................................... 2
4 CODE DATA ..................................................................................................................................................... 2
5 THE SERVICE AND PROTECTION INSTRUCTIONS..................................................................................... 2
6 DISPLAY UNIT ................................................................................................................................................. 3

6.1 BUTTONS:.................................................................................................................................................... 3
6.2 LEDS: .......................................................................................................................................................... 3
6.3 CONNECTORS: ............................................................................................................................................. 3
7 STARTUP ......................................................................................................................................................... 3
8 PROBLEM SOLVING ....................................................................................................................................... 4

8.1 THE DISPLAY IS DARK OR DIM ........................................................................................................................ 4
8.2 SERIAL PORT FAULTS ................................................................................................................................... 4
8.3 LED IS BLINKING RED BUT PROGRAM DOESN’T START .................................................................................... 4
9 TECHNICAL DATA .......................................................................................................................................... 4
1 (4)
7.076.2 E rev.: c 2009-06-29
1 Compatibility
The display is compatible with Windows CE and Linux.
2 The installation and service

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

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

Your display is of a high quality product, and it should be used carefully. Following instructions help you to keep
product in good condition for a long time.
• The display shall be cleaned regularly. Wipe out the screen of the device by the soft moist fabric. Do not
use alkaline or alcohol including cleaning agents.
• Do not scratch, damage or press the surface of the display.
If the display would not work correct, please contact MacGREGOR, Service Department, Örnsköldsvik,
Sweden.
2 (4)
7.076.2 E rev.: c 2009-06-29
6 Display unit
X1
1 X2
2 X8
3
4 X5
5
X9
X6
The display screen has 10.4” LCD TFT display with a touch screen.
6.1 Buttons:
1. Power button can be used to turn on/off the unit. If pressed for a long time, there will be a
forced power off.
2. Increase brightness.
3. Decrease brightness.
6.2 LEDs:
4. Red LED that blinks at start up.
5. Light detector of automatic brightness adjustment.
6.3 Connectors:
X1 Power
X2 Ethernet1
X5 Misc (Used as Serial communication port)
X6 CAN1
X8 USB1
X9 USB2
7 Start up
The display starts up at the same time as the crane. First it loads the operating system and after that
the display starts the program. When starting, screen is black and the red LED is blinking.
3 (4)
7.076.2 E rev.: c 2009-06-29
8 Problem solving
If there are some problem with the display check the following first, then call MacGREGOR Service Department.
8.1 The display is dark or dim when crane is working
• Check the brightness adjustment of the screen.
• Check cables and connectors to the display unit.
• Push the power on button on the display unit.
8.2 Communication faults
• Check that the cables are properly connected.
8.3 LED is blinking red but program does not start
• Try to switch off the unit and start again with the power button.
9 Technical Data
This display is especially developed for use of heavy machinery, which guarantees system durability and flexible
expandability to the different applications.
Kernel Power
Processor Intel XScale, 533 MHz Voltage 10 - 36 VDC
Compact Flash 32 MB -> commercially available Current < 500 mA at 24 VDC (6.5’’)
Kernel Flash 32/ 64 MB Environment
RAM -> 256 MB SDRAM IP-class IP65
Graphic controller Silicon motion, 8 MB RAM Temperature range -40 °C - +65 °C (operating)
Interfaces -40 °C - +70 °C (storage)
2 x CAN 2.0B, ISO 11898 – 24V,1 Mbit EMC conformity In accordance with 89/336/EEC:
2 x Ethernet 10/100 Base-T EN 50081-2: 1993
2 x USB 2.0 Software
RS232 OPTION. 115000 baud, replaces Operating system: Windows CE 5.0
Keyboard & Mouse Via USB Internal control
Display Status LED In front panel
10.4’’ SVGA 800x600 TFT Photo diode Automatic backlight control
Backlight CCFL ~400 nit Internal temperature protection against overheating
Touch screen Resistive in abnormal ambient conditions.
Mechanical
Enclosure Aluminum Dimensions
Mounting Stand Screen size: 10.4’’
Connectors DIN M12 Depth: 40 mm
Height: 217 mm
Width: 285 mm
4 (4)
EXTRA EQUIPMENT 7.082.1 E rev.: - 2009-01-15
Installation of Maintenance Platform on Foundation

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

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

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

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

platform.
Fig. 3. Support (customer's responsability). Fig. 4. Foundation.
1 (2)
EXTRA EQUIPMENT 7.082.1 E rev.: - 2009-01-15
2 (2)
9.0 How to order
spare parts
Cargotec Sweden AB
MacGregor Cranes
Sjögatan 4G
Telephone: 46 - 660 - 29 40 00
Telefax: 46 - 660 - 139 77
9.1 Machinery
www.cargotec.com
Spare Parts Manual 9.2 Pump unit

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

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

Please use this form whenever assistance is needed. Service request
Confirmation of
phone call/conv.
From: .. ............................................................. E-mail address: ................................................
.............................................................. Phone no.: ......................................................
.............................................................. Telefax no.: ......................................................
Re: M/V ........................................................ IMO /Lloyd's no.: ..............................................
Crane type: ............................................. Serial no: .........................................................
Crane place: ........................................... Our ref.: ..........................................................
For following spares we would like to: have your quotation
place order, deadline for arrival :................................
Part no. Qty Description Fig./Drwg. Item
1. .......................................... ..... ............................................ .............................. ..............
2. ........................................... ..... ............................................ .............................. ..............
3. ........................................... ..... ............................................ .............................. ..............
4. ........................................... ..... ............................................ .............................. ..............
5. ........................................... ..... ............................................ .............................. ..............
6. See enclosure
Delivery/Agent's address: ............................................................................................................
............................................................................................................
............................................................................................................
...................................................................................................................
Name/ Title/
PARTS MANUAL Date Group Fig. Page
2012-01-18 9.1 625-1450.212 1 (2)
HOISTING WINCH
1212912
625-1450.212
Weight 3.300 kg
2012-01-18 9.1 625-1450.212 2 (2)
HOISTING WINCH
Item Qty Article no Description Supplementary data
000 1 1212912 HOISTING WINCH

2010-12-16 9.1 625-1450.184 1 (2)
LUFFING WINCH
1187739
625-1450.184 /0
Weight 1.490 kg
2010-12-16 9.1 625-1450.184 2 (2)
LUFFING WINCH
000 1 1187739 LUFFING WINCH

2008-05-14 9.1 625-2250.022 1 (2)
WINCH MOUNTING SET
9 800 Nm
10 4
4
3
800 Nm 9
10
9 800 Nm
289 5365-801
625-2250.022
2008-05-14 9.1 625-2250.022 2 (2)
WINCH MOUNTING SET

000 1 289 5365-801 WINCH MOUNTING SET
003 10 489 5009-010 . WASHER
004 10 488 7386-002 . WASHER
005 16 488 7386-001 . WASHER
006 16 488 7386-005 . WASHER
007 2 489 6415-801 . LIMIT SWITCHES BOX, MOUNT. SEE FIG. 625-6248.001
009 26 2121 2037-737 . SCREW M6S 24 x 160 -10.9 spec.
010 10 2126 2039-126 . NUT M6M 24 -10 spec.

2010-12-17 9.1 625-1440.195 1 (2)
ASSEMBLY SET
277 Nm
1192483
625-1440.195
2010-12-17 9.1 625-1440.195 2 (2)
ASSEMBLY SET
000 1 1192483 ASSEMBLY SET
001 8 2121 2030-629 . SCREW M6S 16 x 45 -10.9; DIN 933
002 8 487 2826-002 . WASHER

2010-12-17 9.1 625-1440.196 1 (2)
ASSEMBLY SET
277 Nm
1192647
625-1440.196
2010-12-17 9.1 625-1440.196 2 (2)
ASSEMBLY SET
001 8 2121 2030-630 . SCREW M6S 16 x 50 -10.9
002 8 487 2826-002 . WASHER

2010-09-22 9.1 625-3254.029 1 (2)
ASSEMBLY SET
275 Nm
1 3
1 dl
1192648
625-3254.029
2010-09-22 9.1 625-3254.029 2 (2)
ASSEMBLY SET
001 4 2121 2030-628 . SCREW M6S 16 x 40 - 10.9; DIN 933
002 4 487 2826-002 . WASHER
003 1 1263 2078-001 . MOLYKOTE 1000 Solid lubricant paste

2010-09-28 9.1 625-3256.016 1 (2)
DRIVE IN, COMPLETE
46 Nm 4
3
19
312
1000000279439
311
22
8 10 11
20
25 26
16
15
80 Nm
15 321 322
27
21
12
14
13
46 Nm 28 9
30
5
7
6
Disc arrangement,
item 321 + 322
Motor side
Outer discs
Center line
Inner discs
Gear side
9
875 13004-157
625-3256.016 /0
Weight 50 kg
2010-09-28 9.1 625-3256.016 2 (2)
DRIVE IN, COMPLETE

000 1 875 13004-157 . DRIVE IN, COMPLETE
003 1 875 13027-056 . MOTOR FLANGE
004 12 2121 2532-513 . SCREW MC6S 10x110 -8.8 FZB; DIN 912
005 1 875 13011-002 . BEARING
006 1 875 13012-003 . CIRCLIP
007 1 875 13012-004 . CIRCLIP
008 2 875 13012-019 . CIRCLIP
009 1 875 13007-003 . SHAFT SEALING
010 2 875 13014-037 . SHIM
011 1 875 13003-001 . PRESSURE UNIT
012 1 875 13028-002 . DISC CARRIER
013 2 875 13007-001 . SEALING
014 2 875 13006-002 . PLUG M22
015 2 875 13007-008 . SEALING
016 1 875 13006-004 . PLUG M18
019 1 875 13008-011 . VENTILATION FILTER M10
020 1 875 13010-020 . COUPLING
021 2 875 13005-001 . OIL SIGHT GLASS M22
022 1 875 13008-016 . VENTILATION FILTER M12; 0.2 bar
025 1 875 13023-014 . COVER
026 1 875 13015-053 . O-RING 26 x 3.0
027 18 2121 2532-548 . SCREW MC6S 12 x 80 -8.8 FZB; DIN 912
028 12 2121 2532-501 . SCREW MC6S 10 x 50 -8.8 FZB; DIN 912
030 2 875 13015-046 . O-RING 75,87 x 2,62
311 20 875 13002-001 . SPRING Change all 40 springs at the same time.
312 20 875 13002-002 . SPRING Change all 40 springs at the same time.
321 9 875 13001-001 . MULTIPLE DISC, OUTER Change all 16 discs at the same time.
322 7 875 13001-002 . MULTIPLE DISC, INNER Change all 16 discs at the same time.
2007-11-23 9.1 625-3254.023B 1 (2)
SLEWING GEAR ASSEMBLY SET
5 6
2 275 Nm
1
3
391 0246-801
625-3254.023
2007-11-23 9.1 625-3254.023B 2 (2)
SLEWING GEAR ASSEMBLY SET

