Deck Crain

Dept.
C7250
INSTRUCTION MANUAL
Project No.
Date: 2012-02-16
2/10108.01RHM
Page
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.
GENERAL
TECHN. DESCRIP.
FUNCTION
OPERATION
REV
NAME OF INSTRUCTION
1.000.6 E
SAFETY INSTRUCTIONS
1.005 E
PREFACE
1.009 E
GENERAL INSTRUCTIONS, CLEANLINESS IN HYDRAULIC SYSTEMS
1.102 E
CONVERSION FACTORS
1.518.3 ED
HYDRAULIC AND ELECTRIC SYMBOLS
2/10108.01RHM
TECHNICAL DATA
2.007.96 E
TECHNICAL DESCRIPTION
3.110.127 E
ELECTRIC FUNCTION
3.110.132 E
HYDRAULIC BRAKE FUNCTION, ELECTRIC CRANE
3.142.41 E
CRANE CONTROL SYSTEM CC3000
3.155.6 E
THERMOSTATIC CONTROLLED VENTILATION FAN AND HEATER ELEMENTS
3.155.7 E
HEATING AND COOLING OF CABINETS IN ELECTRIC CRANES
PM40 1885-E00
CREW CHECKLIST
PM40 5500-E00
OPERATING INSTRUCTION
PM40 6494-E00
OPERATION, START AND STOP
PM40 7546-E00
CONTROLS AND INDICATORS
PM41 0001-E
EMERGENCY ESCAPE INSTRUCTIONS
PM41 0014-E00
EMERGENCY ESCAPE INSTRUCTIONS, ROPE LADDER/FIXED LADDERS
4.620.31 E
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
Dept. C7250
INSTRUCTION MANUAL
Project No.
Date: 2012-02-16
2/10108.01RHM
Page
2(6)
TABLE OF CONTENTS
MAINTENANCE
SERVICE
INSTRUCTION NO.
REV NAME OF INSTRUCTION
5.005.70 E
MAINTENANCE CHART
5.018 E
INSPECTION OF STRESSED COMPONENTS AND STRUCTURES
PM51 1733-E00
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
LUBRICANTS FOR DECK MACHINERY
6.000 E
HOW TO ORDER SPARE PARTS
6.000.1 E
STATEMENT REGARDING DELIVERY OF SPARE PARTS TO SWIVELS, LIFTING B
6.000.2 E
RETURN FORM
6.004.1 E
bc
WORLDWIDE SERVICE NETWORK
6.005.10 E
INTRODUCTION
6.100.11 E
MEASURES BEFORE STARTING, DURING & AFTER COMPLETED SERVICE/MAIN
6.120.20 E
SLEWING GEAR
6.120.112 E
WINCHES, HOISTING/LUFFING
6.142.5 E
RECOMMENDATION FOR INSPECTION AND REPLACEMENT OF HYDRAULIC HO
6.189 E
HYDRAULIC PISTON ACCUMULATORS
6.214.1 E
TIGHTENING TORQUES, STUDS/SCREWS AND BOLTS
6.215.21 E
SERVICE DOOR (OPENING AND CLOSING), SERVICE AND LUBRICATION OF DO
6.216.116 E
ROPE REEVING FOR CRANE TYPE GLBE-2
6.222.1 E
HANDLING, INSTALLATION AND MAINTENANCE OF STEEL WIRE ROPES
6.223.26 E
REPLACEMENT OF WIRES, ONE OR TWO FALL RIGGING
625/1473 E
INDENTATION AND WEAR ON WIRE SHEAVES
625/1560 E
LIFTING BLOCK/BEAM
625/1579 E
MEASURING PROCEDURE FOR WEAR IN SLEWING BEARINGS FOR ROPE LUFF
625/1651 E
SLEWING BEARING GREASE SAMPLING PROCEDURE
6
6.0
6.1
6.2
6.3
EXTRA EQUIPMENT 7
6.303.61 E
CARD FRONT MENUS CT2, CC3000
6.303.66 E
TROUBLESHOOTING FOR CRANE CONTROL SYSTEM CC3000, ELECTRIC CRAN
6.303.67 E
ABSOLUTE ENCODER CALIBRATION, CC3000
424 0738
SIGNAL OVERVIEW, CRANE CONTROL SYSTEM CC3000
424 0739
ERROR MESSAGES, CRANE CONTROL SYSTEM CC3000
1000004064
INSULATION TEST, ELCTRICAL CRANE
6.305.19 E
ELECTRICAL EQUIPMENT, GENERAL MAINTENANCE
6.306.7 E
INSTALLATION OF POWER SUPPLY CABLE AND CABLE FOR "GRAB...
6.307.11 E
SLIP-RING UNIT
6.311.14 E
OIL LEVEL TEMPERATURE SENSOR, BRAKE UNIT
6.320.386 E
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
PREPARATION FOR OVERLOAD (OL) TEST MODE
6.324.2 E
PREPARATION FOR RIG MODE
6.990.61 E
EMERGENCY OPERATIONIN CASE OF COMPLETE POWER FAILURE, OPERA
7.075.11 E
MacHEAVYVISOR RELEASE 3.3
7.076.2 E
USER MANUAL DISPLAY, CC PILOT XS
7.082.1 E
INSTALLATION OF MAINTENANCE PLATFORM ON FOUNDATION, (CUSTOMER D
Dept. C7250
INSTRUCTION MANUAL
Project No.
Date: 2012-02-16
2/10108.01RHM
TABLE OF CONTENTS
INSTRUCTION NO.
APPENDICES
SPARE PARTS
REV NAME OF INSTRUCTION
SEE SEPARATE TABLE OF CONTENTS
Page
3(6)
Dept. C7250
PARTS MANUAL
Project No.
Date: 2012-02-16
2/10108.01RHM
Page
4(6)
TABLE OF CONTENTS
GROUP DESCRIPTION
PART NUMBER
FIG
9
9.0
HOW TO ORDER SPARE PARTS
6.000 E
9.1
HOISTING WINCH
LUFFING WINCH
1212912
-/
625-1450.212
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
9.4
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
-/
VALVE UNIT
1204092
A/
625-7207.018
DIRECTIONAL VALVE
1204093
-/
625-7322.082
Dept. C7250
PARTS MANUAL
Project No.
Date: 2012-02-16
2/10108.01RHM
Page
5(6)
TABLE OF CONTENTS
GROUP DESCRIPTION
9.4
PART NUMBER
FIG
PRESSURE SWITCH, C
387 7053-803
L/
625-7444
ACCUMULATOR
1219345
-/
625-7951.007
TUBING BRAKE
1219586
A/
625-7994.004
HYDRAULIC SYSTEM SPECIFICATION
1226154
-/
1000019019
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
HYDRAULIC HOSES
9.5
9.7
625-7970G
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/
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
PARTS MANUAL
Project No.
Date: 2012-02-16
2/10108.01RHM
Page
6(6)
TABLE OF CONTENTS
GROUP DESCRIPTION
PART NUMBER
FIG
9.7
FIRE EXTINGUISHER, MOUNT
490 4074-801
1182916
-/A
LIFE LINE
388 0962-801
-/
A/
624-2524A
GENERAL
1.000.6 E rev.: b 2011-12-07
Safety Instructions
Caution!
Make sure that the frequency converters and other
electronic equipments are disconnected before any
welding in the crane house, and/or foundation and
the pedestal starts, because of risk of damage to the
electronic equipments.
Caution!
Insulation test, electrical crane
Before any kind of insulation test of electric cabinets,
electric motors or any kind of electric equipment in the
crane house and/or foundation and pedestal starts,
carefully read and follow the steps in the instruction.
Make sure that all electronic systems are prepared
according to the instruction "Insulation test, electrical
crane", section 6.3 in the parts manual and section
19 in the installation manual.
Cargo Handling Equipment

The MacGregor crane is a cargo handling device.
It is designed and manufactured to meet international cargo handling standards for quality, safety and
performance within capacity specifications and outreach as per certificate.
The crane is designed for operation in harbour or sheltered water environments where there is no significant
movement of the ship due to wave action.
Testing and examination

The crane shall be tested and thoroughly examined
and certified by a competent person after any substantial repair.
Safe Operating Conditions, Proper Instructions

and Precautions
The responsible officer onboard shall make sure that
the crane is operated under safe conditions, by personnel familiar with its functions and operating instructions. All safety and precautionary issues contained in
this manual must be observed. Proper instructions and
precautions are prerequisites for proper use.
Preparation for Use and Operation According to

Manual
The crane operator, authorized by the responsible
officer onboard, must be familiar with all safety issues
contained in this Chapter and with preparation for use
and operating instructions before work is started.
Maintenance and Service

Prerequisite for proper use is regular maintenance
(see Chapter 5) and service (see Chapter 6).
MacGregor are available for full service of this cargo
crane. MacGregor will take responsibility only for its
own professional services. Our product guarantee
is not valid unless MacGregor authorized service is
used.
The use of proper Spares and Exchange details

MacGregor shall be contacted for ordering of exchange equipment and spares for this crane. Articles
supplied by MacGregor are designed and quality
tested for this application and are supplied with our
warranty for correct function and safe working of the
crane.
MacGregor accepts no liability for the functioning of
the crane systems, nor for the safe use of the crane,
unless original spare parts are used.
Supervision, Instructions, Signs, and Warnings
Proper use of this crane and its equipment is possible
as long as the owners, users and operators maintain
the crane to meet full operational standards. This
includes the replacement of signs, instructions and
warnings as per delivery. MacGregor does not accept
responsibility for any party who fails to ensure that this
manual, signs, instructions, and warnings are legible
and easily accessible to personnel.
1 (16)
GENERAL
1.000.6 E rev.: b 2011-12-07
Improper Use
1. Elevation of persons.
2. Exposing persons to the risks of falling cargo.
3. Overloading.
4. Unlocking the crane or crane jib or operating the
equipment at sea without full acceptance and control of personnel and equipment safety.
5. Unprofessional, intended or unintended, adjustment
of safety locks, hydraulic or electric adjustments.
6. Disregard of occupational and safety standards of
work.
tain measures and procedures must be obeyed.
Functions, Installations and Equipment
Safety Functions and Equipment
General
The MacGregor crane has built-in safety functions
and installations to allow for safe normal use, operation, care, and control. This is applicable to instructed
personnel without specific professional education or
certification, but working according to this manual.
Specific safety equipment is installed and delivered

with this crane and must be available for its intended
use. The owner/operator of the ship and its equipment
is responsible to make that safety functions, installations and equipment are maintained to operational
standards and are not being removed, by-passed or
worn to non-working condition.
Specific service and repair of the electrical, hydraulic

and the mechanical functions, controls and adjustments require professional service personnel knowledgeable of risks involved.
This manual features important presentations of safety

functions, installations and equipment. A summary is
presented below.
Regular Care and Control (Maintenance)

This manual contains checklists for regular care and
control of crane equipment, wire ropes and hydraulic
filters. These checklists routine contain inspections
and maintenance regularly prescribed for safe function, e.g.:
Chapter 4 contains:
Safety Precautions Checklist for Single and Twin
Cranes.
Chapter 5 contains, if applicable:
Inspection of Stressed Components and Structures.
Electrical chart,Crane.
Lubrication chart; Crane.
Lubrication chart; Cable Winch and Stabilizing Equipment.
Lubrication chart; Power Swivel.
Filters.
Before maintenance and service work is started, cer-
2 (16)
Chapter 6 contains:
Measures before Starting Service/Maintenance Work.
Handling, Installation and Maintenance of Steel Wire
Ropes.
Examine the brake adjustments. (Valid for winches
which have electric motors.)
Electric Motors, Electrical Equipment, General Maintenance.
1. Safety Functions
a. Manoeuvring functions:
1. All the cranes working functions are stopped
and the brakes will automatically operate when
the emergency stop button is pressed. The button is loacated in cabin. This action operates
the safety stops and automatic lock positions.
2. The crane has several fail-safe functions to
overrule or stop the operators manoeuvring in
the event that the normal electrical or hydraulic
functions fail, a sudden uncontrolled movement
occurs or during uncontrolled speed operation
(see below).
3. There are limits for hoisting/lowering and luffing
outreaches, which are controlled by software
limits which monitors the encoders' position in
the limit switch box.
4. AutoLaodstep, stop limits and speed reduce for
load-dependent outreach are controlled by the
software.
5. Safety cams are mechanical stop limits for
hoisting, full/empty drum and luffing min/max
GENERAL
1.000.6 E rev.: b 2011-12-07
outreaches, if there is a failure in the software.

6. A check cam in the centre of the working range
of hoisting/lowering motion and luffing outreaches, are used to verify the function of the encoders' position.
2.
b. Hydraulic functions:
1. Hydraulic valve functions are adjusted for exact
pressure. Any change in the adjustments adversely affects the crane operation and must
exclusively be adjusted by MacGregor supervisor (see instructions Hydraulic function).
2. In case of a ruptured control pressure the oil
pipe/hose or other control pressure drops, the
oil control pressure will collapse. If the control
pressure decreases the pump automatically
starts and the control pressure increases.
3. Each winch has an electric motor flanged to
the drive in complete. The hydraulic operated
multi-disc brakes provide braking of the winch.
The winches have one brake each.
4. An electric motor is flanged to each slewing
gear and provides hydraulic operated multi-disc
brake of the slewing gears. The slewing gears
have one brake each.
5. If there is a multi-disc brake failure of the parking
brake, caused by worn out brake discs, sticking
cylinder, brake pilot valve or valve spool, the
function of regenerative braking through the
electric motor by the winches and slewing gears
is still available. Push the Start/Stop pushbutton
position "0" and the system awaits the activating
of the brakes and the crane then stops.
6. In case of overheating oil in the hydraulic system, or oil level drops below the minimum permissible level the crane stops and the multi-disc
brakes are applied.
7. Efficient oil filters with exclusive bypass to the
hydraulic oil tank protect the system from harmful oil conditions. Dirty filter might cause malfunction to the system.
3.
4.
5.
6.
receives information about the torque of the

electric motor from each frequency converter
and is used to measure whether the value of
the loadcell is correct. See also "Crane Control
System CC3000" in section 3 .
During a complete power failure all solenoid
valves are de-energized and all multi-disc
brakes will be applied.
The electronic cabinets have power failure
indicators. This function closes the electronic
signals down which automatically applies all
multi-disc brakes.
The heat sensors in the electric motors stop the
operation that is working, i.e. luffing, hoisting or
slewing, and apply all multi-disc brakes.
If the electric motor is about to overheat temperature switch (klixon) ramps down each movement, luffing, hoisting or slewing operation, of
the crane and stops the crane.
The overcurrent protections on each electric
motor prevent the electric motors from overloading.
Each electric motor is overcurrent protected
and stops the crane operation and applies the
brakes.
A separate electrical feed for the crane house
lights, operators cabin and on jib, maintains
function of lights even during feed disruption to
the crane operating functions. As there is not a
separate emergency illuminating system for the
crane (this is dependent on the ships systems)
the owner of the crane must provide a battery
type flash-light for the operators cabin.
d. Mechanical functions:
1. Automatic sensors recognize dangerous wire
slacks and stop hoisting and luffing movements
that threaten safe control and the equipment
itself.
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

systems.
Dynamic braking, deceleration, is achieved by
2. Covers for electric boxes must be opened only

by authorized personnel.
the regenerative function of the electric motor.