000 1 391 0246-801 SLEWING GEAR ASSEMBLY SET
001 X . SLEWING GEAR See mechanical specification
002 24 2121 2030-632 . SCREW M6S 16 x 60 -10.9
003 24 487 2311-005 . WASHER
005 1 487 7218-002 . NIPPLE
006 1 2152 2151-178 . SEALING

2010-09-24 9.1 625-3255.040 1 (2)
SLEWING GEAR
109 110
1189838
625-3255.040 /0
Weight 225 kg
2010-09-24 9.1 625-3255.040 2 (2)
SLEWING GEAR
000 1 1189838 SLEWING GEAR MODULE 14
003 1 875 13004-157 . DRIVE IN, COMPLETE SEE FIG. 625-3256.016
109 4 875 13007-001 . SEALING
110 4 875 13006-001 . PLUG, MAGNETIC M22

2012-01-19 9.2 625-4935.245A 1 (2)
BRAKE PUMP UNIT
4 3
1219768
625-4935.245 /A
2012-01-19 9.2 625-4935.245A 2 (2)
BRAKE PUMP UNIT

000 1 1219768 BRAKE PUMP UNIT
001 1 1224554 . LEVEL AND TEMP. SENSOR
002 1 1224683 . OIL FILTER
003 1 1224684 . PRESSURE SWITCH
004 1 1224690 . DIRECTIONAL VALVE

2012-01-19 9.3 625-6102.580 1 (4)
CRANE HOUSE ASSEMBLY
30 22
23
29
35
12
35 CT14
CT13
17 18 19 40
110 109
6 4 36 37
14 33
35
5 4 CT2
31
CT1
13 7 35
3
CT10
16 39
38 15
31
1219977
625-6102.580
2012-01-19 9.3 625-6102.580 2 (4)

000 1 1219977 CRANE HOUSE ASSEMBLY
003 x . SLEWING BEARING MOUNTING SEE SLEWING SPECIFICATION
004 1 289 5365-801 . WINCH MOUNTING SET SEE FIG. 625-2250.022
005 x . HOISTING WINCH ASSEMBLY SEE MECHANICAL SPECIFICATION
006 x . LUFFING WINCH ASSEMBLY SEE MECHANICAL SPECIFICATION
007 x . JIB BEARING MOUNTING SEE MECHANICAL SPECIFICATION
012 1 1189584 . CABIN ASSEMBLY CRANE HOUSE SEE FIG. 625-6540.042
013 1 289 5323-801 . LIMIT SWITCHES BOX SEE FIG. 625-6245.635
014 1 289 5449-801 . LIMIT SWITCHES BOX SEE FIG. 625-6245.643
015 1 1192647 . ASSEMBLY SET SEE FIG. 625-1440.196
018 x . SLEWING GEAR ASSEMBLY SEE HYDRAULIC SPECIFICATION
019 2 391 0246-801 . SLEWING GEAR ASSEMBLY SET SEE FIG. 625-3254.023
022 x . CRANE TOP MOUNTING SEE MECHANICAL SPECIFICATION
023 1 390 7581-801 . PROTECTIVE PLATE MOUNT. SEE FIG. 625-6459.051
029 1 390 3274-801 . COVER MOUNTING SEE FIG. 625-6169.005
031 1 1191997 . ENCODER ASSEMBLY SEE FIG. 624-2180.018
033 x . OIL TANK ASSEMBLY SEE HYDRAULIC SPECIFICATION
035 x . ELECTRICAL CABINET SEE TABLE OF CONTENCE SECTION
036 1 1192902 . VENTILATION FAN ASSEMBLY SEE FIG. 625-6625.027
037 x . VENTILATION FAN SEE TABLE OF CONTENTS SECTION
038 x . ELECTRIC MOTOR SEE TABLE OF CONTENTS SECTION

2012-01-19 9.3 625-6102.580 3 (4)
30 22
23
29
35
12
35 CT14
CT13
17 18 19 40
110 109
6 4 36 37
14 33
35
5 4 CT2
31
CT1
13 7 35
3
CT10
16 39
38 15
31
1219977
625-6102.580
2012-01-19 9.3 625-6102.580 4 (4)

109 1 289 3393-801 . SLACK WIRE DEVICE, MOUNT.
110 1 289 3396-801 .. SLACK WIRE DEVICE SEE FIG. 625-6250.023

2011-11-21 9.3 625-6122.029A 1 (2)
SLEWING SPECIFICATION
CRANE
5
FOUNDATION
490 6432-801
625-6122.029
2011-11-21 9.3 625-6122.029A 2 (2)
SLEWING SPECIFICATION
000 1 490 6432-801 SLEWING SPECIFICATION
001 1 289 5663-801 . SLEWING BEARING 10 x greasing nipples. Ball bearing
004 1 391 0032-801 . SLEWING BEARING MOUNTING SEE FIG. 625-6123.003
005 1 391 0033-801 . SLEWING BEARING YARD MOUNTING SEE FIG. 625-6124.003
2011-11-18 9.3 625-6123.003 1 (2)
SLEWING BEARING MOUNTING
391 0032-801
625-6123.003
2011-11-18 9.3 625-6123.003 2 (2)
SLEWING BEARING MOUNTING

000 1 391 0032-801 SLEWING BEARING MOUNTING
002 99 390 9268-010 . STUD M30x265: Special requirements
003 99 2121 2039-130 . NUT M6M 30; Special requirements

2011-11-18 9.3 625-6124.003 1 (2)
SLEWING BEARING YARD MOUNTING
391 0033-801
625-6124.003
2011-11-18 9.3 625-6124.003 2 (2)
SLEWING BEARING YARD MOUNTING

000 1 391 0033-801 SLEWING BEARING YARD MOUNTING
001 100 390 9268-011 . STUD M30x300; Special requirements.
002 100 1205600 . WASHER
003 100 2126 2039-130 . NUT M6M 30; Special requirements.

2010-05-24 9.3 625-6169.005A 1 (2)
COVER MOUNTING
2010-05-24 9.3 625-6169.005A 2 (2)
COVER MOUNTING
000 1 390 3274-801 COVER MOUNTING
001 1 390 3282-801 . COVER ASSEMBLY SEE FIG. 625-6169.006
002 4 2121 2034-455 . SCREW M6S 8 x 30 -A4 -80
003 4 2151 2027-164 . WASHER RB 8.4 x 16 -A4
004 4 2126 2634-118 . LOCKING NUT M6M 8 -A4-80

2003-01-30 9.3 625-6169.006 1 (2)
COVER ASSEMBLY
2003-01-30 9.3 625-6169.006 2 (2)
COVER ASSEMBLY
000 1 390 3282-801 COVER ASSEMBLY
001 1 390 3282-001 . COVER
002 1 389 1581-802 . HANDLE
003 1 1856 2160-001 . SEAL STRIP L= 2010
004 2 389 1903-004 . HINGE
005 6 2121 2034-451 . SCREW M6S 8 x 20 -A4-80
006 6 2151 2027-164 . WASHER RB 8.4 x 16 -A4
007 6 2126 2634-118 . NUT M6M 8 -A4-80

2010-04-21 9.3 625-6170.082 1 (2)
JIB BEARING HOUSING
10
5
4
2
12
5
3 4
9
11
11
12
2
1184754
625-6170.082
2010-04-21 9.3 625-6170.082 2 (2)
JIB BEARING HOUSING

000 1 1184754 JIB BEARING HOUSING
001 1 1184753 . BEARING HOUSING
002 2 388 9574-001 . RING
003 2 388 9575-001 . WASHER
004 24 487 2826-002 . WASHER
005 6 489 3362-001 . CLIP
006 1 490 4616-801 . BEARING
009 12 2121 2030-648 . SCREW M6S 16 x 150 -10.9
010 12 2126 2038-124 . NUT M6M 16 -10
011 2 2152 2115-543 . O-RING
012 2 2186 2187-170 . V-RING

2010-07-17 9.3 625-6170.085 1 (2)
JIB BEARING ASSEMBLY
Notice!
Shaft must be mounted correctly,
grease holes towards jib in 45°.
See punchmark on shaft.
45°
2
Punchmarks
235 Nm
3
4
5
7
1191812
625-6170.085
2010-07-17 9.3 625-6170.085 2 (2)
JIB BEARING ASSEMBLY

000 1 1191812 JIB BEARING ASSEMBLY
001 1 1191825 . JIB BEARING SHAFT
002 1 1184754 . JIB BEARING HOUSING SEE FIG. 625-6170.082
003 12 487 2826-002 . WASHER
004 1 1191826 . PLATE
005 1 490 3578-001 . SPACER
006 12 2121 2030-630 . SCREW M6S 16 x 50 -10.9
007 2 2152 2115-529 . O-RING
008 1 2545 2110-003 . GREASE NIPPLE AM 10 x 1 -A2-50

2011-02-17 9.3 625-6244.077 1 (2)
JIB TOP MOUNTING
18
22
10
10
10
10
10
9
10
8
6
12
22
9
18
1195433
625-6244.077
2011-02-17 9.3 625-6244.077 2 (2)
JIB TOP MOUNTING

000 1 1195433 JIB TOP MOUNTING
006 1 390 4860-001 . SHAFT
008 2 1185110 . DISTANCE
009 4 489 5334-002 . LOCK WASHER
010 6 490 4086-801 . WIRE SHEAVE
012 1 1185111 . DISTANCE
018 1 2121 2034-628 . SCREW M6S 16 x 40 -A2-70

2011-12-07 9.3 625-6245.635B 1 (2)
LIMIT SWITCHES BOX
22 26 27
23 24
31
14 15
16 17
32
18 19 20 21
25
289 5323-801
625-6245.635 /B
2011-12-07 9.3 625-6245.635B 2 (2)
LIMIT SWITCHES BOX

000 1 289 5323-801 LIMIT SWITCHES BOX
001 1 875 15017-012 . CAM DISC WITH ARM, COMPLETE 30° - 55°
014 6 875 15001-001 . MICRO SWITCH 1A
015 2 875 15001-002 . THREADED STUD WITH NUTS M3. Cut to right length.
016 1 875 15003-023 . COVER, COMPLETE Incl. screws and sealing.
017 1 875 15003-002 .. SEALING L = 2000 mm
018 4 2121 2034-457 .. SCREW M6S 8 x 35 -A2-70
019 4 2126 2034-118 .. NUT M6M 8 - A2-70
020 4 2151 2027-164 .. WASHER BRB 8.4 x 16 -A2
021 4 2126 2432-118 .. CAP NUT MHM 8 -6 FZB
022 1 875 15012-013 . WORM GEAR, COMPLETE Incl. screws. Ratio 50:1.
023 1 875 15006-008 . SHAFT COUPLING, COMPLETE
024 1 875 15008-005 . KEY 4 x 4 x 16
025 2 875 15002-003 . CABLE GLAND WITH NUT
026 2 875 15009-003 . SCREW T6SS 4 x 6 -A2
027 1 875 15006-013 . SHAFT
031 1 ENCODER Ordered separately.