True static braking (parking brakes) is provided by multiple-disc brakes.
The mechanical brakes are automatically operated in the event of dangerous oil pressure.
High speed winches are provided with multipledisc brakes. One for each drive in complete on
the hoisting/luffing winch.
Each slewing gear unit has one multiple-disc
brake.
c. Alert and warning signs:

The crane has a system of danger, warning,
caution, and notice signs. These signs are presented on pages 6 - 15.
2. Safety Installations
a. Warning lights, measuring instruments and meters:
1. The operators panel has a warning light which
indicates "Low oil level" in the oil tank for the
brake unit.
2. During crane start-up a warning light on the
operators panel indicates that the starting procedures are still running and that the working
conditions are not acceptable before the lamp
goes off. Manoeuvres are not to be ordered
before the warning light goes off.
3. A pushbutton siren is found in the crane operators cabinet, with which the operator can
tell persons in the working area (e.g. against
prohibited riding on the load or against load
movements).
4. Measuring instruments and meters (e.g. to examine the crane functions, adjustment of valve
positions and functional positions) are supplied
as per agreement with the crane buyer/owner.
Tools and equipment which are eliminated from
the original order to MacGregor are delivered
at the discretion of the owner.
b. Covers and houses:
1. Unauthorized visitors in the crane house, especially during crane operation, is prohibited. The
crane is a dangerous working area and requires
special permission to enter. Instructions given
by the superintendent or responsible officer
must be obeyed.
4 (16)
3. Safety Equipment
a. Locks, seals and keys:
1. Functions and equipment that are essential
for oil pressure adjustments, coordination of
controls and crane movements or expose dangerous high-voltage electricity are locked. All
keys to locked positions and switches must be
kept and controlled by the responsible officer
onboard and are only to be used by approved
personnel.
2. Safety valves for hydraulic pressure adjustments and switches for electric safety circuits
are sealed to secure correct position and trim.
Sealed equipment may be opened and positions
changed only after consulting the MacGregor
service organization for proper handling.
b. Safety belt, rescue line, safety chains:
1. For maintenance, service or entry to the openair outside the crane house, personnel must
wear a safety belt. The connector hook should
be anchored to rails and fixed position while
staying or working on the crane top.
2. The rescue line and equipment for emergency
evacuation of the crane operator must always
be easily accessible on the interior wall-side
of the crane cabin. The equipment status and
completeness must be inspected regularly by
the responsible officer onboard.
3. The safety chains on the open-air crane top and
work platforms inside the crane, must be used
for attendants safety during stay and work.
c. Fire-fighting equipment:
A fire extinguisher shall be made available by
the owner in the operators cabin.
The fire extinguisher is for emergency use inside
the crane.
The equipment must be regularly inspected for
GENERAL
1.000.6 E rev.: b 2011-12-07
proper pressure reading at the meter and must

be serviced annually. This is to be supervised
by the responsible officer onboard.
or policies to obey to avoid danger to the function

and operation of the equipment or damage to the
equipment itself.
d. Test device:
At delivery, the MacGregor crane has two pressure gauges.
Responsible officers onboard must make sure that

the signs are in good condition and readable to any
person admitted to the crane area.
Danger, Warning, Caution and Notice

Signs
Replacement signs must refer to international and

national standards. Signs of non-MacGregor design are not allowed. MacGregor does not accept
responsibility for unauthorized signs.
Principles of Risk Classification

1. DANGER SIGNS are attached to equipment or are
related to operations that will expose personnel to a
life-threatening danger (e.g. high-voltage electricity).
Specific Presentation of Signs and their Message

All signs attached to the crane are illustrated on the
following pages. Each sign is given a specific number
to which it is referred.
Safety installations, covers or houses prevent exposure 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 presented 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 installations 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 OPERATORS 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 knowledgeable 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 adequate 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
PM40 7108-E00
1.000.6 E rev.: b 2011-12-07
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 operators alarm bell, in the crane operators cabin, may be used, preferably.
DANGER SIGN
Attached on the wall side of the crane operators 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 service 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 responsible 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 covers 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 covers or hoses are removed. Access is restricted to qualified and authorized personnel only.
DANGER SIGN
Attached to electrical equipment e. g. electric main motor.
PM40 7122-E00
RISK OF BODILY INJURY - SUSPENDED LOAD - WATCH OUT!

The crane operator must ensure that the suspended load does not expose personnel below to
risks of falling material.
The crane operator must stop operation and alert personnel.
The operators alarm bell in the crane operators cabin is preferably used.
DANGER SIGN
Applied on the wall side of the crane operators 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 operators 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 operators 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 +25C (+80F)

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 service 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 7131-E00

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 equipment (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
PM40 7135-E00
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
12 (16)
Fig. 7. PM40 7108-E00
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
14 (16)
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
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
1226128
INSULATION TEST
(MEGGER TEST) CAN
CAUSE SERIUOS DAMAGE
ON ELECTRICAL EQUIPMENT
SEE INSTRUCTION
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
hydraulic deck crane. We hope that it will prove a
valuable companion to everyone concerned with the
operation of the crane or otherwise in a responsible
position.
Spare parts
General advice how to order spare parts; spare parts
lists and illustrations.
Every manual belongs to a specific crane or piece of

equipment. The identification can be found on the label
on the manuals back.
The manual contains nine sections. The various
sections cover the following subjects:
General
Contents list; Safety; Conversion tables; Hydraulic
and electric symbols.
Technical description
Technical data; description of crane design.
Function
Electric and hydraulic functions of the crane.
Operation
Operating instructions; crane operators checklist.
Maintenance
Lubricating chart and maintenance instructions.
Service
General service instructions for the hydraulic system,
mechanical, control system and electrical equipment.
Extra equipment
Extra equipment, if any; e.g. cargo handling equipment.
Appendices
Other information, which cannot be referred to any of
the above mentioned sections.
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
hydraulic systems and components is absolute
cleanliness.
Many components, e.g. valves and pumps, have
very narrow tolerances, therefore microscopic impurities, invisible to the human eye, may have disastrous effect on the function of a hydraulic system.
The hydraulic system installation contains a cleaner
with a cartridge designed to stop impurities produced within the hydraulic system during operation.
Every care must be taken to prevent external impurities from entering the system when servicing or
repairing it.
Use a brush for cleaning, wipe off with a nonlinting rag, repeat the cleaning if necessary. Finish by spraying the area of operations - hose connections etc. - with the solvent.
4. Mount protective covers immediately after removing a component, a pipe or a hose. Components,
shall also be fitted with covers and plugs in order
to prevent ingress of dirt.
These covers must be kept in clean and closed
packages. After use, covers are to be cleaned in
the workshop.
5. Observe minute cleanliness when handling all
types of quick-release connectors. Spray both
connectors with solvent before making up a connection. Clean all covers before reinstallation.
Storing and filling up of hydraulic oil
This also applies for components that have been

removed and or to be reinstalled. Sooner or later, a
component that has been replaced will be inspected
in a test equipment somewhere. It is important that
the component stays in the same condition as it was
when it was removed, as it may otherwise be
impossible to decide the real cause of a malfunction.
It may also be possible that a component sent in
for inspection is not defective at all, and will be
returned.
Rules when working on the hydraulic system
The following fast rules shall be observed during
working on the hydraulic system:
1. Carry out a rough general clean-up.
2. Protect the area where work shall be done. Use
a sheet of plastic material or similar.
3. Clean well with white spirit or a similar solvent.
Remember that it is not enough to clean only the
parts immediately concerned, but also their surroundings from where accumulated dirt may be
transferred in to the repair area. Do not forget to
clean the tools to be used.
1. Store barrels, hoses and pump as clean as possible and best of all in a warm room. The oil viscosity will then be considerably lower, which
make the filling through filter easier.
2. Barrels, hoses and pump must be carefully handled and cleaned when necessary.
3. Store barrels horizontally, so plugs (or cocks) are
below the liquid level and impurities (e.g., damped
air) does not penetrate the barrels.
4. Observe minute cleanliness when filling up oil carelessness is one of the greatest sources when
impurities penetrates the hydraulic system.
5. Fill up hydraulic oil. See separate instruction.
6. Never use the last drop in the barrel, as it often
consists of water and other impurities dependent on how many times the barrel has been
opened.
1 (2)
GENERAL
1.009 E rev.: a 1996-05-20
2 (2)
GENERAL
1.102 E rev.: c 1999-09-14
Conversion Factors
Pressure
Length
1
1
1
1
mm
m
in
ft (fot)
=
=
=
=
0,0393701 in (tum)
3,28084 ft (fot)
25,4 mm
304,8 mm
Volume
1
1
1
1
dm3
dm3
gallon
gallon
= 1 litre = 0,219969 gallon (UK)

= 1 litre = 0,264172 gallon (US)
(UK)= 4,54609 dm3
(US)= 3,78541 dm3
Mass
1
1
1
1
1
kg
lb
ton
ton
ton
= 2,20463 lb
= 0,45359 kg
(metric) = 1000 kg
(UK)
= 1 longton (US)
(UK)
= 1016,05 kg
1 atm
=
1 atm
=
1 atm
=
1 bar
=
1 at
=
1 at
=
10 lbf/in2 =
10 lbf/in2 =
1 bar
=
1 bar
=
2
1 kp/cm =
1 bar
=
1 Pa
=
1 Pa
=
1 Pa
=
1 Pa
=
1 kp/cm2 =
14,6959 lbf/in2 (psi)

1,01325 bar
1,03323 at
0,986923 atm
14,2233 lbf/in2 (psi)
0,980665 bar
0,689476 bar
0,70307 at
1,01972 at
14,5038 lbf/in2 (psi)
14,2233 lbf/in2
100 kPa = 0,1 MPa
1 N/m2
10,2 10-6 kp/cm 2
0,145 10 -6 lbf/in2
7,5 10-3 mm Hg
98,07 103 Pa
Power
Force
1 kp
1 kp
1 lbf
1 lbf
1N
1N
=
=
=
=
=
=
2,20462 lbf
9,80665 N
4,44822 N
0,453592 kp
0,101972 kp
0,224809 lbf
1
1
1
1
1
1
kW = 1,35962 hk
kW = 1,34102 hp (UK, US)
hk = 0,986320 hp (UK, US)
hp (UK, US) = 1,01387 hk
hk
= 0,735499 kW
hp (UK, US) = 0,745700 kW
Temperature
Moment of force
1 kpm=
1 kpm=
1 Nm
1 lbf ft
1 lbf ft
1 lbf ft
1 daNm
1 daNm
9,80665 Nm
7,23301 lbf ft
= 0,737562 lbf ft
= 0,135582 daNm
= 1,35582 Nm
= 0,13825 kpm
= 1,01972 kpm
= 7,37562 lbf ft
0C
0C
0F
0F
0K
0K
C =
=
=
=
=
=
=
32F
273,15 K
-17,7778C
255,3722 K
-273,15C
-459,67F
1
(F - 32)
1,8
F = C 1,8 + 32
Moment of inertia
1 kg m 2 = 3417,17 lb in2
1 lb in 2 = 0,00029264 kg m2
F = 1,8 (K - 273,15) + 32
K=
1
(F - 32) + 273,15
1,8
C = K - 273,15
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 umfat einen Teil der allgemeinen Bild- und
Anschluzeichen, die in MacGREGOR (SWE) AB, Service Division,
hydraulischen und elektrischen Schemas vorkommen, unterteilt in drei
Gruppen:
1. Hydraulic symbols, basic.

Hydraulische Bildzeichen, einfach.
2. Hydraulic symbols, composite.

Hydraulische Bildzeichen, kombiniert.
3. Electric symbols.
Elektrische Schaltzeichen.
1 (30)
GENERAL/ALLGEMEINES
Hydraulic symbols and valve assemblies

Hydraulische Bildzeichen und VentilBaugruppen
1. Hydraulic Symbols
Hydraulische Bildzeichen
Working oil line.

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

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

Temperaturunabhngige Drosselung.
Flexible hose.
Schlauch, biegsame Leitung.
2 (30)
1.518.3 ED rev.: d 2007-06-08
GENERAL/ALLGEMEINES
1.518.3 ED rev.: d 2007-06-08
Pipe junction.
Leitungsverbindung.
Crossed pipes, no connection.

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

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

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

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

Pumpe, variables Deplacement, 2 Stromrichtungen.
3 (30)
GENERAL/ALLGEMEINES
1.518.3 ED rev.: d 2007-06-08
Motor, fixed displacement, 2 directions of flow, external drain.

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

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

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

Filter mit Anzeiger.
Filter with by-pass valve.

Filter mit Rckschlagventil.
4 (30)
GENERAL/ALLGEMEINES
1.518.3 ED rev.: d 2007-06-08
Air breather.
Luftreiniger.
Pressure electric switch, normally open.

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

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

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

pressure difference.
Rckschlagventil, federvorbelastet mit gewisser
Schlieungsdruckdifferenz.
5 (30)
GENERAL/ALLGEMEINES
1.518.3 ED rev.: d 2007-06-08
Quick coupling or gauge connection.

Schnellkupplung oder Meanschlu.
Gauge connection.
Meanschlu.
Ventilation valve.
Entlftungsventil.
Non-return valve with variable restriction.

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

Zylinder, doppelt wirkend mit konstanter Dmpfung
auf einer Seite.
Pressure gauge.
Manometer.
Thermometer.
Thermometer.
6 (30)
GENERAL/ALLGEMEINES
1.518.3 ED rev.: d 2007-06-08
Oli cooler.
lkhler.
Accumulator.
Druckspeicher.
Shut-off valve.
Absperrventil.
Valve, basic symbol.

Schieber, Grundzeichen.
Electrically controlled valve.

Schieber, elektromagnetisch gesteuert.
Pressure controlled valve.

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

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

Schieber, vorgesteuert, externer Steuerdruck.
Lever controlled valve.

Schieber, knppelgesteuert.
7 (30)
GENERAL/ALLGEMEINES
1.518.3 ED rev.: d 2007-06-08
Mechanically controlled valve.

Schieber, mechanisch gesteuert.
Valve with spring return.

Schieber mit Feder-Rckfhrung.
Valve with detent.

Schieber mit Lagehalter.
4/2 direction valve

Electrically controlled four-way, two-position valve,
spring return to neutral position.
4/2-Wegeventil
4-Wegeschieber mit 2 Arbeitsstellungen, FederRckfhrung in die Nullstellung.
4/3 direction valve

Electrically controlled four-way, three-position valve,
spring centred.
4/3-Wegeventil
4-Wegeschieber mit 3 Arbeitsstellungen, federzentriert.
Proportional valve.
Proportionalventil.
Servo valve.
Servoventil.
8 (30)
GENERAL/ALLGEMEINES
1.518.3 ED rev.: d 2007-06-08
Balance valve (GP- and HH-cranes)

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

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

Flu Regulator mit Rckschlagventil.
Cartridge valve.
Patronenventil.
Pressure limiting valve, adjustable.

Druckbegrenzungsventil, regelbar.
9 (30)
GENERAL/ALLGEMEINES
Pressure limiting valve with remote opening or closing.

Druckbegrenzungsventil mit ferngesteuerter ffnung
oder Schlieung.
Pressure reducing valve.

Druckreduzierventil.
Pressure reducing valve with T-port.

Druckreduzierventil mit T-Anschlu.
10 (30)
1.518.3 ED rev.: d 2007-06-08
GENERAL/ALLGEMEINES
1.518.3 ED rev.: d 2007-06-08
2. Valve Assemblies
Ventil-Baugruppen
Filter unit with by-pass valve.