2007-12-13 9.3 625-6245.643 1 (2)
LIMIT SWITCHES BOX
22 33
23 24
32
1
14 15
2
16 17 5
8
18 19 20 21
9
289 5449-801 25 31 10
625-6245.643 /0
2007-12-13 9.3 625-6245.643 2 (2)
LIMIT SWITCHES BOX

000 1 289 5449-801 LIMIT SWITCHES BOX
014 10 875 15001-001 . MICRO SWITCH 1A
015 2 875 15001-002 . THREADED STUD WITH NUTS M3. Cut to right length.
016 1 875 15003-028 . COVER, COMPLETE Incl. screws and sealing.
017 1 875 15003-002 .. SEALING L = 2000 mm
018 4 2121 2034-457 .. SCREW M6S 8 x 35 -A2-70
019 4 2126 2034-118 .. NUT M6M 8 - A2-70
020 4 2151 2027-164 .. WASHER BRB 8.4 x 16 -A2
021 4 2126 2432-118 .. CAP NUT MHM 8 -6 FZB
022 1 875 15012-005 . WORM GEAR, COMPLETE Incl. screws. Ratio 50:1.
023 1 875 15006-008 . SHAFT COUPLING, COMPLETE
024 1 875 15008-002 . KEY 4 x 4 x 20
025 2 875 15002-002 . CABLE GLAND WITH NUT
031 1 875 15018-001 . PLAIN BEARING

2009-06-15 9.3 625-6248.001B 1 (2)
LIMIT SWITCHES BOX, MOUNT.

2009-06-15 9.3 625-6248.001B 2 (2)
LIMIT SWITCHES BOX, MOUNT.

000 1 489 6415-801 LIMIT SWITCHES BOX, MOUNT.
002 3 2122 2519-378 . SCREW MSK6SS 6 x 40 -A4
003 3 2151 2027-156 . WASHER BRB 6.7 x 14 -A2
004 3 2126 2034-116 . NUT NYLOC - M6M 6 -A4-80

2004-10-13 9.3 625-6250.023 1 (2)
SLACK WIRE DEVICE

2004-10-13 9.3 625-6250.023 2 (2)
SLACK WIRE DEVICE

000 1 289 3396-801 SLACK WIRE DEVICE
001 1 288 2344-801 . SUPPORT
002 1 288 2345-801 . BRACE
003 1 288 2346-801 . BRACE
004 2 388 3290-004 . LIMIT SWITCH PART
005 2 489 5947-001 . SPRING
006 2 489 4601-001 . SCREW
007 2 489 4604-001 . SPACER
008 18 490 4586-001 . ROLLER
009 4 490 4587-001 . WASHER
010 2 490 4591-001 . SCREW
011 20 488 8518-014 . WASHER
012 2 489 6172-001 . SHAFT
013 2 2184 4024-546 . LINK SCREW M12 x 80 FZB
014 2 2121 2032-544 . SCREW M6S 12 x 60 -8.8 FZB
015 8 2121 2532-339 . SCREW MC6S 5 x 40 -8.8 FZB
016 4 2121 2032-331 . SCREW M6S 5 x 20 -8.8 FZB
017 6 2126 2032-122 . NUT M6M 12 -8 FZB
018 6 2126 2636-124 . LOCKING NUT M6M 16 -8 FZB; DIN 982
019 4 2151 2022-185 . WASHER BRB 17 x 30 FZB
020 8 2151 2022-196 . WASHER BRB 23 x 40 FZB
021 4 2114 2014-201 . SPLIT PIN SP 4 x 40 -A4
022 1 5661 4116-512 . LIMIT SWITCH, HOISTING
023 1 5661 4126-001 . LIMIT SWITCH

2006-03-06 9.3 625-6275.004C 1 (2)
CRANE JIB, YARD MOUNTING

2006-03-06 9.3 625-6275.004C 2 (2)
CRANE JIB, YARD MOUNTING

000 1 489 5409-801 CRANE JIB, YARD MOUNTING
001 8 388 7147-009 . SCREW M6S 30 x 210 -10.9 spec.
002 8 490 3816-008 . WASHER

2003-01-29 9.3 625-6404.001 1 (2)
MOUNTING WIRE LOCK JIB TOP

2003-01-29 9.3 625-6404.001 2 (2)
MOUNTING WIRE LOCK JIB TOP

000 1 390 3374-801 MOUNTING WIRE LOCK JIB TOP
001 1 389 3943-001 . SHAFT
002 1 489 4345-003 . LOCKING PLATE
003 2 489 5334-002 . LOCK WASHER 17 SSt
006 2 2121 2034-624 . SCREW M6S 16 x 30 -A4-80

2011-12-20 9.3 625-6404.003 1 (2)
MOUNT. WIRELOCK JIB TOP
7
1
6
3
2
1184729
625-8751.005
2011-12-20 9.3 625-6404.003 2 (2)
MOUNT. WIRELOCK JIB TOP

000 1 1184729 MOUNT. WIRELOCK JIB TOP
001 1 389 3943-002 . SHAFT
002 1 489 4345-003 . LOCKING PLATE
003 2 489 5334-002 . LOCK WASHER
006 2 2121 2034-624 . SCREW M6S 16 x 30 -A2-70

2011-12-20 9.3 625-6404.004 1 (2)
LOAD CELL ASSEMBLY
1223123
625-6404.004
2011-12-20 9.3 625-6404.004 2 (2)
LOAD CELL ASSEMBLY

000 1 1223123 LOAD CELL ASSEMBLY
001 1 1190251 . LOAD CELL
002 1 1184729 . MOUNT. WIRELOCK JIB TOP SEE FIG. 625-6404.003

2011-02-16 9.3 625-6408.120 1 (2)
CRANE JIB MOUNTING
1195432
625-6408.120
2011-02-16 9.3 625-6408.120 2 (2)
CRANE JIB MOUNTING

000 1 1195432 CRANE JIB MOUNTING
003 1 1195433 . JIB TOP MOUNTING
004 1 390 3374-801 . MOUNTING WIRE LOCK JIB TOP SEE FIG. 625-6404.001
2011-01-28 9.3 625-6459.074 1 (2)
CRANE TOP MOUNTING
25 18 15
13
7
9
2
19
16
7
7
7 7
9
19
16
9
10
17
12
20
25
25
14
16
19
11
25
1195405
625-6459.074
2011-01-28 9.3 625-6459.074 2 (2)
CRANE TOP MOUNTING

000 1 1195405 CRANE TOP MOUNTING
001 1 289 1841-001 . SHAFT
002 1 289 1842-001 . SHAFT
007 6 490 4086-801 . WIRE SHEAVE
009 3 1184786 . SPACER
010 1 1184788 . SPACER
011 1 490 3620-001 . COVER
012 1 490 3621-001 . COVER
013 1 489 5223-001 . SPACER
014 1 489 4345-004 . LOCKING PLATE
015 4 489 5334-001 . LOCK WASHER
016 6 489 5334-002 . LOCK WASHER
017 2 2154 2233-192 . LOCK WASHER
018 5 2121 2034-495 . SCREW M6S 10 x 30 -A2-70
019 6 2121 2034-628 . SCREW M6S 16 x 40 -A2-70
020 2 2121 2034-672 . SCREW M6S 20 x 40 -A2-70
025 7 2545 2110-003 . GREASE NIPPLE A-M 10 x 1 -A2-50

2007-01-17 9.3 625-6459.051 1 (2)
PROTECTIVE PLATE MOUNT.
4 3 2
390 7581-801
625-6459.051
2007-01-17 9.3 625-6459.051 2 (2)
PROTECTIVE PLATE MOUNT.

000 1 390 7581-801 PROTECTIVE PLATE MOUNT.
001 1 390 7582-001 . PROTECTIVE PLATE
002 6 2121 2034-542 . SCREW M6S 12 x 50 -A2 -70
003 6 2151 2054-178 . WASHER TBRSUB 13 x 36 FZB
004 6 2126 2634-122 . NUT M6M 12 -A2 -70

92-02-19 9.3 625-6509A 1 (2)
INCLINOMETER, C
92-02-19 9.3 625-6509A 2 (2)
INCLINOMETER, C
000 1 388 0176-801 INCLINOMETER, C
001 1 488 7233-001 . INCLINOMETER
002 3 2121 2254-378 . SCREW MCS 6 x 40 -5.8 G
003 11 2126 2032-116 . NUT M6M 6 -8 FZB
004 1 488 7511-001 . BRACKET
005 5 2151 2022-153 . WASHER BRB 6.4 x 12 G
006 2 2121 2034-370 . SCREW M6S 6 x 20 -A2-70
007 2 2151 2025-153 . WASHER BRB 6.4 x 12 SSt

2010-11-15 9.3 625-6540.042 1 (2)
CABIN ASSEMBLY CRANE HOUSE
1189584
625-6540.042
2010-11-15 9.3 625-6540.042 2 (2)
CABIN ASSEMBLY CRANE HOUSE

000 1 1189584 CABIN ASSEMBLY CRANE HOUSE
001 1 1189585 . CABIN ASSEMBLY SEE FIG. 625-6545.072
002 3 489 5395-801 . BRACKET
003 3 489 5154-003 . SHAFT
004 1 488 9225-001 . WASHER
005 1 1189615 . RUBBER STRIP
007 3 2151 2027-192 . WASHER RB 21 x 37 -A4
008 6 2114 2014-201 . SPLIT PIN SP 4 x 40 A4
010 X 1234 2413-050 . LOCKING FLUID 243

2010-09-27 9.3 625-6545.072 1 (2)
CABIN ASSEMBLY
57
48
16
39
4
42
56 59
47 50
35
16
24 41
20
21
13
1189585
625-6545.072
2010-09-27 9.3 625-6545.072 2 (2)
CABIN ASSEMBLY
000 1 1189585 CABIN ASSEMBLY
004 1 289 2251-801 . CAB CUPOLA ASSEMBLY SEE FIG. 625-6560.007
005 1 390 8573-801 . CAB DOOR ASSEMBLY SEE FIG. 625-6546.008
013 1 390 4053-801 . EMERGENCY DOOR ASSY SEE FIG. 625-6546.001
016 2 488 3152-801 . VENTILATOR, C
020 2 490 3825-001 . PLATE
021 12 489 3492-001 . SHIM
024 1 1188780 . RUBBER STRIP
035 39 2121 2034-495 . SCREW M6S 10 x 30 -A4-80
039 12 2121 2550-339 . SCREW MC6S 5 x 40 A4-80
041 11 2121 2550-370 . SCREW MC6S 6 x 20 -A4 -80
042 6 2121 2550-374 . SCREW MC6S 6 x 30 -A4-80
047 18 2126 2634-114 . LOCKING NUT M6M 5 -A4 -80
048 17 2126 2634-116 . LOCKING NUT M6M 6 -A4 -80
050 39 2126 2634-120 . LOCKING NUT NYLOC-M6M 10-A4-80
056 18 2151 2027-146 . WASHER BRB 5.3 x 10 -A4
057 8 2151 2027-156 . WASHER RB 6.7 x 14 -A4
059 39 2151 2027-173 . WASHER RB 10.5 x 20 -A4

2002-06-26 9.3 625-6546.001 1 (2)
EMERGENCY DOOR ASSY

2002-06-26 9.3 625-6546.001 2 (2)
EMERGENCY DOOR ASSY

000 1 390 4053-801 EMERGENCY DOOR ASSY
001 1 390 4054-001 . WINDOW
002 2 389 1581-801 . HANDLE
003 2 489 5392-801 . HINGE
004 6 2121 2636-331 . SCREW MFS 5 x 20 -A4-80
005 6 2126 2634-114 . NUT M6M 5 -A4 -80
006 6 2151 2027-146 . WASHER BRB 5.3 x 10 -A4
007 1 489 2006-801 . EYE BOLT WITH WIRE
008 X 1236 2135-021 . SEALING COMPOUND

2006-10-30 9.3 625-6546.008 1 (2)
CAB DOOR ASSEMBLY

2006-10-30 9.3 625-6546.008 2 (2)
CAB DOOR ASSEMBLY

000 1 390 8573-801 CAB DOOR ASSEMBLY
001 1 289 4337-001 . DOOR
003 1 390 8574-801 . DOOR LOCK
004 1 1856 2141-006 . RUBBER MOULDING L = 5310 mm

2009-06-29 9.3 625-6560.007A 1 (2)
CAB CUPOLA ASSEMBLY

2009-06-29 9.3 625-6560.007A 2 (2)
CAB CUPOLA ASSEMBLY

000 1 289 2251-801 . CAB CUPOLA ASSEMBLY
001 1 189 2327-001 . CAB CUPOLA
002 1 387 6167-803 . SLIDE WINDOW
003 1 388 0223-001 . GLASS
004 1 388 0145-002 . GLASS
005 1 388 0145-003 . GLASS
006 2 388 0145-004 . GLASS
007 1 289 2251-007 . RUBBER MOULDING
008 1 289 2251-008 . LOCKING LIST
009 1 488 7400-001 . HOLDER
010 4 488 7601-001 . HOLDER
012 17 2126 2034-116 . NUT M6M 6 -A4-80
013 15 2121 2844-374 . SCREW MVBF 6 x 30 -A4-80
015 X 1236 2273-001 . SEALING

2005-05-10 9.3 625-6561.001C 1 (2)
WINDSCREEN CLEANER
2005-05-10 9.3 625-6561.001C 2 (2)
WINDSCREEN CLEANER
000 1 387 6227-802 WINDSCREEN CLEANER
010 1 6179 2151-280 . WIPER MOTOR
011 1 387 6227-920 .. MOUNTING SET For shaft ø20
012 1 387 6227-916 .. MOUNTING SET For shaft ø16
030 1 6179 2153-700 . WIPER BLADE L = 700 mm
090 1 6179 2152-600 . ARM L = 600 mm
101 2 2126 2032-118 . NUT M6M 8 -8 FZB
102 2 2154 2016-164 . SPRING WASHER FBB 8,2 FZB

2010-10-22 9.3 625-6625.014A 1 (2)
VENTILATION FAN
390 2115-801
625-6625.014
2010-10-22 9.3 625-6625.014A 2 (2)
VENTILATION FAN
000 1 390 2115-801 VENTILATION FAN

2010-09-30 9.3 625-6625.027 1 (2)
VENTILATION FAN ASSEMBLY
2 3 4 5
1 3 4 5
1192902
625-6625.027
2010-09-30 9.3 625-6625.027 2 (2)
VENTILATION FAN ASSEMBLY

000 1 1192902 VENTILATION FAN ASSEMBLY
001 1 288 0945-801 . TUB FOR FAN
002 8 2121 2032-459 . SCREW M6S 8 x 40 -8.8 FZB
004 20 2151 2058-165 . WASHER TBRSB 8.4 x 26 FZB
005 X 1236 2296-020 . SEAL STRIP 19 x 2

2011-12-12 9.3 625-7013.126 1 (2)
LIFTING BLOCK
Important!
When replacing genuine parts,
an overload test of the complete
unit has to be done.
New certificate to be issued.
See instruction 6.000.1 E.
12
13 1 2 3
5 6
16
14
7 8
11
10
1205161
625-7013.126
Weight 1170 kg
2011-12-12 9.3 625-7013.126 2 (2)
LIFTING BLOCK
000 1 1205161 LIFTING BLOCK SWL 36 tonnes.
001 1 875 12401-022 . SHEAVE, COMPLETE
002 1 875 12054-004 .. BEARING
003 2 875 12062-003 .. LOCK RING
004 2 875 12009-007 . SPACER
005 1 875 12404-013 . SHAFT, COMPLETE
006 1 2545 2011-025 .. GREASE NIPPLE A-M10 x 1 FZB; DIN 71412
007 1 875 12413-010 . SWIVEL, COMPLETE
008 3 2545 2011-025 .. GREASE NIPPLE A-M10 x 1 FZB; DIN 71412
009 2 875 12073-007 . SHACKLE
010 1 875 12001-027 . HOOK, COMPLETE Incl.safty latch kit.
011 1 875 12064-003 .. SAFETY LATCH KIT Incl. spring, screw, nut.
012 1 1227187 . PROTECTION CAP, COMPLETE Incl. screws
013 6 875 12406-001 . SPACER, COMPLETE Incl. spacer tube, screw, nut.
014 1 875 12409-011 . CABLE LEADER, COMPLETE
016 2 2183 2022-126 . LIFTING EYE BOLT M20 FZV; DIN 580
2011-03-09 9.4 625-7207.018 1 (2)
VALVE UNIT
2 6
18
18
1
2 6
1204092
625-7207.018
2011-03-09 9.4 625-7207.018 2 (2)
VALVE UNIT
000 1 1204092 VALVE UNIT
001 1 187 8727-001 . VALVE BLOCK
002 2 1204093 . DIRECTIONAL VALVE SEE FIG. 625-7322.082
003 1 387 7053-803 . PRESSURE SWITCH, C
006 8 2121 2541-378 . SCREW MC6S 6 x 40 -12.9
018 1 2541 4129-113 . BALL VALVE

2011-03-10 9.4 625-7322.082 1 (2)
DIRECTIONAL VALVE
1204093
625-7322.082
2011-03-10 9.4 625-7322.082 2 (2)
DIRECTIONAL VALVE
000 1 1204093 DIRECTIONAL VALVE
001 1 489 6335-801 . COIL
002 1 489 6334-801 . GASKET SET

87-02-19 9.4 625-7444 1 (2)
PRESSURE SWITCH, C
87-02-19 9.4 625-7444 2 (2)
PRESSURE SWITCH, C
000 1 387 7053-803 PRESSURE SWITCH, C
001 1 2152 2151-204 . SEAL RING TM 130
002 1 488 4933-001 . PLUG

2011-11-23 9.4 625-7951.007 1 (2)
ACCUMULATOR
1219345
625-7951.007
2011-11-23 9.4 625-7951.007 2 (2)
ACCUMULATOR
000 1 1219345 ACCUMULATOR Preload pressure 20 bar.
001 1 1226037 . REPAIR KIT

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.

2012-01-23 9.4 625-7994.004 1 (2)
TUBING BRAKE
2
18
1219586
625-7994.004
2012-01-23 9.4 625-7994.004 2 (2)
TUBING BRAKE
000 1 1219586 TUBING BRAKE
002 3 1204092 . VALVE UNIT SEE FIG. 625-7207.018
003 1 1219345 . ACCUMULATOR SEE FIG. 625-7951.007
018 4 2152 2151-178 . SEALING

2010-09-27 9.5 625-8563.069 1 (2)
DRIVERS DESK
7 8
14 72 73 9 10
15
11 12
13
1189978
625-8563.069
2010-09-27 9.5 625-8563.069 2 (2)
DRIVERS DESK
000 1 1189978 DRIVERS DESK
002 1 390 8558-001 . DRIVER SEAT
003 1 1189898 . CONTROL PANEL SEE FIG. 625-8597.057
004 1 414 6792-801 . CONTROLLER SEE FIG. 625-8596
006 1 314 3980-801 . SIREN
007 1 5915 4262-002 . ARMATURE 60 W
008 1 5911 4145-060 . LAMP BULB 220 V 60 W E27
009 1 387 6227-802 . WINDSCREEN CLEANER SEE FIG. 625-6561.001
010 1 388 9799-001 . COVER
011 3 5217 4837-240 . SCREW CONNECTION
012 3 5217 4838-240 . BULKHEAD HOUSING
013 1 314 4244-801 . CABIN HEATER
014 1 287 4867-002 . ARM REST
015 1 288 1058-001 . ARM REST
072 1 488 7461-001 . SIGN
073 1 488 6906-001 . SIGN

2011-11-27 9.5 625-8564.023 1 (2)
EL.INST.CRANE HOUSE
53 54
2 5 1
1 2 4 5
52
1212847
625-8564.023
2011-11-27 9.5 625-8564.023 2 (2)
EL.INST.CRANE HOUSE
000 0 1212847 EL.INST.CRANE HOUSE
001 2 324 1408-801 . ABSOLUTE SINGLETURN ENCODER
002 2 324 1409-801 . INCREMENTAL ENCODER 5000 SEE FIG. 624-2180.025
004 2 390 9852-801 . MOUNTING ENCODER SEE FIG. 624-2180.015
005 1 390 9851-801 . MOUNTING ENCODER SEE FIG. 624-2180.014
008 2 324 1353-801 . HEATING FAN
052 1 5375 4231-024 . SWITCH
053 4 5912 4102-020 . FLUORESCENT TUBE 18 W
054 2 5915 4315-001 . ARMATURE 2 x 18 W