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

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

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

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

Filtereinheit mit Shuntventil und Zustandsanzeige.
12 (30)
1.518.3 ED rev.: d 2007-06-08
GENERAL/ALLGEMEINES
1.518.3 ED rev.: d 2007-06-08
Pump for hoisting winch.

Pumpe fr Lastwinde.

Pumpe fr Lastwinde.
13 (30)
GENERAL/ALLGEMEINES

Pumpe fr Lastwinde.
Pump for luffing winch.

Pumpe fr Einziehwinde.
14 (30)
1.518.3 ED rev.: d 2007-06-08
GENERAL/ALLGEMEINES
1.518.3 ED rev.: d 2007-06-08
Pump for luffing winch.

Pumpe fr Einziehwinde.
Pump for luffing or slewing.

Pumpe fr Einziehwinde oder Schwenkantrieb.
15 (30)
GENERAL/ALLGEMEINES
Pump for slewing or luffing.

Pumpe fr Schwenkantrieb oder Einziehwinde.
Pump for slewing.

Pumpe fr Schwenkantrieb.
16 (30)
1.518.3 ED rev.: d 2007-06-08
GENERAL/ALLGEMEINES
1.518.3 ED rev.: d 2007-06-08
Hoisting winch with 84-series motor and motor valve.

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

valve.
Lastwinde mit Motor Typ 63/64 und Motor-Umschaltventil.
17 (30)
GENERAL/ALLGEMEINES
Hoisting winch with variable high speed hydraulic motor.

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

Einziehwinde mit Motor Typ 63/64 und MotorUmschaltventil.
18 (30)
1.518.3 ED rev.: d 2007-06-08
GENERAL/ALLGEMEINES
1.518.3 ED rev.: d 2007-06-08
Unloading and flushing valve, slewing.

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

Entlastungs- und Splventil, Lastwinde und Schwenkantrieb.
Flushing valve.
Splventil.
19 (30)
GENERAL/ALLGEMEINES
Valve unit for stabilizing winch.

Ventileinheit fr Stabilisierungswinde.
Unloading unit for feed pump.

Entlastungsventil fr Speisepumpe.
20 (30)
1.518.3 ED rev.: d 2007-06-08
GENERAL/ALLGEMEINES
1.518.3 ED rev.: d 2007-06-08
Valve unit, cylinder luffing.

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

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

Leitungsverbindung, fest.
Conductor junction, separable.

Leitungsverbindung, trennbar.
Crossed conductor, no connection.

Kreuzende Leitungen, ohne Verbindung.
Slip ring with brush.

Schleifring mit Brste.
Fuse, supply side indicated.

Sicherung, Zufhrungsseite markiert.
Magnetic relay, contactor.

Steuergert, elektromagnetische Erregerwicklung.
Make contact.
Arbeitskontakt.
Break contact.
Schaltkontakt.
22 (30)
1.518.3 ED rev.: d 2007-06-08
GENERAL/ALLGEMEINES
1.518.3 ED rev.: d 2007-06-08
Main contact.
Hauptkontakt.
Contact, manually operated.

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

Kontakt, von Hand bettigt, nicht selbstrckstellend.
Emergency stop.
Notschalter.
Contact with delayed opening.

Kontakt mit Ausschalt-Verzgerung.
Contact with delayed closing.

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

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

Kontakt, thermisch gesteuert.
23 (30)
GENERAL/ALLGEMEINES
Pressostat.
Pressostat.
1.518.3 ED rev.: d 2007-06-08
Level switch.
lstandswchter.
Temperature switch, thermostat.

Temperaturwchter, Thermostat.
Touch free contact.

Berhrungsfreier Geber.
Inductive contact.
Induktiver Geber.
Ammeter.
Strommesser.
Voltmeter.
Voltmesser.
Hour counter.
Stundenzhler.
Earth (hull) connection.

Massenverbindung (Rumpf).
24 (30)
GENERAL/ALLGEMEINES
1.518.3 ED rev.: d 2007-06-08
Rectifier.
Gleichrichter.
Transformer with two windings.

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

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

Dreipoliges thermisches Relais (berstrom-Auslsung).
Frequency converter.
Frequenzumformer.
25 (30)
GENERAL/ALLGEMEINES
1.518.3 ED rev.: d 2007-06-08
Diode.
Diode.
Light emitting diode.

Leuchtdiode.
Pilot lamp.
Meldeleuchte.
Light.
Beleuchtung.
Flood light.
Scheinwerfer.
Alarm signal.
Alarmsignal.
Alarmsiren.
Alarmhupe.
Single-phase outlet.
Steckdose, einphasig.
26 (30)
GENERAL/ALLGEMEINES
1.518.3 ED rev.: d 2007-06-08
Position encoder.
Drehfeldgeber.
Puls/speed encoder
Geschwindigkeitsgeber
Flexible lead connector.

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

Potentiometer mit Schleifer und einer Festanzapfung.
Heater.
Heizkrper.
Motor.
Motor.
27 (30)
GENERAL/ALLGEMEINES
1.518.3 ED rev.: d 2007-06-08
Condenser.
Kondensator.
Heater, cabin.
Heizkrper in der Fahrerkabine.
Air condition.
Klimaanlageapparat.
VL . . . .
Solenoid valve.
Magnetventil.
Oil tank heater.

lbehlterheizer.
28 (30)
GENERAL/ALLGEMEINES
1.518.3 ED rev.: d 2007-06-08
Controller, hoisting.
Steuerknppel, Lastwinde.
Controller, luffing and slewing.

Steuerknppel, Einziehwinde und Schwenkantrieb.
29 (30)
GENERAL/ALLGEMEINES
1.518.3 ED rev.: d 2007-06-08
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
BASIC DATA
Lifting height
15
Lifting height
25
Hoisting
capacity,
SWL
Hoisting
capacity,
GRAB
Hoisting
capacity,
PART SWL
Jib radius,
Minimum
Jib radius,
Maximum
(ton)
(ton)
(ton)
(m)
(m)
30
25
24
25
1 (8)
TECHNICAL DATA
Speed - Hoisting
Hoisting
capacity,
SWL
Hoisting
speed,
(ton)
(m/min)
4
36
30
18
Hoisting speed diagram
Fig. 1 Hoisting speed diagram
2 (8)
TECHNICAL DATA
Speed - Luffing
Luffing speed,
PART SWL
Luffing speed, Luffing speed

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
Rated current
490
708
V DC
708
V DC
Output UZ11
Rated voltage
HOISTING DRIVE (UF1)

Input
Rated voltage
Output
Variable frequency
Rated variable voltage
Rated current
3 Phase ~ 0 - 100
0 - 500
210
Hz
V AC
A
3 (8)
TECHNICAL DATA
ELECTRICAL DATA - Frequency converters

LUFFING DRIVE (UF2)
Input
Rated voltage
708
V DC
Output
Variable frequency
Variable voltage
Rated current
3 Phase ~ 0 - 100
0 - 500
Hz
V AC
200
708
V DC
SLEWING DRIVE (UF3, UF4)

Input
Rated voltage
Output
Variable frequency
Variable voltage
Rated current
3 Phase ~ 0 - 100
0 - 500
60
Hz
V AC
A
ELECTRICAL DATA - Electric motors

HOISTING MOTOR (M1)
Rated voltage
Rated frequency
500
V AC
3 Phase ~ 50
Hz
Rated power
75
kW
Rated current
159
4 (8)
TECHNICAL DATA
LUFFING MOTOR (M2)

Rated voltage
Rated frequency
500
V AC
3 Phase ~ 60
Hz
Rated power
63
kW
Rated current
99
ELECTRICAL DATA - Electric motors

SLEWING MOTORS (M3, M4)
Rated voltage
Rated frequency
Rated power
Rated current
500
V AC
3 Phase ~ 50
Hz
18.5
kW
28
BRAKE UNIT MOTOR (M6)

Rated voltage
Rated frequency
Rated power
Rated current 3 x 440V - 60Hz
380 - 440
V AC
3 Phase ~ 60
Hz
0.55
kW
1.3
5 (8)
TECHNICAL DATA
OIL VOLUME / OIL FILLING (per unit)

Hydraulic Brake unit oil tank
15
liters
Emergency brake unit oil tank
8.2
liters
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
Hoisting winch gearbox
WIRE ROPE
Hoisting wire rope
30 mm 235.5 m
No. 1221289
Luffing wire rope
28 mm x 163
No. 1188175
6 (8)
TECHNICAL DATA
Limit Switches in Hoisting and Luffing Winch Systems
7 (8)
TECHNICAL DATA
LOADSTEP DIAGRAM
Fig. 2 Loadstep diagram
8 (8)
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
CT2
Display
CT13
CT1
CT14
CT10
CT13
CT10
El. motors (SL)

Crane
operator's
cabin
Winch (Lu)
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

units with all machinery enclosed in the crane house
and, thus, well protected against external abuse.
When delivered, the cranes are mechanically,
hydraulically and electrically complete in every respect
and ready to be installed on a suitable foundation fixed
in the ships deck or on a crane carriage travelling on
deck.
Design
All crane movements - hoisting, luffing and slewing are driven by electric motors. These are connected
to frequency converters, which allows stepless speed
control of the motors for each electric circuit. The
converters are linked to the LINE-units via a DC-bus.
The LINE-units allow powerflow in both directions.
LCL-filters for each LINE-unit eliminates harmonics
and any disturbances that may occur during back
power generation.
The hoisting winch is driven by an electric motor. A
brake is integrated in the winch gear set. When the
winch is running, the brake is automatically released
by a hydraulic unit. The hoisting winch have also a
pressure roller and one layer of wire on the drum.
Slackwire limit switches on the hoisting and luffing
winches operate if the wire slackens and to preclude
the complete unwinding of the wire from the wire
drums.
2.007.96 E rev.: a 2011-06-10
The crane house is an all-welded structure on a rigid

baseplate, and encloses all mechanical and hydraulical
machinery and associated electrical equipment for an
adequate protection against rain, sleet and waves
breaking over the ship. Catwalks, ladders, platforms,
and handrails facilitate the maintenance of the crane.
The top of the crane house and of the jib head are
fitted with sheaves for the hoisting and luffing wire
ropes. All sheaves and their shafts are secured by
lockplates.
Various software limits, encoders, load cell (SWL)
together with jib outreach are supplied.
The cranes are supplied with test certificates to the
requirements of National Swedish Board of Shipping
and Navigation. The design meets the requirements
of ILO and the relevant classification societies whose
certificates will be supplied if specially ordered.
Overload protection
To prevent the crane from being overloaded, i.e. lifting
a too heavy load, the electrical system has an overload
system. Pressure sensing switches, which normally
enable the operation, stop the hoisting movement if a
too heavy load is lifted at the current jib outreah. The
pressure sensing switch or load cell gives a signal to
the control system overload logic, which senses the
overload input signal to the control system CC3000.
Crane operators cabin
The crane jib is raised and lowered by the luffing winch

whose general design is similar to that of the hoisting
winch.
The crane has several slewing gears and the slewing
drive of the crane uses the electric motors. On
customers order encoders can be supplied to define
the slewing range of the crane.
The temperature and brake oil levels of the brake
circuits are monitored by the control system CC3000.
2 (4)
The crane operators cabin affords an allround view of

the entire work area.
The cabin contains of control panels with various
switches, pushbuttons and signal lamps and joysticks
for hoisting and luffing/slewing movements.
Air conditioning is available as an optional feature.
The emergency exit is through the cabin's side window.
A display in the cabin shows continuous information
about load, outreach, possible movements etc.
2.007.96 E rev.: a 2011-06-10
Jib
Crane control system CC3000
The jib is made of two box girders joined by transverse

tubular steel struts. The foot of the jib mounts on two
trunnion journals at the sides of the crane house. A
halogen floodlight is mounted on the jib.
Control of the outreach is load depending.The load

cell gives information about the load (SWL) to the
control system CC3000 and compares the outreach
through the encoders for luffing outreach and stops in
the chosen software limits.
Electrical equipment
Certain electric cables outside of the crane house,
e.g. on the jib, are carried in steel conduit. All cables
and electrical accessories are specially designed for
marine use.
Hydraulic hoses
The hydraulic hoses are high-pressure tested and
carefully cleaned and inspected before assembly.
Cargo handling gear
The slip-ring unit linking the crane network with the

shipboard network is put under the crane, inside the
foundation and is bolted to the bottom plate.
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
other components of the electrical installation. The
main power switch is put on the cabinet CT1.
Lighting
Lighting is installed in the crane house and cabin. Can
also be installed in the foundation and pedestal, if
required.
The swivel, hook, shackles, rings, and chains, all have

ample safety margins for the maximum load to be
handled by the crane. The non-rotatory, langs lay wire
ropes are galvanised and oiled.
Surface treatment
All surfaces of the crane are carefully prepared by
sandblasting before being given a coat of Primer. As
standard the crane is painted with an anti-corrosive
system basically based on a two-component epoxy
paint and an acrylic finishing coat.
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)
2.007.96 E rev.: a 2011-06-10
4 (4)
FUNCTION
3.110.127 E rev.: b 2012-02-02
ELECTRICAL FUNCTIONS
WARNING! Separate feed in the cabinet CT1 and

electric motors!
Some components in the crane are still energized
when the main power switch is off. Refer to electric
diagram for information about energized components.
WARNING! Voltage remains for 5 minutes in the electric cabinets CT10, CT13 and CT14 when power is
switched off. The electric cabinets store the frequency
converters and line unit.
General
Electric system
The following description refers to the standard electric system of MacGregor electric deck cranes, normal
version.
Minor variations in the electric system may occur in individual cranes of the same type, and the objective of
this description is only to provide a general orientation
concerning the arrangement of the electric system.
The winches for the hoisting, luffing and slewing gears

are driven by electric motors. These are connected
to the motor inverters, which invert the DC-current
to AC-current and supply variable stepless speed
control of the motors. The inverters are linked to the
LINE-unit through a DC-bus. The line unit rectifies
the current from AC to DC and supplies power to the
motor inverters. LCL-filter for the line unit protects
the electric network by eliminating harmonics and
any disturbances that may occur during back power
generation. The electrical system allows powerflow
in both directions.
The complete electrical system drawing, relating specifically to your crane, will be found in
the instruction manual, section Spare Parts,
Group 9.5.
Symbols
Every electric component is represented by a special
symbol in the circuit diagram. The meaning of the symbols 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
Fig. 1. Electrical system.
2 (4)
UF2
FUNCTION
3.110.127 E rev.: b 2012-02-02
Starting and stopping
Other electric functions
Preheating
Note! The heating fans are to make sure that the
temperature in the crane house is always kept above
-10C. This is necessary for the operation of the frequency converters and line units.
Overheating protection
An analogue temperature sensor in each electric motor is connected to its respective frequency converter.
When the electric motor begins to overheat, the ramp
time increases during acceleration. If the temperature
continues to rise above the maximum permitted level,
the motion is ramped down to a stop.
The heating fans for the crane house are started with
a switch on the electrical cabinet CT1. These heating fans, which are controlled with a thermostat in
the cabinet CT1, stop if the temperature in the crane
house exceeds +15C.
The heating elements in the electric cabinets will
warm up the electric and electronic equipment inside
the cabinets automatically. They are thermatatically
controlled.
Starting sequence
When the start button is pushed, the DC bus is precharged and then the main contactor operates. The
frequency converter system and the motor fans start.
The pump for the brake system also starts. Now there
is communication between the control system and the
frequency converters.
Operating sequence
Input from the control levers magnetizes the electric
motor and the brakes are released. The permitted
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
to the motor inverters. The motor inverters control
the electric motors accordingly. The ramp time for the
hoisting and luffing movement is based on constant
acceleration and the retardation to standstill takes
the same amount of time regardless of the maximum
current load.
Stop sequence (normal operations)