2010-12-23 9.5 625-8567.045A 1 (2)
EL. INST. JIB LIGHT, CRANE
124 0647-801
625-8567.045
2010-12-23 9.5 625-8567.045A 2 (2)
EL. INST. JIB LIGHT, CRANE

000 1 124 0647-801 EL. INST. JIB LIGHT, CRANE
001 1 1684 2126-301 . CABLE MPRX 3 x 1.5 L=7m
002 2 2121 2550-370 . SCREW MC6S 6 x 20 -A2-70
003 2 2126 2634-116 . LOCKING NUT M6LM 6 - A2-70
004 2 2151 2027-156 . WASHER BRB 6.7 x 14 -A2
005 1 2166 2051-823 . CABLE GLAND Pr 22.5
007 1 5388 4121-002 . CONNECTION BOX

2011-10-05 9.5 625-8567.046C 1 (2)
EL. INST. JIB LIGHT (PACKING)
25 26
2 14 13 12
124 0648-801
625-8567.046
2011-10-05 9.5 625-8567.046C 2 (2)
EL. INST. JIB LIGHT (PACKING)

000 1 124 0648-801 EL. INST. JIB LIGHT (PACKING)
002 2 490 5473-001 . SCREW
005 1 1190048 . CABLE L = 40m
012 2 2126 2634-122 . LOCKING NUT M6LM 12 - A2-70
013 2 2151 2027-178 . WASHER BRB 13 x 24 -A2
014 2 2151 2027-185 . WASHER BRB 17 x 30 -A2
025 1 5911 4529-410 . HALOGEN LAMP 1000W
026 1 5921 2141-101 . FLOOD LIGHT

92-11-03 9.5 625-8595 1 (2)
CONTROLLER, C
92-11-03 9.5 625-8595 2 (2)
CONTROLLER, C
000 1 314 2721-802 CONTROLLER, C
001 1 414 5396-801 . POTENTIOMETER WITH CARD
002 1 414 2081-801 BELLOWS WITH BRACE SPARE PART NO: 662 0034-000
91-11-14 9.5 625-8592C 1 (2)
CONTROLLER, LUFFING/SLEWING
91-11-14 9.5 625-8592C 2 (2)
CONTROLLER, LUFFING/SLEWING
000 1 314 2006-802 CONTROLLER, LUFFING/SLEWING
001 2 414 5396-801 . POTENTIOMETER WITH CARD
002 1 414 2081-801 BELLOWS WITH BRACE SPARE PART NO: 662 0034-000
1997-10-07 9.5 625-8596 1 (2)
CONTROLLER
1997-10-07 9.5 625-8596 2 (2)
CONTROLLER
000 1 414 6792-801 CONTROLLER
001 1 414 7054-001 . COVER
002 1 314 2006-802 . CONTROLLER, LUFFING/SLEWING SEE FIG. 625-8592
003 1 2152 2067-018 . COVER PLATE
004 1 2121 2550-331 . SCREW MC6S 5 x 20 A4-80
005 2 2126 2634-114 . NUT M6M 5 -A4 -80
006 1 2151 2027-146 . WASHER RB 5.3 x 10 -A4

2010-09-23 9.5 625-8597.057 1 (4)
CONTROL PANEL
1189898
625-8597.057
2010-09-23 9.5 625-8597.057 2 (4)
CONTROL PANEL
000 1 1189898 CONTROL PANEL
001 1 224 0206-001 . COVER
002 1 314 2721-802 . CONTROLLER, C
006 1 424 0641-801 . SWITCH WITH HANDLE
011 1 424 0643-001 . LENS WITH SYMBOL
012 1 424 0643-004 . LENS WITH SYMBOL
013 1 1190001 . LENS WITH SYMBOL
015 1 424 0643-002 . LENS WITH SYMBOL
016 1 424 0643-006 . LENS WITH SYMBOL
028 1 424 0646-001 . SIGN
030 1 424 0644-002 . SIGN
032 1 424 0644-005 . HEADLINE SIGN
033 1 424 0644-006 . HEADLINE SIGN
038 5 5298 2070-100 . PILOT LAMP RED
045 1 5372 2206-003 . CONTACT BLOCK
046 1 5372 2206-002 . CONTACT BLOCK
048 1 5372 2203-001 . PUSH BUTTON
049 1 5372 2204-102 . PUSH BUTTON
050 1 5372 2202-101 . EMERGENCY STOP
053 2 5375 4340-102 . SWITCH
056 1 5375 4341-112 . SWITCH WITH KEY
058 1 5672 4245-002 . CIRCUIT BREAKER
061 13 2152 2069-225 . BLANKING PLUG
062 1 5372 2205-122 . PUSH BUTTON

2010-09-23 9.5 625-8597.057 3 (4)
CONTROL PANEL
1189898
625-8597.057
2010-09-23 9.5 625-8597.057 4 (4)
CONTROL PANEL
063 1 2152 2067-018 . COVER PLATE
064 1 2121 2550-331 . SCREW MC6S 5 x 20 -A2-70
066 2 2126 2634-114 . LOCKING NUT M6LM 5 - A2-70
068 1 2151 2027-146 . WASHER BRB 5.3 x 10 -A2
069 1 5372 2207-004 . CONTACT BLOCK

2011-01-26 9.5 625-8597.061 1 (2)
EL. INST JIB LIGHT (CABIN)
324 2043-801
625-8597.061
2011-01-26 9.5 625-8597.061 2 (2)
EL. INST JIB LIGHT (CABIN)

000 1 324 2043-801 EL. INST JIB LIGHT (CABIN)
001 1 5372 2207-011 . CONTACT BLOCK
003 1 5372 2205-142 . PUSH BUTTON

2011-01-27 9.5 625-8597.062 1 (2)
EL. INST. DECK LIGHT (CABIN)
2 3
14 15
324 1722-801
625-8597.062
2011-01-27 9.5 625-8597.062 2 (2)
EL. INST. DECK LIGHT (CABIN)

000 1 324 1722-801 EL. INST. DECK LIGHT (CABIN)
002 1 5372 2205-143 . PUSH BUTTON
003 1 5372 2207-011 . CONTACT BLOCK
014 2 5921 2141-101 . FLOOD LIGHT
015 2 5911 4529-410 . HALOGEN LAMP 1000W

2011-01-27 9.5 625-8597.063 1 (2)
EL. INST. FORCE LIMIT GRAB (CA
324 1724-801
625-8597.063
2011-01-27 9.5 625-8597.063 2 (2)
EL. INST. FORCE LIMIT GRAB (CA

000 1 324 1724-801 EL. INST. FORCE LIMIT GRAB (CA
001 1 5375 4340-131 . SWITCH
002 1 424 0644-014 . SYMBOL

2011-03-28 9.5 625-8597.069 1 (2)
EL.INST. VENTILATION FAN (CAB)
1, 2
324 2098-801
625-8597.069
2011-03-28 9.5 625-8597.069 2 (2)
EL.INST. VENTILATION FAN (CAB)

000 1 324 2098-801 EL.INST. VENTILATION FAN (CAB)
001 1 5375 4340-102 . SWITCH
002 1 424 0644-008 . SIGN
003 1 414 4354-002 . VENTILATOR

2011-03-30 9.5 625-8597.074 1 (2)
EL INST AIR CIRCUL FAN (CABIN)
1 12
324 1848-801
625-8597.074
2011-03-30 9.5 625-8597.074 2 (2)
EL INST AIR CIRCUL FAN (CABIN)

000 1 324 1848-801 EL INST AIR CIRCUL FAN (CABIN)
001 1 5375 4340-102 . SWITCH
004 1 6480 2150-024 . FAN
012 1 424 0644-008 . SIGN

2011-06-27 9.5 625-8597.081 1 (2)
CABIN DISPLAY ASSEMBLY
1182879
625-8597.081
2011-06-27 9.5 625-8597.081 2 (2)
CABIN DISPLAY ASSEMBLY

000 1 1182879 CABIN DISPLAY ASSEMBLY
004 1 1183160 . CABLE

2012-01-18 9.5 625-8598.140 1 (6)
ELECTRICAL CABINET CT1/CT2
1213177
625-8598.140
2012-01-18 9.5 625-8598.140 2 (6)

000 1 1213177 ELECTRICAL CABINET CT1/CT2
001 1 1189718 . TEMPERATURE SENSOR
002 1 1188839 . THERMOSTAT
003 1 1188840 . HEATER
004 1 5349 2021-102 . KNOB
005 1 1190324 . ENCLOSURE
006 1 5692 4740-024 . HOUR METER
007 1 1188132 . POWER SUPPLY
008 2 1188133 . POWER SUPPLY
009 1 1188414 . CABINET
010 1 1189715 . TRANSFORMER
011 3 1212929 . FUSE
012 2 2611 3109-104 . COLLECTOR RAIL
013 7 2611 3130-116 . CONN. LINK
014 2 1196903 . CONNECTING LINK
015 5 2663 4383-102 . TERMINAL BLOCK
016 16 2669 4160-015 . END HOLDER
017 3 2669 4180-060 . FUSE TERMINAL
018 1 324 1165-801 . TRANSFORMER 1-PHASE
019 1 424 0644-013 . SIGN
020 2 1193301 . RESISTOR
021 1 5340 2011-501 . CIRCUIT BREAKER
022 1 1190309 . CIRCUIT BREAKER
023 1 5347 4262-202 . CIRCUIT BREAKER

2012-01-18 9.5 625-8598.140 3 (6)
1213177
625-8598.140
2012-01-18 9.5 625-8598.140 4 (6)

024 1 1187547
. COMPACT FLASH CARD Must be ordered separately
026 5 5354 4130-400 . CONTACTOR RELAY
027 1 1196887 . RELAY
028 8 5354 4273-009 . CONTACTOR
029 3 5354 4273-012 . CONTACTOR
030 1 5372 2202-101 . EMERGENCY STOP
031 1 5381 4280-001 . ELECTRICAL OUTLET
032 2 5572 4105-063 . MOTOR SWITCH
033 3 5572 4105-160 . MOTOR SWITCH
034 2 5572 4105-916 . MOTOR SWITCH
035 1 5638 1000-230 . SAFETY RELAY
036 2 5639 4161-202 . IMPULSE RELAY
037 1 1211917 . CONTROL UNIT Must be ordered separately
038 X 1187548 . SENSOR MODULE Must be ordered separately
039 2 7635 4113-200 . THERMOSTAT
040 3 7426 4200-050 . SURGE SUPPRESSOR
042 2 5672 4212-140 . FUSE
043 1 5672 4212-120 . FUSE 5x20 2A
044 2 5347 4262-206 . CIRCUIT BREAKER
047 9 5354 4137-501 . AUXILIARY CONTACT BLOCK