The stop button, S13, needs only to be pushed once,
then the system waits for the brakes to be applied.
When the brakes are applied, the crane stops.
A temperature switch in the electric motor stops the

crane if the motor is about to overheat. It switches off
the current at a higher temperature than that permitted by the analogue sensor, and therefore acts as a
back-up to the analogue sensor.
Oil level in brake unit

If the oil level in the hydraulic oil tank drops too low
the crane ramps down and stops. An alarm system
is switched on by the float oil level switch. Indicator
light H5 comes on.
Siren
The pushbutton "SIREN" in the cabin allows the crane
operator to warn people on deck.
Ventilation fan
A ventilation fan is installed in the crane house. This
is controlled by a thermostat, BT1, which is installed
in the cabinet CT1.
Lighting and heating

Electric power is supplied by separate slip-rings for
lighting in the crane house, in the operators cabin,
and on the jib and heating in the cabin.
The crane house lighting is operated by switches on
the roof of the platform. The cabin lighting and the jib
light are operated by switches on the control panel
in the cabin.
Control system error

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

of a MacGregor electric deck crane.
The control-pressure, brake circuit have these main

components, see Fig. 1:
This is a general description of the hydraulic brake

circuit, and may not be fully correct with your crane.
A complete hydraulic circuit diagram for your crane
will be found in the instruction manual, section 9.4.
4111
4102
4333
4145
4148
4161
1
There are separate hydraulic brake circuits for brake

release of the hoisting winch, luffing winch and slewing gears. The control pressure brake circuit is the
brake unit.
Symbols
Every hydraulic component is represented by a special symbol in the circuit diagram. The symbols are
explained in section General in the manual.
Component identification
The main components are identified by four-digit numbers in the diagram and on the actual components
in the crane. The first digit of each number is the circuit
to which the component belongs:
1... Hoisting brake circuit
2... Luffing brake circuit
3... Slewing brake circuit
4... Control-pressure, brake circuit
5... Additional programming equipment *)
7... Other additional hydraulic equipment *)
*) Equipment installed at request of customer.
Pump
Filter unit
Oil level /temperature guard
Pressure switch
Pressure relief valve (safety)
Accumulator
Gauge connection
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
system operates between switching pressure 3.0-6.0
MPa (30-60 bar).
Pressure switch 4145 has a min pressure set to 3.0
MPa (30 bar) and a max pressure set to 6.0 MPA (60
bar) and is measured at gauge connection 1.
Control fluid is supplied by the pump in the brake unit.
If control pressure decreases below 3.0 MPa (30 bar)
the pump in the brake unit automatically starts or if
the control pressure increases more than 6.0 MPa
(60 bar) the pump stops.
The pressure relief valve (safety) 4148 is set to 7.0
MPa (70 bar) and is measured at gauge connection 1.
Note!
For exact pressure settings, see pressure list in the
hydraulic diagram.
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 +85C.
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

components:
The luffing winch brake circuit have these main components:
1211
1226
1227
1249
1381
2211
2226
2227
2249
2381
Hydraulic brake
Direction valve
Direction valve
Test nipple - air
Low pressure switch
Brake release
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
the motor gets magnetized and the brake 1211 is
released. Direction valves 1226 and 1227 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
system.
Hoisting safety function

Pressure switch 1381 stops the crane if the control
pressure is too low.
Hydraulic brake
Direction valves
Direction valves
Test nipple - air
Pressure switch
The luffing and slewing movements are operated by

the same control lever, see Fig. 2.
Brake release
When the luffing control lever is in neutral position the
brake is engaged and holds the load. When the control
lever is moved forward or backward the motor gets
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
"test nipple - air" 2249 to bleed air out of the hydraulic
system.
Luffing safety function

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 components:
3211
3212
3226
3227
3249
3381
Hydraulic brake
Hydraulic brake
Direction valve
Direction valve
Test nipple - air
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
"test nipple - air" 3249 to bleed air out of the hydraulic
system.
Slewing safety function

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

General
The following description refers to the microcomputer
based crane control system CC3000 for MacGregor
Cranes electric deck cranes, single crane versions.
Minor variations in the use of the control system input
and output signals due to differences in the hydraulic
system for the brakes and electric system can occur.
The objective of this description is only to supply a
general orientation concerning the principles of the
control system.
CT2
MC
"Ho"
Main
hoist
For detailed information about the control system a

complete electrical circuit specification, relating
specifically to your crane, will be found in the
instruction manual, section "Spare Parts", Group 9.5.
Detailed information about the hydraulic brake system, a complete hydraulic circuit specification, can
be found in section "Spare Parts", Group 9.4.
Motor
inverter
Ho
Fieldbus
Run Enable
HOISTING
Brakes
Brake valve
Brake valve
3-phase
DCsupply
bus PWM
Fieldbus
CC
"Sc"
Run enable
Line
Unit
Elmotor
Hoisting
winch
Super
-visory
MC
"Lu"
Fieldbus
Luffing
Run Enable
Motor
inverter
Lu
LUFFING
Brakes
Brake valve
Memory
Card
Brake valve
DC-bus
PWM
Elmotor
MC
"SL"
Fieldbus
Slewing
Run Enable
Motor
Inverter
SL
Luffing
winch
Motor
Inverter
SL
Brakes
SLEWING
Brake valve
Brake valve
DCbus
PWM
PWM
Slewing
gear
Elmotor
Elmotor
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)
Em.Op.
SP
Hardware
324 1665-901
ErrorMP
SP
CC
MC
MC
MC
Sc Ho Lu Sl
Normal
Rigg
Select / Info Select / Info Select / Info Select / Info

Up
OL-Test
Up
Down / Exit
PC COM
Software
CC3K H01.00
Rev B
A1
IO_485.1 1
485.1
IO_A3
P1110
C22
C23
Sp
AU_SSI
C44
C36
C52
AU_485.11
A3T
SSI
IO_Sp
AU_A3
C58
C57
C28
C17
IO_C1
AU_C1 1
IO_A1
IO_C2 1
C18
C2
IO_A2
AU_C2 1
A2
P1102
P1103
SSI
AU_A2
P1101
P1109
485.1
P510
Sp
C50
C49
A3T
AU_Sp
SL_485.11
SL_A3
P1108
C2
C53
A2
P502
IO_SSI
1
AU_A1
SL_C1 1
SL_A1
SL_C2 1
SL_A2
P501
P503
SSI
SL_Sp
C6
C1
P509
485.1
P410
Sp
SL_SSI
LU_485.11
C41
A3T
A1
P508
C2
C45
A2
P402
P403
SSI
LU_SSI
C42
LU_C1 1
LU_C2 1
P401
P409
485.1
P310
Sp
IO_C3 1
SC_C1 1
HO_C1
1
1
A3T
LU_A3
HO_485.11
P302
P303
SSI
LU_Sp
SC_485.11
P210
Sp
C1
P408
C2
C37
A2
LU_A2
HO_C2 1
P301
P309
485.1
HO_A3
IO_485.2 1
SC_485.2 1
C12
C11
A3T
C34
SC_A3
IO_485.3 1
SC_Sp
SC_485.3 1
P202
P203
SSI
C1
P308
C2
C29
A2
P209
485.1
P110
Sp
C33
A3T
P102
HO_Sp
P1117
SC_SSI
P1116
485.2
P103
P118
C1
LU_A1
HO_A1
SC_A1
IO_C4
P201
P109
P116
485.2
P117
A1
P208
C2
C7
A2
SC_C2 1
P101
SC_A2
SC_C4
P108
C4
P1115
C4
C1
HO_A2
P115
A1
AUAuxiliary IOInput/Output
A1
SC_C3 1
SLSlewing
C1
P1118
P107
P106
P207
P206
P307
P306
P407
50
42
358
356
353
348
337
335
333
331
329
326
320
318
315
312
308
304
302
50
359
357
355
349
338
336
334
332
330
327
325
319
317
314
311
307
303
301
50
50
259
257
255
253
251
248
245
241
239
237
235
233
231
229
226
220
218
215
212
210
208
204
202
50
50
42
42
161
158
153
149
141
136
134
132
130
127
125
118
116
114
112
110
108
104
102
50
50
258
256
254
252
249
247
243
240
238
236
234
232
230
227
225
219
217
214
211
209
207
203
201
50
50
42
42
160
157
151
143
137
135
133
131
128
126
119
117
115
113
111
109
107
103
101
P406
P507
P506
P1107
P1106
32
50
50
459
457
453
449
438
436
434
432
430
427
425
419
417
414
411
407
403
401
Down / Exit
PC COM
Software
CC3K H01.00
Rev B
A1
485.3 485.3
Up
Down / Exit
PC COM
Software
CC3K H01.00
Rev B
SCSupervisory
HOHoisting LULuffing
C3
HO_SSI
The joystick linear potentiometers are supplied with

0V, +6V and +12V. The output level is approximately
+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.
Up
Down / Exit
PC COM
Software
CC3K H01.00
Rev B
SC IO
C3
458
455
451
448
437
435
433
431
429
426
420
418
415
412
408
404
402
33
Hardware
324 1665-901
ErrorMP
34
SP
35
Hardware
324 1665-901
ErrorMP
36
Encoder
calibration
Normal
SP
Output Input Output Input Output Input Output

27
33 36
33 36
33 36
07
07
07
28
39 43
39 43
39 43
29
34 37
34 37
34 37
08
08
08
30
40 45
40 45
40 45
31
09
31
09
31
09
31
30
30
30
32
10
32
10
32
10
32
33
19 Sw19
19 Sw19
19 Sw19
34
20 Sw20 55
20 Sw20 55
20 Sw20 55
35
11 14 Sw14
11 14 Sw14
11 14 Sw14
36
56 Sw56
56 Sw56
56 Sw56
37
12 15 Sw15
12 15 Sw15
12 15 Sw15
38
26
26
26
27
27
27
39
58 59
58 59
58 59
40
49 17
29
49 17
29
49 17
29
53
51 18
53
51 18
53
51 18
53
61
52
52
52
54
54
54
57
C1
R1
57
C1
R1
57
C1
R1
C2 MP
C2 MP
C2 MP
Com
Com
Com
S1
50
50
Hardware
324 1670-901
ErrorMP
Input
07 18
08 19
09 20
10 26
11 49
12 51
13 56
14 57
15 58
16 59
17 60
24V
Com
C1 R1
C2 R2
C3 R3
C4 MP
31
30
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"
for slewing).
50
50
50
50
50
98
96
94
92
90
88
86
84
82
80
78
76
74
72
70
68
66
64
62
60
26
14
12
10
8
6
4
2
456
452
351
240
42
42
42
42
42
97
95
93
91
89
87
85
83
81
79
77
75
73
71
69
67
65
63
61
27
25
24
23
22
21
20
19
18
17
16
15
13
11
9
7
5
3
1
454
354
241
239
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
for each crane motion, hoisting, luffing and slewing.
Each MC card is separately controlled by respective
joystick.
Fig. 2. Crane control system CC3000 in cabinet CT2.
The rampformer gives smooth acceleration and

deceleration to the crane motions.
Cabinet CT2 contains the crane control system and is

protected against humidity by a casing with protection
class IP54 (dust and splash water proof).
The brake release logic circuit releases and applies

the brake in the correct sequence when the electric
motor starts and stops.
The brake circuit contains two separate control signals, each signal can be manouvered separately and
contains one relay and one hydraulic valve each.
CC3000 and the VFD can close the brakes
independently.
At power on each brake control circuit is independently
checked to ensure the double controllability.
2 (4)
Cabinet CT2
19" subrack with electronic cards

All electronic cards are installed in a standard 19" aluminium subrack. The system is powered with 24V via
the backplane card. To be able to read the connection
points for sensors and communication each CC and
MC Card is connected to the extended backplane card.
The configuration of the crane is stored in the memory
card.
3.142.41 E rev.: a 2010-12-14
FUNCTION
Electric motors
The electrtic motors are controlled by the variable
frequency drives. The current from the common DC
bus, which is supplied by the Active Line Module
(ALM), is converted by the VFD to required voltage
and frequence corresponding to requested speed from
CC3000.
Overload protection
Cranes are protected from lifting heavier loads than
specified Safe Working Load (SWL). This is obtained
by using a load cell where the measured value is
compared with the maximum load parameter. As an
extra precaution the value from the load cell is
compared to the motor torque.
For empty hook and lighter loads it is possible to run
at higher speed than with max SWL. If the crane is
specified with different outreaches depending on the
load then the overload varies.
All safety function based on overload are handled by
the crane control system CC3000.
Hoisting winch limit switch box
The limit switch box contains cams with limit switches
and encoders. They prevent operation outside working
area.
Each MC card is a complete stand-alone

microprocessor system with processors, several types
of memories and communication channels, analogue
and digital inputs as well as analogue and digital output current drivers. Each card can fully handle all input and output signals needed for one variable
frequency drive, i.e. one crane motion.
The safety system consists of a secondary
microprocessor, which monitors the behavior of the
main processor.
Software
All cards, CC and MC, are programmed with the same
crane control software. Each card senses, which rackposition and hence which function/crane motion it
controls.
All cards identify themselves by showing a twocharacter abbreviation of the function/motion name on
the front panel display:
- Sc - supervisory
- Ho - hoisting
- Lu - luffing
- SL - slewing.
The leftmost card, the CC "Sc", is only used for
supervisory functions such as communication with
other cards and distribution of control system parameters from the parameter memory card.
Luffing winch limit switch box

The limit switch box contains cams, limit switches
and encoders. They prevent operation outside working
area.
New versions of the crane control software can be

loaded/programmed into the cards by using a standard notebook PC.
Slackwire limit switches
Parameter memory card
The limit switch for hoisting stops the lowering motion, and the limit switch for luffing stops both the luffing
out and hosting motions.
All parameter values are stored in the memory card.