2012-01-18 9.5 625-8598.140 5 (6)
1213177
625-8598.140
2012-01-18 9.5 625-8598.140 6 (6)

048 2 5572 4105-400 . MOTOR SWITCH
049 X 1187549 . COMMUNICATION CARD (CAN) Must be ordered separately
053 10 1190937 . CABLE CLAMP
054 4 1189943 . CABLE
056 3 324 0089-801 . RELAY CARD WITH LED’S SEE FIG. 625-8599.020
057 3 5349 2002-105 . CONNECTOR
058 1 5349 2011-105 . COVER
059 10 1190938 . CABLE CLAMP
061 1 1197848 . CABLE PROTECTION
062 3 5354 4137-510 . AUXILIARY CONTACT BLOCK
063 2 1202852 . CONTACTOR
066 1 5347 4262-106 . CIRCUIT BREAKER
067 1 5375 4340-122 . SWITCH
068 1 1196427 . CABINET CONTROL SEE FIG. 625-8600.020
069 1 2166 2058-004 . MOUNTING BASE
070 2 2124 2550-228 . SCREW
071 6 2638 3100-544 . COPPER BRAID
072 9 5218 3107-111 . AUXILIARY CONTACT
073 2 5347 4262-306 . CIRCUIT BREAKER
074 2 1196599 . DRIVECLIQ CABLE 0.6m
075 1 1191510 . MOTOR SWITCH
076 4 2663 4382-025 . TERMINAL BLOCK
077 1 2669 4106-025 . PARTITION PLATE

2012-01-18 9.5 625-8598.141 1 (4)
EL.CABINET (CT10)
1213017
625-8598.141
2012-01-18 9.5 625-8598.141 2 (4)
EL.CABINET (CT10)
000 1 1213017 EL.CABINET (CT10)
004 2 1189578 . ASSEMBLY PLATE
005 12 2121 2032-449 . SCREW M6S 8 x 16 -8.8 FZB
006 1 1188842 . HEATER
007 1 1189614 . TERMINAL STRIP
008 1 2166 2058-004 . MOUNTING BASE
010 3 1193301 . RESISTOR
011 1 1189100 . BUSBAR CU
013 1 1189895 . CABLE 0,2m
014 12 1189825 . WASHER
015 3 1190046 . CABLE
017 3 1192689 . CABLE CLAMP
018 3 1192690 . CABLE CLAMP
019 2 2641 2101-505 . CABLE TERMINAL
020 6 2641 2101-920 . CABLE TERMINAL
021 5 1186625 . CABLE
022 20 1189888 . CABLE
023 1 1189890 . CABLE
024 48 2154 2033-009 . WASHER BRIF 8.4 G
025 24 2121 2032-451 . SCREW M6S 8 x 20 -8.8 FZB; DIN 933
027 X 1187539 . ACTIVE INTERFACE MODULE Must be ordered separately
028 X 1214628 . ACTIVE LINE MODULE Must be ordered separately

2012-01-18 9.5 625-8598.141 3 (4)
EL.CABINET (CT10)
1213017
625-8598.141
2012-01-18 9.5 625-8598.141 4 (4)
EL.CABINET (CT10)
101 1 1188819 . CABINET BASIC
102 1 1196389 .. FILTER MAT
220 8 1188837 . FILTER Incl. filter mat
221 1 1196388 .. FILTER MAT
231 1 1196387 .. FILTER MAT

2012-01-18 9.5 625-8598.142 1 (4)
ELECTRICAL CABINET (CT13)
1213018
625-8598.142
2012-01-18 9.5 625-8598.142 2 (4)

000 1 1213018 ELECTRICAL CABINET (CT13)
004 6 2121 2034-495 . SCREW M6S 10 x 30 -A2-70
005 1 1188842 . HEATER
006 2 1189655 . ASSEMBLY PLATE
007 25 1189888 . CABLE
008 6 1189890 . CABLE
010 3 1190283 . CABLE
011 48 2154 2033-009 . WASHER BRIF 8.4 G
012 1 1189100 . BUSBAR CU
014 1 2166 2058-004 . MOUNTING BASE
017 3 1193301 . RESISTOR
018 6 2126 2634-120 . LOCKING NUT M6LM 10 - A2-70
019 12 2151 2027-173 . WASHER BRB 10.5 x 20 -A2
020 24 2121 2032-451 . SCREW M6S 8 x 20 -8.8 FZB; DIN 933
021 1 1189895 . CABLE 0,2m
023 6 2121 2032-449 . SCREW M6S 8 x 16 -8.8 FZB
024 6 1189825 . WASHER
025 1 1197830 . CABLE PIT
026 3 1189891 . CABLE
027 1 1194728 . CABLE
028 4 2641 2101-705 . CABLE SOCKET

2012-01-18 9.5 625-8598.142 3 (4)
1213018
625-8598.142
2012-01-18 9.5 625-8598.142 4 (4)

029 1 2641 2101-505 . CABLE TERMINAL
030 5 1192689 . CABLE CLAMP
031 1 1192690 . CABLE CLAMP
032 X 1214531 . SINGLE MOTOR MODULE
101 1 1188821 . CABINET
102 1 1196390 .. FILTER MAT
221 1 1196387 .. FILTER MAT
231 1 1196388 .. FILTER MAT

2011-11-29 9.5 625-8598.110A 1 (4)
EL. CABINET (CT14)
1189233
625-8598.110
2011-11-29 9.5 625-8598.110A 2 (4)
EL. CABINET (CT14)

000 1 1189233 EL. CABINET (CT14)
004 1 1188842 . HEATER
006 3 1193301 . RESISTOR
008 1 1189095 . END COVER
009 1 1189099 . CONNECTION ADAPTOR 250A
010 1 1189098 . CONNECTION ADAPTOR 800A
011 2 1189094 . BUSBAR SUPPORT
012 2 1189100 . BUSBAR CU
013 1 1189097 . BASE TRAY
014 1 1189096 . COVER SECTION
015 5 2166 2058-004 . MOUNTING BASE
016 6 1189890 . CABLE
018 12 2121 2032-368 . SCREW M6S 6 x 16 -8.8 FZB; DIN 933
019 12 1190082 . WASHER
020 1 2166 2304-806 . CABLE PIT
021 6 1189888 . CABLE
022 9 1186625 . CABLE
023 3 1190283 . CABLE
024 2 2121 2034-497 . SCREW
025 2 2126 2634-120 . LOCKING NUT M6LM 10 - A2-70
026 4 2154 2033-010 . WASHER
027 6 1189891 . CABLE

2011-11-29 9.5 625-8598.110A 3 (4)
EL. CABINET (CT14)
1189233
625-8598.110
2011-11-29 9.5 625-8598.110A 4 (4)
EL. CABINET (CT14)

028 5 1186617 . CABLE
029 2 2641 2101-103 . TUBE TERMINAL
030 1 2641 2101-104 . CABLE TERMINAL
031 9 1192689 . CABLE CLAMP
032 1 1192690 . CABLE CLAMP
033 1 1194728 . CABLE
034 X 1187543 . SINGLE MOTOR MODULE Must be ordered separately.
035 X 1187544 . DC ADAPTER Must be ordered separately.
036 X 1187545 . 24V PLINTH ADAPTER Must be ordered separately.
037 X 1187575 . SINGLE MOTOR MODULE Must be ordered separately.
038 X 1187550 . SHIELD CONNECTION Must be ordered separately.
039 X 1187577 . SHIELD CONNECTION Must be ordered separately.
101 1 1188823 . CABINET
102 1 1196391 .. FILTER MAT
221 1 1196387 .. FILTER MAT
230 1 1188843 . FILTER FAN Incl. filter mat
231 1 1196387 .. FILTER MAT

2000-03-28 9.5 625-8599.020 1 (2)
RELAY CARD WITH LEDs

2000-03-28 9.5 625-8599.020 2 (2)
RELAY CARD WITH LEDs

000 1 324 0089-801 RELAY CARD WITH LEDs
006 4 414 4667-007 . SPACER
007 4 2121 2254-220 . SCREW MCS 3 x 6 -5.8 FZB
008 4 2126 2636-110 . NUT NYLOC-M6M 3 -8 FZB
009 4 2154 2022-124 . WASHER AZ 3.2 FZB

2010-02-2 9.5 625-8600.020 1 (2)
CABINET CONTROL
6 4 3 11
50 50
50
459
458 457
455 453
451 449
Hardware Hardware Hardware Hardware 448 438
xxx xxxx-xxx xxx xxxx-xxx xxx xxxx-xxx xxx xxxx-xxx 437 436
435 434
Error MP SP Error MP SP Error MP SP Error MP SP 433 432
431 430
Input Output Input Output Input Output Input Output
07 18 27 33 36 33 36 33 36 429 427
07 07 07 426 425
08 19 28 39 43 39 43 39 43
09 20 29 34 37 34 37 34 37 420 419
08 08 08 418 417
10 26 30 40 45 40 45 40 45
29
415 414
11 49 31 09 31 09 31 09 31
30 30 30 412 411
12 51 32 10 32 10 32 10 32
408 407
13 56 33 19 Sw19 19 Sw19 19 Sw19
404 403
Encoder 14 57 34 20 Sw20 55 20 Sw20 55 20 Sw20 55
402 401
calibration 15 58 35 11 14 Sw14 11 14 Sw14 11 14 Sw14
16 59 36 56 Sw56 56 Sw56 56 Sw56
28
17 60 37 12 15 Sw15 12 15 Sw15 12 15 Sw15
50 50
24V 38 26 27 26 27 26 27
42 359
Com 39 58 59 58 59 58 59
358 357
C1 R1 40 49 17 29 49 17 29 49 17 29
356 355
Normal C2 R2 53 51 18 53 51 18 53 51 18 53
353 349
Em.Op. C3 R3 61 52 54 52 54 52 54
348 338
C4 MP 57 C1 R1 57 C1 R1 57 C1 R1
337 336
C2 MP C2 MP C2 MP
335 334
Com Com Com
333 332
331 330
CC MC MC MC
329 327
326 325
320 319
318 317
315 314
Sc Ho Lu Sl
312 311
308 307
Select / Info Select / Info Select / Info Select / Info 304 303
Normal 302 301
Up Up Up Up
Rigg OL-Test
Down / Exit Down / Exit Down / Exit Down / Exit
50 50
50 50
259 258
257 256
50 42
255 254
PC COM PC COM PC COM PC COM 50 42
253 252
50 42
251 249
50 42
248 247
50 42
Software Software Software Software 245 243
98 97
241 240
96 95
239 238
94 93
237 236
92 91
235 234
90 89
233 232
SC IO SC Supervisory HO Hoisting LU Luffing SL Slewing AU Auxiliary IO Input/Output 88 87
231 230
C28
C36
C44
C52
C17
C6
86 85
C3 C3 A1 C1 A1 C1 A1 C1 A1 C1 A1 C1 A1 C1 229 227
SC_C3 1
IO_C3 1
SC_C1 1
HO_C1 1
LU_C1 1
SL_C1 1
AU_C1 1
IO_C1 1
84 83
226 225
82 81
HO_A1
AU_A1
SC_A1
LU_A1
SL_A1
IO_A1
220 219
80 79
218 217
78 77
P115 P1115 P108 P208 P308 P408 P508 P1108 215 214
76 75
P101 P201 P301 P401 P501 P1101 212 211
C29
C37
C45
C53
C18
74 73
C7
C4 C4 A2 C2 A2 C2 A2 C2 A2 C2 A2 C2 A2 C2 210 209
72 71
1
SC_C2 1
HO_C2 1
LU_C2 1
SL_C2 1
AU_C2 1
IO_C2 1
208 207
70 69
HO_A2
SC_C4
AU_A2
SC_A2
LU_A2
SL_A2
IO_C4
IO_A2
204 203
68 67
202 201
66 65
P109 P209 P309 P409 P509 P1109 50 50
64 63
P116 P1116 P102 P202 P302 P402 P502 P1102 50 50
62 61
485.2 485.2 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1 42 42
60 23
SC_485.2 1
IO_485.2 1
SC_485.11
HO_485.11
LU_485.11
SL_485.11
AU_485.11
IO_485.1 1
42 42
22 21
HO_A3
AU_A3
SC_A3
LU_A3
SL_A3
161 160
IO_A3
20
158 157
19
P103 P110 P210 P310 P403 P410 P510 P1110 153 151
P203 P303 P503 P1103 18
149 143
P117 P1117
C12
C34
C33
C42
C41
C50
C49
C58
C57
C23
C22
C11
17
141 137
485.3 485.3 Sp SSI Sp SSI Sp SSI Sp SSI Sp SSI Sp SSI 16
SC_485.3 1
IO_485.3 1
136 135
15
134 133
14 13
HO_SSI
AU_SSI
SC_SSI
LU_SSI
SL_SSI
HO_Sp
IO_SSI
132 131
AU_Sp
SC_Sp
LU_Sp
SL_Sp
IO_Sp
12 11
130 128
10 9
127 126
P118 P1118 8 7
125 119
6 5
118 117
P107 P106 P207 P206 P307 P306 P407 P406 P507 P506 P1107 P1106 4 3
116 115
2 1
114 113
112 111
110 109
108 107
104 103
102 101
1196427
625-8600.020
2010-02-2 9.5 625-8600.020 2 (2)
CABINET CONTROL
000 1 1196427 CABINET CONTROL
003 3 . MC-CARD See table of contents section 9.5
004 1 . CC-CARD See table of contents section 9.5
006 1 324 1663-X . MEMORY CARD X = Crane manufacturing No.
011 5 5245 4507-003 . POWER RESISTOR
028 1 1202073 . SWITCH
029 1 1202072 . SWITCH

2010-09-30 9.5 625-8635.007 1 (2)
ELECTRIC MOTOR
1
2
1188770
625-8635.007 /0
2010-09-30 9.5 625-8635.007 2 (2)
ELECTRIC MOTOR
000 1 1188770 ELECTRIC MOTOR
001 1 5692 4607-101 . INCREMENTAL ENCODER
002 1 1197621 . FAN WITH MOTOR

2010-09-30 9.5 625-8635.008 1 (2)
ELECTRIC MOTOR
1
2
1188769
625-8635.008 /0
2010-09-30 9.5 625-8635.008 2 (2)
ELECTRIC MOTOR
001 1 5692 4607-101 . INCREMENTAL ENCODER
002 1 1197622 . FAN WITH MOTOR

2012-01-19 9.5 625-8635.011 1 (2)
ELECTRIC MOTOR
1188771
625-8635.011
2012-01-19 9.5 625-8635.011 2 (2)
ELECTRIC MOTOR

2010-10-08 9.5 625-8650.001 1 (2)
EL. INST. IMPULS RELAY
224 0116-801
625-8650.001
2010-10-08 9.5 625-8650.001 2 (2)
EL. INST. IMPULS RELAY

000 1 224 0116-801 EL. INST. IMPULS RELAY
002 1 5639 4161-202 . IMPULSE RELAY

2011-02-02 9.5 625-8650.005 1 (2)
EL. INST. FORCE LIMIT GRAB CT1
1, 2
4
224 0547-801
625-8650.005
2011-02-02 9.5 625-8650.005 2 (2)
EL. INST. FORCE LIMIT GRAB CT1

000 1 224 0547-801 EL. INST. FORCE LIMIT GRAB CT1
001 1 5354 4133-221 . CONTACTOR RELAY
002 1 7426 4200-050 . SURGE SUPPRESSOR
004 1 2669 4160-015 . END HOLDER

2011-03-28 9.5 625-8650.010 1 (2)
EL. INST. POWER SUPPLY (CT1)
1, 2
224 0506-801
625-8650.010
2011-03-28 9.5 625-8650.010 2 (2)
EL. INST. POWER SUPPLY (CT1)

000 1 224 0506-801 EL. INST. POWER SUPPLY (CT1)
001 1 2669 4180-060 . FUSE TERMINAL
002 1 5672 4212-140 . FUSE
003 1 4762 4201-100 . POWER SUPPLY
005 1 2669 4160-015 . END HOLDER

2011-02-03 9.5 625-8655.001 1 (2)
CABIN DISPLAY
424 0715.801
625-8655.001
2011-02-03 9.5 625-8655.001 2 (2)
CABIN DISPLAY
000 1 424 0715-801 CABIN DISPLAY
001 1 5730 1003-101 . DISPLAY
002 1 424 0632-801 . USB CABLE
003 1 424 0786-801 . BUZZER CABLE

2010-10-05 9.5 625-8750.023 1 (2)
SLIPRING DEVICE
196
196 8 8
52
52
Earth 52
11
1192979
625-8750.023 /0
Weight 54 kg
2010-10-05 9.5 625-8750.023 2 (2)
SLIPRING DEVICE
000 1 1192979 SLIPRING DEVICE
003 4 875 17206-001 . CABLE TERMINAL
008 30 875 17202-001 . SIGNAL BRUSH, COMPLETE 20 A
009 1 875 17205-001 . RUBBER BELLOW
011 1 875 17205-003 . CLAMP
052 4 875 17201-001 . POWER BRUSH, COMPLETE 400 A, Qty 1 used as earth.
196 32 875 17203-001 . HOLDER Qty 2 used as gap fillers.

2008-10-30 9.7 624-2180.014 1 (2)
MOUNTING ENCODER
390 9851-801
624-2180.014
2008-10-30 9.7 624-2180.014 2 (2)
MOUNTING ENCODER
000 1 390 9851-801 MOUNTING ENCODER
001 1 490 4982-001 . TORQUE ARM
002 3 2121 2550-220 . SCREW MC6S 3 x 6 -A2-70

2008-10-30 9.7 624-2180.015 1 (2)
MOUNTING ENCODER
390 9852-801
624-2180.015
2008-10-30 9.7 624-2180.015 2 (2)
MOUNTING ENCODER
000 1 390 9852-801 MOUNTING ENCODER
001 1 490 4982-001 . TORQUE ARM
002 3 2121 2550-220 . SCREW MC6S 3 x 6 -A2-70

2010-12-20 9.7 624-2180.018 1 (2)
ENCODER ASSEMBLY
6 10 12
18
19 22 8 17
5 11 13
2 4 1 9 14
1191997
624-2180.018
2010-12-20 9.7 624-2180.018 2 (2)
ENCODER ASSEMBLY
000 1 1191997 ENCODER ASSEMBLY
001 1 390 4817-001 . LOCKING PLATE
002 1 1192022 . SHAFT
004 1 390 7664-801 . JIB
005 2 490 4056-001 . BUSHING
006 1 490 4982-001 . TORQUE ARM
007 1 2186 2111-118 . SEALING
008 1 1192056 . TUBE
009 2 2121 2034-540 . SCREW M6S 12 x 40 -A2-70
010 3 2121 2550-220 . SCREW MC6S 3 x 6 -A2-70
011 3 2121 2550-370 . SCREW MC6S 6 x 20 -A2-70
012 3 2151 2027-124 . WASHER BRB 3,2 x 7 -A2
013 3 2151 2027-156 . WASHER BRB 6.7 x 14 -A2
014 2 2151 2054-178 . WASHER TBRSUB 13 x 36 FZB
017 1 2545 2110-001 . GREASE NIPPLE G 1/4 A2-50
018 1 2154 2421-114 . CIRCLIP
019 1 2151 2027-178 . WASHER BRB 13 x 24 -A2
022 X . ABSOLUTE ENCODER See table of contents section 9.7

2011-07-07 9.7 624-2180.023 1 (2)
ABSOLUTE SINGLETURN ENCODER
324 1408-801
624-2180.023
2011-07-07 9.7 624-2180.023 2 (2)
ABSOLUTE SINGLETURN ENCODER

000 1 324 1408-801 ABSOLUTE SINGLETURN ENCODER

2011-09-12 9.7 624-2180.025 1 (2)
INCREMENTAL ENCODER 5000
324 1409-801
624.2180-025
2011-09-12 9.7 624-2180.025 2 (2)
INCREMENTAL ENCODER 5000

000 1 324 1409-801 INCREMENTAL ENCODER 5000

2010-12-13 9.7 624-2196.001 1 (2)
ELECTRICAL PEDESTAL ASSEMBLY
20 = Electrical System
13 14
13 14
13 14
13 14
12
11 30
10
31
1196430
624-2196.001
2010-12-13 9.7 624-2196.001 2 (2)
ELECTRICAL PEDESTAL ASSEMBLY

000 1 1196430 ELECTRICAL PEDESTAL ASSEMBLY
010 1 1196673 . ELECTRICAL OUTLET
011 1 1200949 . SWITCH
012 1 5375 4231-024 . SWITCH
013 4 5915 4315-001 . ARMATURE 2 x 18 W
014 8 5912 4102-020 . FLUORESCENT TUBE 18 W
020 1 1202034 . ELECTRICAL SYSTEM
030 1 1196543 . JUNCTION BOX, X71A SEE FIG. 624-2196.002
031 1 1196773 . JUNCTION BOX, X71B SEE FIG. 624-2196.003