Stored parameter values are not dependent on power
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
and is assembled on the backplane card that also holds
all the card connectors. The lifetime of the battery is
10 years.
Microprocessor Cards - CC and MC

Hardware
The control system consists mainly of one CC card
and three MC cards. All MC cards are identical and
interchangeable.
3 (4)
FUNCTION
Anti-condensation heating
To avoid condensation on the electronic cards, the
temperature inside the cabinet must be higher than
the temperature outside. Heating elements are
therefore installed behind the terminal strip. They are
powered with 24V AC when the control system is
switched off or when the crane is not operational.
Signal overview CC3000
3.142.41 E rev: a 2010-12-14
Error messages
Built-in diagnostic system
The CC3000 control system has its own built-in
diagnostic system which is capable to detect several
types of malfunctions.
Internal problems such as loss of communications and
loose connections are continuously checked.
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,
yellow and red LEDs (Light-Emitting Diodes) on the
front panel of each card.
- Green LEDs are used for normal input and outputs.
- Yellow LEDs indicate that the crane motion
concerned is driven with slower speed.
- 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)
Error message sign

If a malfunctions found the "control system error" lamp
in the cabin start flashing. The error codes can be
read on the card display or on the cabin display. The
procedure to retrieve the error information is described
in the ERROR MESSAGES sign located in the cabinet
or in section 6.3.
FUNCTION
3.155.6 E rev.: - 2010-10-27
Thermostatic Controlled Ventilation Fan and Heater Elements
General
Thermostat BT5
The ventilation fan and heater elements are

thermostatic controlled and installed inside the crane
house, see Fig. 1.
The heater elements are automatically switched off

if the temperature exceeds +15C inside the crane
house. The thermostat bulb is installed outside the
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, positioned in the cabinet CT1, see Fig. 2. The thermostat
bulb is installed outside the cabinet.
Thermostat BT1 starts at +25C. The thermostat
can be adjusted, see Fig. 3.
Thermostat BT1
Thermostat BT5
Thermostat bulbs
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,

all mounting plates have heater elements. They are
supplied with 24V and are shut off when the crane
starts.
It is of great importance that the frequency converters

and line units have enough cooling air. The big modules have their own built-in fans. The small converters
need an additional cooling through a separate fan in
the door. It is important to replace the air filters in the
cabinets refer to instruction "Maintenance Chart" in
section 5 in the manual.
Heating
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 system only allows the crane to start if the temperature
inside all the cabinets is more than 0C. The crane
computer tells if the temperature is too low in any of
the cabinets.
1 (2)
FUNCTION
Position of heaters and fans

electric cabinets
3.155.7 E rev: a 2010-12-03
in the
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.
M7

CT2.
section 5.
R4, R5, R6 Heater elements for the anti-condensation

in cabinet CT13.
EH13/14
M8
M7
2 (2)
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.
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 -10C. 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.
Set the summer switch

to position "1" if ambient
temperature is more than
+15C.
Set main switch

in cabinet CT1 to
position "1".
Unclamp jib and loose gear

Unclamp jib and loose gear from its
parking position.
Winter - Heating fans
Wires and sheaves

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

to position "2" if ambient
temperature is less than
+15C. The heating fans
turn off when crane house
temperature is more than
+15C.
Set main switch

(Q1) in cabinet
CT1 to position
"1" approximately
24 hours before
operation.
1 (4)
OPERATION
PM40 1885-E00 rev.: a 2012-02-02
DURING CRANE OPERATION

List
Make sure that the ship does not list more than 5
degrees.
Trim
Make sure that the ship does not trim more than 2 degrees.
Max 5
Max. 2
IF CRANE DOES NOT START
IF CRANE STOPS
Do below check:
- Make sure that the emergency stops are not operated.
Reset all the emergency stops, see instruction
"Controls and Indicators" in section 4.
Do below checks:
a. Crane overheated (indicated on display in cabin).
- Examine motor circuit breakers for all fan motors.
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 section 4 of the instruction manual.
2 (4)
OPERATION
PM40 1885-E00 rev.: a 2012-02-02
AFTER SEA STOWING

e anti-condensation heaters are powered when the
crane's control system is off.
C-00218
Examine that all the heating elements in the electronic

cabinets operate.
Also see instruction "Crane control system CC3000"
in section 3.
Heating elements in CT2 cabinet
C-00216
C-00221
C-00217
C-00220
3 (4)
OPERATION
PM40 1885-E00 rev.: a 2012-02-02
4 (4)
OPERATION
PM40 5500-E00 rev.: b 1996-08-08
Handling of dangerous cargo

- Dangerous substances shall be handled in accordance with the
relevant requirements of National or Local Regulations and applicable National and International standard, only under the supervision 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
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
1
Push pushbutton, position 1 (START) to start the crane.

The crane starts within 20 seconds and is operational
when the red warning light goes off.
Do not operate on red light.
STOP
0
- Let go of control levers

- Push pushbutton, position 0 (STOP). The crane
turns off within 3 seconds.
1 (4)
OPERATION
PM40 6494-E00 rev.: - 2011-08-26
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,
SLEWING / LUFFING
Luffing out
Slew left
CONTROL LEVER,
HOISTING / LOWERING
Lowering
Slew right
Luffing in
Neutral
Hoisting
With the slewing/luffing control lever in neutral, the

brakes are engaged.
With the hoisting winch control lever in neutral, the

winch brake is engaged and holds the load.
Moving the lever a short distance from neutral releases

the brakes. The load stands still at brake opening.
Moving the hoisting winch lever in hoisting or lowering

direction releases the winch brake. The load stands still
at brake opening. The maximum speed is depending
on the load.
Moving the lever left or right starts the crane to slew

in the direction chosen.
Moving the lever forwards or backwards starts operation of the luffing winch.
2 (4)
OPERATION
PM40 6494-E00 rev.: - 2011-08-26
DURING CRANE OPERATION

Max 5
Max. 2
List
Make sure that the ship does not list more than 5
degrees.
Trim
Make sure that the ship does not trim more than 2 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)
OPERATION
PM40 6494-E00 rev.: - 2011-08-26
4 (4)
OPERATION
PM40 7546-E00 rev.: -
2012-02-01
Controls and Indicators

CT3
CT3
Display
Luffing out
31
32
Slew
left
Lowering
Slew
right
Luffing in
Hoisting
Fig. 1. Controls and indicators in the crane cabin.
Warning!
Only ship's crew is allowed to operate key switches.
WARNING!
Store Keys Safely
When the crane is rigged ready for operation, all keys
for all lockable switches must be stored in a safe place
H1
DO NOT OPERATE
Indicator light. Comes on during starting sequence
of the crane (main electric motor and supply to electronics).
H2
CONTROL SYSTEM ERROR
Indicator light. Comes on when an error is sensed by
the crane control system in the electronic cabinet CT2.
H3
BRAKE FAILURE
Indicator light. Comes on when an error is sensed in
the brake system. Carefully lower the load and park
the crane in its support and stop the crane.
H4 RESET EMERGENCY STOP

Pushbutton with indicator light.
The indicator light comes on when the emergency stop
button(s) is/are pushed. The crane cannot be started.
- To reset the emergency stop indicator light, stop
the crane.
- Push the "RESET EMERGENCY STOP" button.
- Start the crane again. Use pushbutton START/
STOP S13.
- If the pilot light still illuminates any of the emergency
stops operate. Make sure that all emergency stops
are reset.
1 (6)
OPERATION
H5
BRAKE, LOW OIL LEVEL
Indicator light. Comes on as a warning for low oil level
in the brake unit. If light comes on, lower the load and
fill oil in the brake unit oil tank.
WARNING!
Do not push Emergency Stop when "Brake, low oil
level" indicator light is on. Lower the load slowly. Check
for possible oil leaks. Fill oil to the correct level.
PM40 7546-E00 rev.: -
2012-02-01
S17 SIREN
Pushbutton. Starts the siren.
S18 JIB LIGHT

Pushbutton. Switches on/off the jib light.
0
1
H6 OVERLOAD
Indicator light. Comes on at overload.
S20 PARKING OF JIB

Key switch with two positions, 0/1.
0 - Normal position
1
0
S13 START / STOP

Pushbutton with two positions, 1/0:
1 - Start
Position 1 starts the complete crane. During the
starting sequence the DO NOT OPERATE indicator
light comes on.
0 - Stop
Position 0 stops the complete crane. The power
supply to the main electric motor and electronics will
be broken.
1 - Parking
The parking position is used when maximum outreach
is reached for the jib. Further lowering is possible for
parking of the jib when switch is in parking position "1".
0
1
S22 WIPER
Switch. 0/1 (On/Off). Starts and stops the window wiper.
0
1
F14 RESET WIPER

Pushbutton. Resets the wiper motor (automatic fuse),
when the wiper motor has stopped due to a surge in
current.
S23 CAB LIGHT

Switch. 0/1 (On/Off).
ME
RGENC
Y
S15 EMERGENCY STOP

Pushbutton. Stops the complete crane in case of
emergency. The pushbutton has to be reset, otherwise
the crane cannot be started again.
S16 DECK LIGHT

Pushbutton. Switches on/off the deck light placed
under the cabin.
2 (6)
S24 CAB HEATER

Switch , 0 / 1(On/Off). Starts and stops the cabin heater.
0
1
S25 FAN 0/1

Switch, 0 / 1(On/Off). Starts and stops the ventilation
fan in the cabin.
OPERATION
S26
CARGO / GRAB HANDLING
Key switch with two positions, 0/1.
0 - Cargo
Normal SWL.
1 - Grab
- Reduced SWL for operation with grab.
- Interlock connection of "grab control equipment".
See instruction "Installation of Power Supply Cable
", section 6.3.
PM40 7546-E00 rev.: -
2012-02-01
S31 CONTROL LEVER, HOISTING/LOWERING

Note! Joystick for hoisting/lowering motion must be in
neutral position when starting the crane. If the joystick
has been moved in any direction when pressing the
start button the motion is blocked. Move the joystick
to neutral position then operation is possible.
When the control lever is in neutral position the brake
is engaged and holds the load. Moving the control
lever in hoisting or lowering direction gives an input
to the electric motor, the motor is magnetized and the
brake is released.
The hoisting speed is dependent of the load. To give
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 corresponding 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
Retardation -stop
Start - acceleration
Empty hook
Speed
Max. load
Time
2 sec.
2 sec.
Acceleration
Retardation
Fig. 2. Hoisting/Lowering.
3 (6)
OPERATION
S32
PM40 7546-E00 rev.: -
CONTROL LEVER, LUFFING/SLEWING
Note! Joystick for luffing motion must be in neutral

position when starting the crane. If the joystick has
been moved in any direction when pressing the start
button the motion is blocked. Move the joystick to
neutral position then operation is possible.
Retardation - stop
With the control lever in neutral position the brakes

are engaged.
Empty hook
Speed
Moving the control lever short distance from neutral

gives an input to the electric motors, the motors are
magnetized and releases the brakes for luffing winch
or/and slewing machinery.
Moving the control lever furthermore in luffing or
slewing direction means continued speed increase
from zero to maximum speed.
To give a smooth acceleration and retardation to the
luffing winch movement and the slewing movement,
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.
Retardation - stop
Empty hook
Speed
Max. load
Time
2 sec.
2 sec.
Acceleration
Retardation
Fig. 3. Luffing.
4 (6)
2012-02-01
Max. load
Time
3 sec.
3 sec.
Acceleration
Retardation
Fig. 4. Slewing.
OPERATION
PM40 7546-E00 rev.: -
2012-02-01
Cabin Display
The display gives the real-time information about the
status of the crane during its operation. The information presented depends of the crane's configuration.
CONTROL LEVER INDICATOR, (S32)
The application in the display is called MacHeavyvisor,

see section 7.
The circle with four green arrows represents the left

control lever and the four motions it controls. (Luffing
in/out and slewing left/right)
Note! If there is no communication with the CC3000

system, the message "Disconnected" will appear on
the screen.
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.
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.
The specific diagram for this crane can be found in
Technical Data in section 2 of this manual.
LOAD IN HOOK
The current load in the hook. If the value exceeds the
overload limit the box background will flash in red and
an audio warning is also given. The overload information is indicated by CC3000.
CONTROL LEVER INDICATOR, (S31)

The circle with two green arrows and a small white ball
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
speed during hoisting and lowering. Clockwise rotation means hoisting and counterclockwise rotation
means lowering.
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)
OPERATION
PM40 7546-E00 rev.: -
2012-02-01
Electric Cabinet CT1

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

Pushbutton. Stops the complete crane in case of
emergency. The pushbutton has to be reset, otherwise
the crane cannot be started again.
S51 Emergency Stop

Q1
CT1
Fig. 5. Electric cabinet CT1/CT2.
Q1
MAIN POWER SWITCH
Switch with two positions 0/1 (OFF/ON).
0
0 - OFF
Stops the power supply to the electric cabinet CT1.
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.
S52
CRANE HOUSE LIGHT SWITCH
Switch. 0/1 (On/Off). Turns on and off the crane house

lights. Switch is installed on the roof of the pedestal.
1 - ON
Starts the power supply to the electric cabinet CT1.
ME
RGENC
Y
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

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 controlled by a person on deck by alternately tightening 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)
OPERATION
PM41 0014-E00 rev.: a 2010-02-03

Rope Ladder / Fixed Ladders
Leaving Crane Operator's Cabin Using
Rope Ladder
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 removing the straps and pull the rope ladder out and let
it fall towards the deck. See Fig.1 pos. 2.
Rotating
ladder
Emergency
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)
OPERATION
PM41 0014-E00 rev.: a 2010-02-03
2 (2)
OPERATION
4.620.31 E rev.: - 2012-01-12
Parking the Crane, Sea Stowing

General Instruction
General
Prior to sea voyage the crane should be parked correctly. Parking according to recommendations will relieve mechanical equipment from unnecessary stress
during sea voyage and extend the lifetime of the components.
Parking jib in support

When the jib enters the parking area beyond maximum
outreach the function Force Limitation is automatically activated and limits the pulling force and speed
for hoisting, luffing, and slewing motions. See also
instruction Limit switches in section 6.3.
1. Place the jib at maximum outreach above the jib
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
reaches the jib support.
3. Place the lifting block in correct parking position.
4. Stop the crane.
2. Secure lifting block to deck with lashing lines, the

lashing needs to have a manual stretching screw,
fibrestrops with low ultimate load or similar. See Fig.
2.
3. Tighten the lashing manually. Do not exceed 50 kN
pulling force on lifting block.
CAUTION!
It is strongly recommended to tighten and loosen lashing lines manually. The lifting block will start to hoist
when the brake in the winch is released, which can
cause damage to lashing lines.
PARKING OF JIB
0
1
Fig.1. Key switch on control panel, "Parking of Jib".
Securing of jib in support by lashing lifting block

to deck
1. With the lifting block in its parking support it is necessary to secure the jib prior to sea voyage.
Rope connection
Stretching
screw turnbuckle
Deck
Note! Hand-tighten
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
C-00255
Fig. 3. Jib parking arrangement with lifting block angled to deck.
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 lubrication). 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)

Power cable and stabilizing wire
Power cable and stabilizing wire should be parked on
jib top during sea voyage. Parking on hook block is
for temporary use only. See also separate instruction.
Parking suggestions of power swivel

It is recommended to park the power swivel separately
from block prior to sea voyage, this to aviod excessive
wear on equipment.
Parking suggestions of electro-hydraulic grab

It is recommended to park the grab separately prior
to sea voyage, this to aviod excessive wear on equipment.
Park the grab accordingly to manufacturers recommendation.
The grab should be lowered to the deck when the
crane is temporarily parked, this to avoid load on the
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
Fig. 7. Power swivel secured to deck.
4 (4)
Angle bar
Fig. 8. Power swivel with lifting block secured to deck.
OPERATION
4.630 E rev.: - 1994-02-04
Handling Hatches by Deck Crane
Handling hatches
When pulling hatch covers by means of deck
cranes, it is very important that the pulley blocks are
so placed that the hoisting wire can be maintained
very nearly vertical during operation. The crane jib
should be set at an angle where it will not require
any subsequent shifting in order to achieve the
required lifting height.
Always check that the pulley blocks are correctly

positioned, so that the hoisting ropes cannot deviate
more than 5, at the most, from the crane house
centre line.
N.B. The capacity of the wire pulling the hatch cover
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.
- Do not exceed the maximum safe pull of the
hoisting sling wire.
- No extra limit switches are operated for handling
hatches.
During crane operation of the hatch covers there must

be another person observing the operation from the
opposite side, prepared to stop the operation in case
of an equipment malfunction or an emergency.
C-00120
Before emergency operation with the crane for hatch

covers read the instruction manual for hatch covers
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
eye on the pedestal
1. Lifting block
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 attached to the lifting eye on the pedestal and to lifting
block. If it loosens persons can be hurt and equipment
can be damaged.
When opening and closing hatches by means of the

deck crane, it is extremely important that the hoisting
wire remains vertical during the whole operation. The
hoisting wire must not deviate more than 5o from the
centre line of the crane house. See Fig. 2. Adjust
hoisting wire angle by luffing the jib out or in.
Max
5
Max
5
C-00124
CAUTION!
The hoisting wire must be straight. If the angle between
the hoisting wire and the centre line of the crane house
exceeds 5o, the luffing winch can be overloaded.
Fig. 3 Sling wire between foundation and hatch, seen

from above
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
1
C-00119
C-00121
Fig. 2 . Handling hatches with crane.
2 (4)
Fig. 4 Lifting of hatch cover.