2010-12-10 9.7 624-2196.002 1 (4)
JUNCTION BOX, X71A
1196543
624-2195.002
2010-12-10 9.7 624-2196.002 2 (4)
JUNCTION BOX, X71A

000 1 1196543 JUNCTION BOX, X71A
001 1 224 0348-801 . CASING
002 1 1189895 . CABLE 0,2m
003 1 2641 2101-505 . CABLE TERMINAL
004 1 1201763 . SIGN
005 16 2121 2032-451 . SCREW M6S 8 x 20 -8.8 FZB; DIN 933
006 3 2124 2550-228 . SCREW
007 8 1201609 . DISTANCE
008 16 2126 2032-118 . NUT M6M 8 -8 FZB
009 1 414 3662-002 . CLAMP
010 2 2121 2550-329 . SCREW MC6S 5 x 16 -A2-70
011 1 1201817 . SHEET
012 4 2154 2033-006 . WASHER KSB 5.3 x 11 FZM
013 6 2166 1904-140 . CABLE GLAND
014 4 2151 2022-146 . WASHER BRB 5.3 x 10 FZB; DIN 125
015 4 2121 2550-325 . SCREW MC6S 5 x 10 -A2-70
016 0 2175 4115-025 . MOUNTING RAIL
019 3 1196590 . CONNECTION BAR
023 9 2663 4386-120 . TERMINAL BLOCK
025 4 2669 4107-120 . PARTITION WALL
026 2 2669 4160-025 . END HOLDER
028 6 2940 4108-999 . MARKING
030 2 5237 4101-210 . COVER
031 2 5237 4150-340 . CABLE FLANGE

2010-12-10 9.7 624-2196.002 3 (4)
JUNCTION BOX, X71A
1196543
624-2195.002
2010-12-10 9.7 624-2196.002 4 (4)
JUNCTION BOX, X71A

033 4 5239 2102-210 . GASKET

2011-02-28 9.7 624-2196.003A 1 (4)
JUNCTION BOX, X71B
1196773
625-2196.003
2011-02-28 9.7 624-2196.003A 2 (4)
JUNCTION BOX, X71B

000 1 1196773 JUNCTION BOX, X71B
001 1 224 0348-801 . CASING
005 8 2121 2032-451 . SCREW M6S 8 x 20 -8.8 FZB; DIN 933
006 1 1201763 . SIGN
007 8 2121 2032-455 . SCREW M6S 8 x 30 -8.8 FZB
008 16 2126 2032-118 . NUT M6M 8 -8 FZB
009 12 2124 2550-228 . SCREW
010 8 1201609 . DISTANCE
011 1 414 3662-002 . CLAMP
012 2 2121 2550-329 . SCREW MC6S 5 x 16 -A2-70
013 1 1201817 . SHEET
014 9 2166 1904-132 . CABLE GLAND
015 2 1189937 . BRACKET
016 4 2121 2550-325 . SCREW MC6S 5 x 10 -A2-70
017 1 2175 4115-027 . MOUNTING RAIL
018 4 2151 2022-146 . WASHER BRB 5.3 x 10 FZB; DIN 125
019 1 1197148 . TERMINAL
020 8 2647 4155-040 . EARTH TERMINAL
021 3 1197150 . TERMINAL
022 68 2663 4382-025 . TERMINAL BLOCK
023 4 2154 2033-006 . WASHER KSB 5.3 x 11 FZM

2011-02-28 9.7 624-2196.003A 3 (4)
JUNCTION BOX, X71B
1196773
625-2196.003
2011-02-28 9.7 624-2196.003A 4 (4)
JUNCTION BOX, X71B

024 5 2669 4106-025 . PARTITION PLATE
025 1 1197806 . CABLE
026 6 2669 4160-015 . END HOLDER
027 1 1186615 . CABLE
028 80 2940 4108-999 . MARKING
029 1 1192204 . CABLE L=3m
030 2 5237 4101-210 . COVER
031 1 1196857 . CONNECTOR BAR
032 2 5237 4150-632 . CABLE FLANGE
033 4 5239 2102-210 . GASKET
034 3 2152 2270-132 . STOP PLUG
035 1 2641 2101-165 . CABLE TERMINAL

2011-01-25 9.7 624-2196.005 1 (2)
CABINET ADD. COMPONENTS, X71B
1201179
624-2196.005
2011-01-25 9.7 624-2196.005 2 (2)
CABINET ADD. COMPONENTS, X71B

000 1 1201179 CABINET ADD. COMPONENTS, X71B
001 1 5639 4161-204 . IMPULSE RELAY
002 1 1196857 . CONNECTOR BAR
004 2 2647 4155-040 . EARTH TERMINAL
005 2 2669 4160-015 . END HOLDER
006 10 2663 4382-025 . TERMINAL BLOCK
007 12 2940 4108-999 . MARKING
008 X 1192204 . CABLE L=3m

2012-01-20 9.7 624-2196.015 1 (2)
PEDESTAL PUSHBUTTON
1202077
624-2196.015
2012-01-20 9.7 624-2196.015 2 (2)
PEDESTAL PUSHBUTTON
000 1 1202077 PEDESTAL PUSHBUTTON
001 1 414 6713-801 . SWITCH

2007-04-11 9.7 624-2498 1 (2)
HAND PUMP
Oil
150 30 140
10
11
560 500 20 130

570
189 6211-801
624-2498
2007-04-11 9.7 624-2498 2 (2)
HAND PUMP
000 1 189 6211-801 HAND PUMP
010 1 875 29031-011 . PUMP D = 45 cc
011 1 875 29031-012 . HANDLE
020 1 875 29031-006 . PRESSURE RELIEF VALVE Setting 25 bar, seal-locked
030 1 875 29031-015 . SAFETY VALVE, COMPLETE
130 1 2522 2105-012 . PLUG WITH SEAL G 1/2"
140 1 875 29031-005 . MANOMETER 60 bar
150 1 875 29031-013 . OIL CAP WITH AIR FILTER G 1/2"
500 1 875 29031-014 . HYDRAULIC HOSE WITH COUPLINGS 3/8" L = 3000
560 1 2529 2458-111 .. QUICK COUPLING G 3/8"
570 1 2528 2512-612 .. PIPE COUPLING G 3/8"

2010-08-13 9.7 624-2524A 1 (2)
FIRE EXTINGUISHER, MOUNT
490 4074-801
624-2524
2010-08-13 9.7 624-2524A 2 (2)
FIRE EXTINGUISHER, MOUNT

000 1 490 4074-801 FIRE EXTINGUISHER, MOUNT
003 1 6956 2020-060 . FIRE EXTINGUISHER POWDER

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INSTRUCTION MANUAL Project No.

GENERAL 1 1.000.6 E b SAFETY INSTRUCTIONS

TECHN. DESCRIP. 2 2/10108.01RHM a TECHNICAL DATA

FUNCTION 3 3.110.127 E b ELECTRIC FUNCTION

OPERATION 4 PM40 1885-E00 a CREW CHECKLIST

MAINTENANCE 5 5.005.70 E - MAINTENANCE CHART

6.0 6.000 E e HOW TO ORDER SPARE PARTS

6.2 6.214.1 E a TIGHTENING TORQUES, STUDS/SCREWS AND BOLTS

6.3 6.303.61 E c CARD FRONT MENUS CT2, CC3000

EXTRA EQUIPMENT 7 7.075.11 E - MacHEAVYVISOR RELEASE 3.3

SPARE PARTS 9 SEE SEPARATE TABLE OF CONTENTS

9.0 HOW TO ORDER SPARE PARTS e 6.000 E

9.1 HOISTING WINCH 1212912 -/ 625-1450.212

9.2 BRAKE PUMP UNIT 1219768 A/ 625-4935.245A

9.3 CRANE HOUSE ASSEMBLY 1219977 C/ 625-6102.580

9.4 VALVE UNIT 1204092 A/ 625-7207.018

9.4 PRESSURE SWITCH, C 387 7053-803 L/ 625-7444

9.5 DRIVERS DESK 1189978 A/ 625-8563.069

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

9.7 FIRE EXTINGUISHER, MOUNT 490 4074-801 A/ 624-2524A

Testing and examination

Improper Use tain measures and procedures must be obeyed.

Functions, Installations and Equipment Safety Functions and Equipment

Specific safety equipment is installed and delivered

Specific service and repair of the electrical, hydraulic

b. Covers and houses:

d. Test device: Responsible officers onboard must make sure that

Replacement signs must refer to international and

Principles of Risk Classification

Those risks classified as DANGER sign are pre-

2. WARNING SIGNS are attached to equipment or

The danger does not exist unless protection installa-

3. CAUTION SIGNS are attached to equipment or

Any person should be able to avoid the danger.

4. NOTICE SIGNS are attached to equipment and

Alert / Warning signs

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

PM40 7103-E00 HIGH NOISE LEVEL - USE EAR PROTECTION!

PM40 7104-E00 LADDER WILL ROTATE WITH CRANE - WATCH OUT!

WARNING SIGN Attached to the crane wall surfaces close to winches.

PM40 7109-E00 RISK OF FALLING DOWN - USE SAFETY BELT!

PM40 7111-E00 ROTATING FAN - KEEP HANDS OFF!

PM40 7112-E00 RIDING ON CARGO FORBIDDEN

PM40 7114-E00 DANGEROUS OIL PRESSURE - BE CAREFUL!

PM40 7115-E00 SLIPPERY SURFACES - WATCH OUT!

PM40 7118-E00 RISK OF FALLING DOWN - APPLY SAFETY CHAIN!

DANGER SIGN Attached to electrical equipment e. g. electric main motor.

PM40 7122-E00 RISK OF BODILY INJURY - SUSPENDED LOAD - WATCH OUT!

The crane operator must stop operation and alert personnel.

PM40 7125-E00 DANGER - KEEP OUT OF WORKING AREA!

DANGER SIGN Attached on both sides of the crane jib.

PM40 7129-E00 STARTS AUTOMATICALLY WITHOUT NOTICE AT +25°C (+80°F)

PM40 7130-E00 DANGEROUS OIL PRESSURE. BE CAREFUL!

PM40 7132-E00 HOT OIL AND SURFACES - WATCH OUT!

WARNING SIGN Attached to the crane wall surfaces close to winches.

DANGER SIGN Attached to electric cabinet CT1.

DANGER SIGN Attached to the cover of slipring device in the foundation.

NOTICE SIGN Attached on the door inside the cabinet CT2.

PM40 7147-E00 STARTS AUTOMATICALLY WITHOUT NOTICE

NOTICE SIGN Attached on the electric motor fan protection.

CAUTION SIGN Attached on the door outside the electrical cabinets

Fig. 4. PM40 7104-E00