1. Lifting block
2. Lifting eye
OPERATION
4.630.7 E rev.: - 2011-04-01
Maximum lifting height
Release sling wire
Maximum lifting height is when the hoisting sling wire

is in horisontal position between lifting eye on the
pedestal and the pulley on the hatch cover. Hatch must
only be lifted to maximum 60. See Fig 5.
When hatch cover is in fully open position make sure

that the folding pairs are in locked position at both
sides of the hatch cover.
Slacken the sling wire and release the chain blocks.
Remove the sling wire.
The crane can now be used for normal operation.
Carefully lift the hatch cover to max lifting height. Make

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.
C-00123
C-00122
Max
60
Fig. 6 Hatch cover in stowed position

1. Sling wire
2. Chain block
3. Lifting eye on wheel arm
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

CHART.
Daily or before taking crane into operation
Oil tank, brake unit

- Examine oil level. See instruction "Oil tank, Brake
Unit" in section 5.
Oil tank, bevel gear hoisting winch

- Examine oil level. See "Hositing Winch" instruction,
section 6.1.
After 50 operating hours (running-in period)

Oil tank, power swivel (optional)
- The first oil change see instruction, section 7.
Every month
Escape device
- Visual inspections should be carried out with particular 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.
Winches gearbox, hoisting and luffing

- Examine oil level. See Winch instructions, section
6.1. The oil quantity is marked on the name plate
and in instruction "Technical Data", section 2.
Limit switches; compare section 6.3 instruction
for stop position
- Testrun all functions and make sure that they are
working properly.
Slack wire switch

- Function test, see instruction, section 6.3.
Loose gear
- Make sure that the block, beam, hook, swivel, and
shackle are intact refer to instruction "Lifting Block/
Beam", section 6.2.
Every 200 operating hours or every two

months
Pump, brake unit.
- Make sure there are no leaks.
Multiple-disc brake, slewing gear/winches

- The drain plug shall be taken out every 200 hours
of operation, to drain off oil that may have been
collected.
Slewing bearing screws, studs/nuts

- 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,
tighten all screws or studs/nuts with a torque wrench
or a hydraulic tensioner refer to drawing "Slewing bearing, yard mounting" and "Slewing bearing,
mounting", section 9.3.
1 (4)
MAINTENANCE
Wire rope sockets

- Make sure that wire rope thimbles are safely secured.
- Examine split pin for wear and damage.
- Replace, if necessary.
5.005.70 E rev.: - 2012-01-05
- Wire ropes are inspected refer to stipulations issued

by classification associations and national bodies.
- Make sure that the wire rope clamps on the wire
drums are safely secured.
Load cell (optional)

- Make sure that the load cell are safely secured.
Wire sheaves
- Inspect for wear.
- Make sure that the shafts are safely secured.
After 200 operating hours
Climb protection, jib top

- Inspect the climb protection for wear and damage.
- Measure the play between wire sheave and climb
protection. See instruction in section 6.2.
Slewing gear
- The first oil change. (Running-in period 200 hours.)
See instruction, section 6.1.
Winches gear box, hoisting and luffing

See instructions, section 6.1.
Oiltank, Bevel gear

See instruction "Lubrication Chart", section 5
See instruction "Hoisting Winch", section 6.1
Slack wire device

- Inspect rollers for wear or damage.
Electrical equipment including slip-ring unit

- Inspect refer to Electrical Equipment, General
Maintenance in section 6.3.
Heating elements, cabinet CT2

- Make sure that the elements in cabinet CT2 are
working i.e. get warm.
Crane house, foundation and jib welding joints

- Inspect for any sign of cracks.
See "Inspection of Stressed Components and
Structures", section 5.
Every 500 operating hours or every six

months
Oil analysis, oil tank brake unit

- Get a sample of oil and analyse the oil every six
month.
Hand pump
- Do a functional test of the hand pump refer to instruction "Emergency Lowering in Case of Complete Power Failure, Operation of Crane Using a
Hand Pump (Optional)", section 6.3.
Oil filter, oil tank brake unit

- Replace oil filter element. See instruction "Oil Tank,
Brake Unit", section 5.
Wire ropes, wire rope clamps

- Inspect for wear. See instruction "Handling, Installation and Maintenance of Steel Wire Ropes" in
section 6.2.
2 (4)
Air filter, oil tank brake unit

- Examine air filter, replace if clogged. See instruction
"Oil Tank, Brake Unit", section 5.
MAINTENANCE
Slewing gear, pinion

- Measure the backlash.
Slewing bearing
- Examine the seals.
Slip-ring unit
- Examine brush holders and wire brushes refer to
instruction in section 6.3.
5.005.70 E rev.: - 2012-01-05
Oil tank bevel gear, Hoisting winch

- Change oil. See instruction "Hoisting Winch" section 6.1.
Hydraulic accumulators
- Measure the pressure. If necessary, charge again.
See instruction Hydraulic Piston Accumulators,
section 6.1.
Fan with air filters in cabinet CT2/ CT10/ CT13/

External access ways
- Inspect for wear and damage.
Emergency escape ladder (optional)

- Inspect for wear or damage.
Every 1000 operating hours or at least

every year
Emergency handpump
- Change oil.
Slewing gear
- Change oil. See instruction "Slewing gear" in section
6.1.
Hoisting winch
- Change gearbox oil.
- Oil analysis . See instruction "Hoisting Winch" section 6.1.
Luffing winch
- Change gearbox oil.
- Oil analysis . See instruction "Luffing Winch" section 6.1.
Oil tank brake unit

- Change oil. See instruction "Oil Tank, Brake Unit",
section 5.
CT14
- Replace the air filters.
Cable winch (optional)

- V-belt, check tension.
- Slip-ring unit, check.
- Brake discs, check.
- Brush holders, check.
See instruction, section 7.
Multiple-dics brake, motor side

- Do a leakage check.
- Examine the braking torque. See instruction "Winches, Hoisting/Luffing", section 6.1.
Slewing bearing
- Grease sampling, see instruction " Slewing bearing
grease sampling procedure", section 6.2.
Frequency converters
- Dust deposits inside the device must be removed at
regular intervals (or at least once a year) by qualified
personal on line with the relevant safety regulations.
The unit must be cleaned using dry compressed air.
- The ventilation openings in the devices must never
be obstructed. The fans must be checked to make
sure that they are functioning correctly.
- Cable and screw terminals must be checked regularly to ensure that they are secure in position and
if necessary retightened. Cabling must be checked
for defects. Defective parts must be replaced immediately.
3 (4)
MAINTENANCE
5.005.70 E rev.: - 2012-01-05
Every 2000 operating hours or every two

years
Every five years or every 5000 operating

hours
Multiple-disc brake, slewing gear

- Examine the discs.
- See instruction "Slewing Gear", section 6.1.
Multiple-disc brake, motor side

- Replace the brake discs.
- See instruction "Winches, Hoisting/Luffing", section
6.1.
Multiple-disc brake, winches

- Examine the discs.
- See instructions "Hoisting Winch" and "Luffing
Winch", section 6.1.
Hydraulic hoses inside crane house

- Examine the hydraulic hoses for damage. See instruction, section 6.1.
Oil tank, cable winch (optional)

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

- Drain oil and clean the reservoir. See instruction,
section 7.
Every four years or every 4000 operating 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, rnskldsvik, Sweden, before replacement of studs or
screws with any other specifications than recommended.
4 (4)
- Replace all hydraulic hoses. See instruction, section

6.1.
MAINTENANCE
5.018 E rev.: b
2004-05-24
Inspection of Stressed Components and Structures

Introduction
Stressed parts of the crane structure subjected to
high loads require inspection for signs of cracks and
other damage at regular intervals.
Cracks detected at an early stage do not generally
impair the handling safety of the crane unless they
are not repaired.
For safety reasons, service routines should include
a regular inspection of the entire crane, with particular attention paid to stressed parts. Check also
the parking support for wear and cracks, see Fig.
2.
Inspection
A thorough visual inspection is fairly easy to carry
out as cracks will generally show by cracking or
flaking of the paint followed by a brownish discoloration by rust.
(Inspect welds and surrounding material.)
This inspection should be performed at intervals according to the Maintenance Chart.

Note!
Rust on a painted surface does not necessarily
mean that there is a crack in the underlying material.
Remedy
When rust is found on top of or near a weld, grind
the topmost surface layer away to expose the crack
clearly. When in doubt, use Magnaflux to identify
the crack.
Before repairing of a crack in a stressed part, always contact MacGREGOR Cranes, Service Department for advice.
Example:
Fig. 1. Crane structure.
Fig. 2. Parking support.
1 (2)
MAINTENANCE
5.018 E rev.: b
2 (2)
2004-05-24
LUBRICATING CHART
PM51 1733-E00 rev.: d 2012-01-11
Item Part of crane (see page 2-4 for location)
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
a
Daily
b
Every 100 working hours
(or before taking winch into operation, item 17)
c
Every 200 working hours or every two months
d
Every 500 working hours or every six months
e
Every 1000 working hours or every year
Key to symbols
Grease for ball and roller bearings
Grease for plain bearings
Grease for wire ropes
Grease for open spur gears
Grease for jib bearings
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)
LUBRICATING CHART
PM51 1733-E00 rev.: d 2012-01-11
5. Luffing wire thimble
1. Wire sheaves
CT2
CT1
CT10
9.Door hinges
8. El.motor
(luffing)
CT14
CT13
8. El. motor
(hoisting)
10. Jib bearing
8. El. motor
(slewing)
19.Oil tank, winch

bevel gear.
11. Oil tank

brake unit
17, 18 Winch (luffing)
14. Slewing gear

17, 18 Winch (hoisting)
10. Jib bearing

16. Slewing bearing
2 (4)
15. Slewing bearing teeth
LUBRICATING CHART
PM51 1733-E00 rev.: d 2012-01-11
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,
central greased
1 Example: Wire sheaves crane top, manually

greased
6. Swivel (optional)
8 Electric motor
Grease nipples
Grease nipples
Grease nipples
3 (4)
LUBRICATING CHART
PM51 1733-E00 rev.: d 2012-01-11
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.
C-00226
Grease
nipple
1
20 Emergency handpump, oil tank.

Oil filling directly into oil tank.
Oil filling
4 (4)
MAINTENANCE
5.250.1 E rev.: - 2011-11-07
Slewing Bearing Studs

Yard Mounting for inner studs and Slewing Bearing
Mounting for outer studs.
General
The slewing bearing studs are screwed in to correct
detpth and streched with a special tensioning tool
before the nut is tightend.
Inspection of studs
Hit the nuts with a hammer to make sure that the
studs are tight. If one stud is not tight, all studs must
be stretched to the correct tension.
Contact Cargotec Services if you remove/install the

complete crane for the correct assembly and tensioning at the slewing bearing studs.
Tighten 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
correct tensioning tool and that you know how to use it.
Refer to the spare part pictures for correct assembly of
studs and correct prestressing force, Slewing Bearing
Note!
The drawings are examples for guidence only, type
of bearing and number of studs may be different on
your crane.
1. Make sure the studs are screwed in at the correct

depth.
2. Stretch the studs with a hydraulic tensioner. Stretch
the stud two times to get correct pre-stressing force.
3. Stretch the studs in correct order, see Fig 2.
4. Repeat the process on the first tightened nuts, until
all studs have the correct pre-stressing force. The
tightening of other nuts reduces the load on the first
tightened nuts.
1. Inner studs
2. Outer studs
3. Install depth of studs
4. Pre-stressing force
C-00228
C-00227
Fig. 2. Tightening sequence
Fig. 1. Slewing bearing studs
1 (2)
MAINTENANCE
5.250.1 E rev.: - 2011-11-07
2 (2)
MAINTENANCE
5.302.37 E rev.: - 2012-01-25
Brake Unit
General
The brake unit with oil tank is placed on the crane
house floor or wall. The pump is located inside the oil
tank and supplies oil to the control system. The oil
returns to tank via a drain line. Refer to "Hydraulic
Brake Function" in section 3 for more info.
Maintenance
For maintenance intervals refer to the "Lubricating
Chart" and "Maintenance Chart" in section 5.
For type of oil and grease refer to "Lubricants for Deck
Machinery" in section 5.
For oil volume refer to the "Technical data" in section 2.
Oil level check

The oil level is shown (cm) on the level/temperature
sensor display, see Fig 1.The oil level must be between
14 and 16 cm. The oil tank has also an oil level dipstick
to show if there is oil in the tank, see Fig. 1.
Note!
If the oil level is to low the "BRAKE, LOW OIL LEVEL"
indicator light on the control panel in the cabin comes
on. Refill oil.
Replace oil
1. Connect a drain hose to the oil drain, see Fig. 1.
2. Open the ball valve to drain the oil.
3. Remove a drain hose, see Fig. 1 item 2.
4. Make sure the oil tank is clean. If necessary, remove the tank top and clean the oil tank.
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.
Oil level/temperature sensor

The display shows the oil level (cm). Refer to "Oil
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
chart.
1.
2.
3.
4.
5.
6.
Oil drain, ball valve G"

Oil filling (drain hose connected)
Oil level/temperature sensor
Oil filter
Pressure switch
Oil dipstick/Air breather
Fig. 1. Oil tank, brake unit.
1 (2)
MAINTENANCE
5.302.37 E rev.: - 2012-01-25
2 (2)
MAINTENANCE
5.315.3 E rev.: - 2007-03-23
Sampling of Oil to Verify the Cleanliness

in Hydraulic System
General
Procedure for oil sampling
This service information describes sampling oil from

a hydraulic crane system.
- Oil temperature in the system should be 40-50oC.

- Special oil sampling bottles should be used and
can be purchased from oil companies.
- Open ball valve 4332, see Fig. 1 and bleed out
approximately 0.5 litre of oil in a bucket. This oil
to be disposed.
- Fill the oil sample bottle.
- Send the oil sample to an oil company for
analysis.
The oil company will be able to recommend if the
oil can be further used.
Feedback on the oil analysis can also be obtained
from MacGREGOR (SWE) AB.
This procedure is general and there can be some

differences depending of crane type.
Type of oil to be used in the system can be found
in Section 5.
When to sample oil
To verify the oil condition, an oil sample should be
taken every six months and sent for analysis. This
analysis is done by the oil companies and can be
of different levels. When the result is received, a
recommendation is normally given if the oil is approved or has to be changed.
For maximum particle contamination in the system,
see Table 1.
Procedure if oil sample is showing too high

contamination
If the oil analysis shows too high contamination, the
oil and the filters should be changed. The crane
should be driven for approx. 1 hr and a new oil sample should be taken and sent for analysis.
Oil tank
Ball valve 4332

Bucket
Oil sample bottle
Fig. 1. Sampling hydraulic oil.
1 (2)
MAINTENANCE
5.315.3 E rev.: - 2007-03-23
Cleanliness Level Correlation Table

Particles/millilitre
ISO 5 Micro- 15 MicroACFTD
Code meters
meters
Gravimetric
Level, mg/L
Not
OK
OK
NAS
1638
(1964)
Disavowed
"SAE" Level
(1963)
26/23 640.000
80.000
1000
25/23 320.000
80.000
23/20
80.000
10.000
21/18
20.000
2.500
20/18
10.000
2.500
20/17
10.000
1.300
20/16
10.000
640
19/16
5.000
640
10
18/15
2.500
320
17/14
1.300
160
16/13
640
80
15/12
320
40
14/12
160
40
14/11
160
20
13/10
80
10
12/9
40
11/8
20
2.5
10/8
10
2.5
10/7
10
1.3
10/6
10
.64
100
12
11
10
0.1
1
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
oxidation, rust and foaming, as well as wear inhibitor
and/or EP additives.
Slewing gear unit
Synthetic oil (polyglycol type).
Viscosity 220 cSt/40C.
Viscosity index (VI) 210.
Solidification point -30C or better.
The oil must fulfil specifications according to DIN
51354, FZG stage 12.
CAUTION! The oil must not be mixed with mineral oil
or synthetic gear oil on PAO-basis. The oil can also
dissolve paints and some seals.
Example: Shell Tivela S220 or similar.
Oil tank, winch bevel gear
Hoisting/ luffing winches and bevel gear
Hydraulic system, brake unit
For service in normal conditions:
Viscosity 34.6 cSt/40o C approx. (ISO VG 34.6 HV).
Viscosity index (VI) min. 160.
Solidification point -39o C or better.
Example: SHELL DONAX TA (D-21666).
SHELL SPIRAX S3 ATF MD3
Cable winch, turbo coupling (if applicable)

Viscosity 22 cSt/40C (ISO VG 22).
Example: SHELL MORLINA.
Cable winch, spur gear (if applicable)
Synthetic oil brand.
Example: MOBILE Glygoyle 30.
Hydraulic system, oil tank emergency
hand pump
For service in normal conditions:
Viscosity 34.6 cSt/40o C approx. (ISO VG 34.6 HV).
Viscosity index (VI) min. 160.
Solidification point -39o C or better.
Example: SHELL DONAX TA (D-21666).
SHELL SPIRAX S3 ATF MD3
Note!
Fill up with the same oil type as in the brake unit.
Do not mix the oil types.
B. GREASES
Plain bearings and wire rope sockets
Lithium grease with molybdenum disulphide.
Base oil viscosity 150 cSt/40C.
Dropping point 180C.
Example: MOBILGREASE Special 530303.
Crane jib bearing
Lithium/mineral oil-based grease.
NOTE: MUST NOT contain molybdenum disulphide.
Example:
SKF LGMT2 or SKF LGEP2. (-30C to +110C)
TEXACO MULTIFAC EP2. (-30C to +100C)
Roller/ball bearings
Grease with EP additives.
Must withstand wet conditions.
Example: SHELL Alvania EP (LF) 2 (-20 to +130C).
Arctic climate: SHELL Albida PPS2.
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 properties. (Very thin.)
Temperature range -30 to +100C.
Viscosity 9.8 cSt/40C.
Example: FUCHS Cedracon.
Arctic climate: FUCHS Ceplattyn.
Open spur gear units
Grease with good adhesion properties.
Example: SHELL MALLEUS GL95 (-15 to +150C).
SHELL MALLEUS GL65 (-30 to +150C
Please contact Cargotec Service Organisation, when

choosing lubricants for extreme temperatures.
2 (2)
Cargotec Sweden AB
MacGregor Cranes
Sjgatan 4G
SE-891 85 RNSKLDSVIK, Sweden
Telephone: 46 - 660 - 29 40 00
Telefax:
46 - 660 - 139 77
www.cargotec.com
How to order
spare parts
6.0
Hydraulic system
6.1
Mechanical
equipment
6.2
Electrical
equipment
6.3
SERVICE
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.: ......................................................
M/V ........................................................
IMO /Lloyd's no.: ..............................................
Crane type: .............................................
Serial no: .........................................................
Crane place: ...........................................
Our ref.: ..........................................................
Re:
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
HEALTH IN DOCK WORK, section A, B and D.
Section D
Section D stipulates the Test loading is needed.
Section A
Paragraph A.1.1 stipulates that every lifting
appliance should be with the provisions of section
D.1:
(a)
(b)
(c)
before taking in to use the first time

after the renewal or repair of any stress bearing
part; and
at regular four-year intervals, after the date on
which the appliance was first taken in to use.
Paragraph A.1.2 stipulates that the following

exceptions to the requirements of paragraph A.1.1
may nevertheless be allowed:
(a)
where any part is renewed or repaired, it should

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

adequate proof load test certified by a competent
person, in general MacGREGOR (SWE) AB,
rnskldsvik, cannot supply separate spare parts
to hook blocks, swivels, lifting beams etc. to the
owner or managers. However, it is possible to
deliver such parts to the MacGREGOR service
organization, if they can guarantee that the proof
load test and appreciate inspection according to ILO
will be performed under their responsibility.
MacGREGOR (SWE) AB, rnskldsvik
Quality Department
Gunnar Tjrnstrm
Quality Manager
Section B
Paragraph B.1.2 stipulates that every item of loose
gear, including cargo blocks, lifting beams and lifting
frames, should be tested:
(a)
(b)
before it is taken in to use the first time

after any renewal or repair of a stress-bearing
part.
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
Bjrnavgen 2
SE-891 41 RNSKLDSVIK
SWEDEN
Transport means, if necessary: Advised by us on request.

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

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

have to be enclosed.
The above refers only to the return shipment as such.
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.:
Ships name:
IMO no.:
Crane place on board:

Crane serial no.:
Returned parts
drawing or article
no, serial no.:
Part description:
Serial no. of unit

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

Marine Service: Worldwide Service Network
AUSTRALIA
DENMARK
INDIA
Sydney Office
Tel:
+61-2-464 741 49
Fax:
+61-2-464 770 03
24 hrs: +61-408-494 777
Copenhagen Office
Tel:
+45-44-538 484
Fax:
+45-44-538 410
24 hrs: +45-44-538 484
Esbjerg Office
Tel:
+45-44-538 484
Fax:
+45-44-538 410
24 hrs: +45-44-538 484
Mumbai Office
Tel:
+91-22-2758 2222
Fax:
+91-22-2758 2227
BELGIUM
Antwerpen Office
Tel:
+32-3-546 4640
Fax:
+32-3-542 4772
24 hrs: +32-3-546 4640
Zeebrugge Office
Tel:
+32-50-84 05 50
Fax:
+32-50-84 09 50
INDONESIA
Batam Office
Tel:
+62-778-737 2207
Fax:
+30-778-737 2210
ESTONIA
ITALY
Tallinn Office
Tel:
+372-6 102 200
Fax:
+372-6 102 400
24 hrs: +372-53-018 716
BRAZIL
Genoa Office
Tel:
+39-010-254 631
Fax:
+39-010-246 1194
24 hrs: +39-335-139 4779
FINLAND
Rio de Janeiro Office
Tel:
+55-21-2516 1790
Fax:
+55-21-2516 1743
24 hrs: +55-21-9121 1986
JAPAN
Turku Office
Tel:
+358-2-412 11
Fax:
+358-2-412 1517
24 hrs: +358-400-824 414
CHINA
FRANCE
Hong Kong Office
Tel:
+852-2394 1008
Fax:
+852-2787 7652
24 hrs: +852-9097 3165
Shanghai Office
Tel:
+86-21-2606 3000
Fax:
+86-21-6391 2276
24 hrs: +86-1350-1828 932
Le Havre Office
Tel:
+33-235-247 299
Fax:
+33-235-247 298
24 hrs: +33-611-643 942
Marseilles Office
Tel:
+33-491-095 252
Fax:
+33-491-609 020
24 hrs: +33-679-826 544
CROATIA
GERMANY
Rijeka Office
Tel:
+385-51-289 717
Fax:
+385-51-287 154
24 hrs: +385-98-440 260
Zagreb Office
Tel:
+385-1-3837 711
Fax:
+385-1-3835 563
CYPRUS
Limassol Office
Tel:
+357-25-763 670
Fax:
+357-25-763 671
24 hrs: +357-99-463 862
MacGregor Cranes
Cargotec Sweden AB
www.macgregor-group.com/cranes
Bremerhaven Office
Tel:
+49-471-780 41
Fax:
+49-471-740 80
24 hrs: +49-471-780 41
Hamburg Office
Tel:
+49-40-254 440
Fax:
+49-40-2544 4444
24 hrs: +49-40-2544 4120
GREECE
Piraeus Office
Tel:
+30-210-428 3838
Fax:
+30-210-428 3839
24 hrs: +30-6974-300 541
Address
Sweden
Kobe Office
Tel:
+81-78-846 3220
Fax:
+81-78-846 3221
24 hrs: +81-90-4387 9992
Kumozu Office
Tel:
+81-59-234 4114
Fax:
+81-59-234 0040
Tokyo Office
Tel:
+81-3-5403 1966
Fax:
+81-3-5403 1953
24 hrs: +81-90-7188 0377
KOREA
Busan Office
Tel:
+82-51-704 0844
Fax:
+82-51-704 0414
24 hrs: +82-51-704 0844
MALAYSIA
Kemaman Office
Tel:
+60-985-92 129
Fax:
+60-985-82 272
24 hrs: +60-985-92 129
Kuala Lumpur Office
Tel:
+60-377-828 136
Fax:
+60-377-852 131
24 hrs: +60-122-786 889
Miri Office
Tel/fax:
+60-854-28 136
24 hrs: +60-122-786 889
Telephone
(+46) 660-29 40 00
Telefax
(+46) 660-139 77
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
Tel/fax:
+52-938-286-1528
24 hrs: +1-985-641-3853
Singapore Office
Tel:
+ 65-6597 3888
Fax:
+ 65-6597 3799
24 hrs:
+65- 6597 3777
Aberdeen Office
Tel:
+44-1224-347 050
Fax:
+44-1224-347 051
24 hrs:
+44-7850-313 733
Liverpool Office
Tel/fax:
+44-151-708 4177
24 hrs:
+44-7768-334 419
Newcastle Office
Tel:
+44-191-295 2180
Fax:
+44-191-295 2188
24 hrs:
+44-7768-334 419
Portsmouth Office
Tel:
+44-2392-210 703
Fax:
+44-2392-210 734
24 hrs:
+44-7768-334 419
THE NETHERLANDS
Rotterdam Office
Tel:
+31-10-283 2121
Fax:
+31-10-429 3219
24 hrs: +31-10-283 2121
NORWAY
Bergen Office
Tel:
+47-56-313 300
Fax:
+47-56-313 070
24 hrs: +47-905-873 71
Kristiansand Office
Tel:
+47-91-68 60 00
Fax:
+47-38-01 87 01
Oslo Office
Tel:
+47-23-10 34 00
Fax:
+47-23-10 34 01
24 hrs: +47-905-873 71
PANAMA
Balboa Office
Tel:
+506-603-45 032
24 hrs: +1-757-558-4580
POLAND
Gdynia Office
Tel:
+48-58-785 5110
Fax:
+48-58-785 5111
24 hrs: +48-602-725 088
SPAIN
Bilbao Office
Tel:
+34-94-480 7339
Fax:
+34-94-431 6945
24 hrs:
+34-609-428 066
Cadiz Office
Tel/fax:
+34-956-877 611
Ferrol Office
Tel:
+34-696-946 086
Fax:
+34-981-354 624
SWEDEN
Bjuv Office
Tel:
+46-42-85 800
Fax:
+46-42-85 899
Enkping Office
Tel:
+46-171-232 00
Fax:
+46-171-232 99
Gothenburg Office
Tel:
+46-31-721 50 00
Fax:
+46-31-424 946
24 hrs:
+46-31-721 50 00
rnskldsvik Office
Tel:
+46-660-29 40 00
Fax:
+46-660-139 77
24 hrs:
+46-31-721 50 00
THAILAND
Bangkok Office
Tel:
+660-2-726 9516
Fax:
+660-2-726 9514
QATAR
UNITED ARAB EMIRATES
Doha Office
Tel:
+974-4460 7310
Fax:
+974-4460 7314
24 hrs: +974-5507 1093
RUSSIA
St. Petersburg Office
Tel:
+7-812-493 4284
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
Cargotec Sweden AB
www.macgregor-group.com/cranes
2 (2)
Abu Dhabi Office

Tel:
+971-2-5541 690
Fax:
+971-2 5541 601
24 hrs:
+971-50-4510 715
Dubai Office
Tel:
+971-4-3213 933
Fax:
+971-4-3413 110
24 hrs:
+971-50-651 0371
Address
Sweden
UNITED STATES
Fort Lauderdale Office
Tel:
+1-954-600-4199
24 hrs:
+1-757-558-4580
Houston Office
Tel:
+1-713-681-5452
Fax:
+1-713-681-8204
Jacksonville Office
Tel:
+1-904-821 0340
Fax:
+1-904-821 0850
24 hrs:
+1-757-558-4580
Lafayette Office
Tel:
+1-337-231-5961
Fax:
+1-337-231-5966
New Orleans Office
Tel:
+1-985-892-9833
Fax:
+1-995-892-9837
24 hrs:
+1-985-892-9833
New York Office
Tel:
+1-914-305-9091
Fax:
+1-914-305-9091
24 hrs:
+1-914-305-9090
Norfolk Office
Tel:
+1-757-558 4580
Fax:
+1-757-558 4581
24 hrs:
+1-757-558-4580
Slidell Office
Tel:
+1-985-641-3853
Fax:
+1-985-641-3856
24 hrs:
+1-985-641-3853
Telephone
(+46) 660-29 40 00
Telefax
(+46) 660-139 77
SERVICE
6.005.10 E rev.: - 2007-03-23
Introduction
Before proceeding to trouble-shooting, the crane operator and the service staff should familiarize
themselves with the construction and functions of the
crane. It is a bit late in the day to learn how to operate
the crane when it has already broken down.
Begin by learning the hydraulic and electric symbols
used in the circuit diagrams to facilitate tracing the
probable fault in the circuit diagrams, Fig. 2 and 3,
checking the findings afterwards in the crane proper.
Trouble-shooting may thus be divided into a theoretical and a practical part, each subdivided into hydraulic, electric, and mechanical trouble-shooting. The
hydraulic and electric operations presuppose knowledge of the locations of various points of measurement and checking.
Take care always to have correct circuit diagrams
available on board. If a diagram has gone astray, a
new one can be had from MacGREGOR (SWE) AB.
Proper measuring instruments must always be
available, e.g. pressure gauges and voltmeters.
The trouble-shooting method described here is only
intended as a general guide. Methods and practices
may vary, but the purpose is always the same: to
find the fault quickly and methodically in order to put
it right.
When a crane function ceases to operate properly, it
generally does so in actual operation. This means
that the crane operator will often be able to give
valuable suggestions, e.g.:
- Did the crane function fail without warning?
- Was the operating speed first reduced, or did
the movement run irregularly?
- What manoeuvre immediately preceded the
failure?
Fig. 1.
Hydraulic circuit diagram
Fig. 2.
Electric circuit diagram

Fig. 3.
1 (2)
SERVICE
As a first check always try to operate the crane and

at the same time check the status of the troubleshooting panel in the CT2 cabinet, according to error
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)
6.005.10 E rev.: - 2007-03-23
All important pressure adjusting devices are sealed.

Breaking a seal voids the guarantee unless done with
the explicit consent of MacGREGOR (SWE) AB.
SERVICE
6.100.11 E rev.: a 2012-02-07
Measures Before Starting, During and After Completed

Service/Maintenance Work
WARNING !
When it is necessary to search for/or correct faults in the
crane's electrical, hydraulic or mechanical systems with
the crane powered up, only authorized personnel may
carry out such work.
The following measures must be taken before any
service or maintenance work is started.
1. The jib must be secured preferably in the parking
support, (see separate instruction).
6. If some special arrangements to the crane are

done for testing during the service/maintenance
work, these arrangements have to be removed at
completion.
7. Function test safety items i.e. limit settings, brakes
etc. must be placed back to their correct positions
after completion.
8. Protections i.e. covers, rails etc. must be placed
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 ships
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
force.
- Use the hand pump to release the disc brake
hydraulically. Input drive sleeve must turn easily.
- Measure the slewing gear backlash (pinion-tobearing gear). See description in paragraph
"Measurement and adjustment of slewing bearing
backlash".
- 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
ventilation valve at marked position "a" (optional to
install with a tube turn). See Fig. 1.
- 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.
- Before the assembly of the electric motor, grease
shaft and gear teeth with a suitable grease for
protection against corrosion; we suggest
OPTIMOLY PASTE White T.
- Do a functional test of the slewing gear with the
electric motor running and pay particular attention
to the function of the brake.
1
3
2
Fig. 1. Slewing gear.
1.
2.
3.
4.
5.
6.
Brake connection
Oil filling plug
Gear ventilation valve
Oil inspection glass
Oil level
Oil drain with magnet plug
Maintenance
Oil level check
Lubrication
The slewing gear is splash lubricated. The output shaft
roller bearing is for-life lubricated with ball bearing
grease.
- Investigate the oil level when the gear is at rest

and with the brake engaged.
- Examine the oil level on the oil inspection glass.
- 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

hot. Remove also the oil filling plug(s).
- For oil change open oil drain plug, see Fig. 1.
- At low ambient temperatures, flush the gearbox with
a quantity of fresh oil to remove abraded matter
and contamination products.
- Fill the correct amount of oil refer to Technical Data,
section 2.
The maximum permissible amount of foreign matter

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

Sampling oil
Get a sample of the gearbox oil for analyse at intervals
as described in the "Maintenance Chart".
To obtain a representative sample, drain the gearbox
during operation and with the oil at operating temperature.
Oil discoloration
A darkish or black colour of the used oil suggests
that temperatures in excess of 100oC did occur in operation, causing accelerated aging of the oil and
impaired lubricating properties. In this case the oil
should be changed at shorter intervals.
If the oil sample displays a cloudy aspect, it may be
that water has managed to seep into the oil. The oil
must then be changed a t o n c e, and the gearbox
flushed out very thoroughly several times with fresh
oil.
The gearbox should preferably be dismantled for
inspection beginning at the input side, and the
components examined for signs of corrosion.
If coarser abraded matter (above 25 ) or flake off

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
the gear.
Hydraulic-Release Multiple-Disc Brake

Technical description
The brake comprises the following major components:
- Brake piston
- Brake cylinder
- Disc carrier
- Internal discs
- External discs
- Sealings
- Thrust springs
The brake housing is mounted on top of the gearbox,
with long assembly screws through the motor adapter
housing and both parts of the brake housing.
The sleeve disc carrier, with the internal discs, is fixed
on the driven shaft with a shaft key or by splines.
The disc assemblies are pressed together by a set of
thrust springs and the brake is disengaged by hydraulic power.
Foreign solid matter

- As a first simple test, drop some of the used oil
onto the filter fleece specified. Coarse foreign matter, if present, will then show up on inspection,
preferably through a magnifying glass.
- A better test may be made by diluting an oil sample
with n-heptane, passing it through a diaphragm
filter, washing and drying it, and weighing it to
determine the mass difference.
2 (4)
Maintenance
The brake is self-adjusting.
Troubleshooting
a. Braking torque insufficient
SERVICE
6.120.20 E rev.: - 2010-11-11
Motor side
Thrust springs
Brake piston
Brake cylinder
Pressure oil
connection
Sealing
Sealing
Total
thickness
of discs
Internal discs
Leakage oil
Disc carrier
External discs
Gear side
Fig. 2. Disc brake.

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

- Drive the hydraulic motors against closed brakes.
Brakes shall be able to withstand motor torque
without slipping.
Note! Test procedure shall be done only for a short
period, a few seconds.
- Inspect the brake discs and replace if excessively
worn.
- If discs are coloured dark yellow to blue, the discs
have been overheated. Replace discs and springs.
- Inspect sealings for wear. If sealings are defect
replace brake cylinder and piston with sealings to
new ones.
b. Brake heats
Make sure that the hydraulic pressure is sufficient in
order to disengage the brake completely.
Measurement and adjustment of slewing

bearing backlash
An oversize backlash between the pinion and the
slewing bearing will cause irregularities in the slewing
movement of the crane. Read this instruction carefully
prior to measurement or adjustment!
Measurement of backlash
The backlash should be measured by a dial gauge or
a feeler. When slewing the crane, the backlash may
vary from one position to another due to some slight
excentricity of the slewing bearing. It is therefore
recommended to measure the backlash at four
positions of the slewing bearing.
Proceed as follows:
- Measure the backlash at one spot.
- Slew the crane 90 degrees and measure.
- Proceed to measure the backlash at four 90-degree
position in the bearing.
- Put the dial gauge on the tooth of the pinion. By
manual turning at the input, the pinion can be moved
in both directions up to contact with the teeth. Now,
the tooth flank clearance can be exactly measured
on the dial gauge.
- Measure the backlash at one spot
- Slew the crane 90. measure again
- Proceed to measure the backlash at four 90-degree
positions in the bearing
- Compare the four backlash values.
Backlash values: See drawing "Slewing
assembly".
The backlash shall be adjusted at the position of the
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:
- 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.
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
similar compound.
If the upper part has been removed
If the upper part has been removed, clean its contact
surfaces and apply Loctite 640 Sealant or a similar
compound. Make sure not to strain the hoses. Apply
Loctite 242 on the screws holding the upper part, install
and tighten.
4 (4)
Fig. 3. Slewing gear.
1. Upper part.
2. Screws
3. Screws holding the gear to crane house floor.
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
an inner gearbox. See Figs. 1 and 2.
The gearbox is a planetary gearbox. It is filled with oil

and has splash lubrication. The gearbox is behind the
brake inside the winch.
The bevel gear on hoisting and luffing winch has a
forced lubrication and is filled with oil from oil tank.
The brake is a hydraulic release multiple disc brake.

Springs keep the brake discs pressed together. The
1
1.
2.
3.
4.
5.
11
3
6.
7.
8.
9.
10.
11.
C-00101
10
Journal bearing, grease nipple

Pressure relief valve of gearbox, 0.2 bar
Bevel gear
Thermo switch, 100-95 (NC)
Oil filler inlet, bevel gear /
Pressure release of bevel gear, 0.2 bar
Oil tank, bevel gear
Oil drain, bevel gear
Oil heater with thermostat, bevel gear
Oil sight glass
Oil drain, gearbox
Oil filler inlet, gearbox / Oil dipstick
Fig. 1. Luffing winch

1
1.
2.
3.
4.
5.
6.
12
3
7.
8.
9.
10.
11.
12.
10
C-00100
11
Journal bearing, grease nipple

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

6. Note the oil level.
7. Put back the dipstick.
8. Put back the pressure relief valve
Replace oil, winch gearbox

Remove the inlet plug before the oil drain plug. Drain
oil while still hot. At low ambient temperature, flush
out the gearbox with clean pre-heated oil to remove
particles and sediment. See Figs. 1 and 2. Fill oil to
maximum oil level.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
C-00173
Disc carrier
Inner discs
Arrangement of the brake discs
Gear side
Outer discs
Pressure valve / Air filter / Oil leak
Pressure unit
Piston
Motor side
Pressure springs
Connection, pressure oil
Fig. 3. Disc brake
Maintenance
For maintenance intervals and number of grease nipples refer to the "Lubricating Chart" and "Maintenance
Chart" in section 5.
For type of oil and grease refer to "Lubricants for Deck
Machinery" in section 5.
For oil volume refer to the "Technical data", section 2.
Oil level check, winch gearbox

Oil level can only be inspected when the winch not
is in operation.
1. Remove the pressure relief valve
2. Remove the oil dipstick.
3. Clean the dipstick.
4. Put back the dipstick.
2 (4)
Oil level check, oil tank bevel gear

Check the oil level on the oil inspection glass. See
Figs 1, 2 and 4.
MAX - oil level at top of the inspection glass.
MIN - oil level at the bottom of the inspection glass.
MAX. oil level
MIN. oil level

C-00104
Fig. 4. Oil sight glass, oil tank bevel gear
Replace oil, oil tank bevel gear

Replace oil in oil tank, bevel gear, see Figs. 1 and 2.
Fill oil to maximum oil level, see Fig. 4.
Grease flange bearing

Grease flange bearing, see Figs. 1 and 2.
Brake
Inspect brake for leakage. If leakage is detected in
oil pressure unit, the complete pressure unit must be
replaced.
SERVICE
6.120.112 E rev.: b 2012-01-02
Test brake torque by driving the motors against closed

brake.
On hoisting winch, close the stop cock 1663 for the
pressure to the brake.
On luffing winch, close the stop cock 2661 for the
pressure to the brake.
Drive the motors only for a few seconds, the winch
drum must not rotate.
Inspect brake discs and replace if excessively worn.
If brake discs are colored dark yellow to
blue, the discs have been overheated. Replace discs
and springs.
Check the hydraulic pressure to make sure that it

is sufficient to open the brake completely. Refer to
hydraulic diagram.
Adjustment of pressure roller (if applicable)

After replacement of wire the pressure roller must be
adjusted. Refer to Fig. 5.
1. Tighten adjusting nut carefully until the pressure
roller touches the hoisting wire on the drum.
2. Tighten adjusting nut 12 turns to get correct
spring force.
3. Secure with the locking nut.
1
3
1. Adjusting nut
2. Locking nut
3. Pressure roller
Fig. 5. Hoisting winch with pressure roller
3 (4)
SERVICE
Gearbox oil test

Sampling oil
Take a sample of gearbox oil for inspection at intervals 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 100C did occur in operation, 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)
6.120.112 E rev.: b 2012-01-02
SERVICE
6.142.5 E rev.: a 2002-01-09
Recommendation for Inspection and

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

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

All hydraulic hoses assembled inside crane house
should be replaced after ten (10) years due to safety
reasons.
All hydraulic hoses assembled on outside of crane
house should be replaced after five (5) years due to
safety reasons.
Hose coupling
Mating coupling
O-ring
Screw
Fig. 1. Hose coupling with O-ring.
Fig. 2. Flange coupling with O-ring.
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 pressurized fluid. Conversely, when the pressure falls off,
the accumulator supplies oil to the hydraulic system.
All crane motors must be immobilized.
Note! - Do not bleed hydraulic accumulators!

Charging equipment
To charge hydraulic accumulators, art. nos. see
below, MacGREGOR (SWE) AB supply a charging
valve and associated equipment, Fig. 2, comprising:
- a three-way valve
- a 0-25 bar pressure gauge
- a 0-60 bar pressure gauge
- a 1-metre hose with a W24 connector for nitrogen cylinder
- two reduction connectors, W24/32M and W24/14D.
Charging pressure for 388 0362-801: 15 1 bar at
20C.
20C.
20C.
20C.
1.
Dismount valve guard and unscrew the

protective cap from gas valve.
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.
2a. Old design, see Fig. 2. Connect the three-way
valve to the gas valve of the accumulator. The
filling screw of the three-way valve shall be
backed out completely, and the bleed valve
tightly closed.
3. Connect the charging valve, see Fig. 3 to the
reducing valve at the nitrogen cylinder.
4. Back out the adjusting screw of the reducing
valve on the nitrogen cylinder until the valve
spring is unloaded.
5. Open the nitrogen cylinder valve.
6. Adjust the reducing valve to the correct charging pressure.
New design
Valve guard
Gas valve
Protective cap
Gas valve
Valve guard
Protective
cap
Open/close
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

on the gas valve counter-clockwise to stop, by
using a 19 mm fork wrench.
7a. Old design, see Fig. 2. Screw in the filling screw
of the three-way valve but not so tightly that the
gas valve of the accumulator is damaged.
8. Fill nitrogen.
9. New design, see Fig. 1. Check the nitrogen
pressure when the temperature and the pressure
of the gas become stable. When the correct
charging pressure has been obtained, close the
gas valve by turning the hexagonal nut clockwise
by use of the 19 mm fork wrench.
9a. Old design, see Fig. 2. Check the nitrogen
pressure when the temperature and the pressure
of the gas have become stable. When the correct
charging pressure has been obtained, again
back out the filling screw of the three-way valve.
10. Close the nitrogen cylinder valve.

11. Open the bleed screw of the three-way valve to
discharge the pressure in the filling hose.
12. Adjust the reducing valve to zero.
13. Unscrew the charging equipment from the nitrogen cylinder and from the accumulator.
14. Check tigthness of accumulator gas valve, using soap water.
Note! - The protective cap shall be fitted with an
O-ring which must fit correctly into its groove.
15. Screw on protective cap of the gas valve.
16. After charging the accumulator, fit a lable carrying the charging date and signed by the operator.
Note! For charging, it is not necessary to install a
reducing valve on the nitrogen cylinder.
Old design
Valve guard
Valve guard
Protective cap
Gas valve
Gas valve
Fig. 2. Old design. Piston accumulators.
2 (4)
Protective
cap
SERVICE
6.189 E rev.: f 2007-04-11
Filling screw, to be
used for old design
Pressure gauge
connection
Bleed valve
Connector for accumulator

gas valve
Connector for hose

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

"Slewing bearing yard mounting" in Section 9.3.
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
M
4
5
6
7
8
10
12
14
16
18
20
22
24
27
30
33
36
39
42
Tightening torque in Nm
10 Nm 1 kpm
8.8
10.9
12.9
2.5
4.9
8.4
13.8
20.6
40.4
69.7
110
169
237
331
445
572
826
1127
1522
1961
2520
3130
3.4
7.0
12.0
19.8
28.4
55.9
98
156
238
332
465
626
804
1161
1582
2133
2761
3543
4395
4.2
8.3
14.6
23.2
34.4
67.9
117
187
286
398
558
752
963
1393
1901
2563
3311
4248
5280
Thread
M
4
5
6
7
8
10
12
14
16
18
20
22
24
27
30
33
36
39
42
10 Nm 1 kpm
8.8
10.9
12.9
2.9
5.7
9.8
16.1
24.0
47.0
81.0
128
197
275
385
518
665
961
1310
1770
2280
2930
3640
4.0
8.1
14.0
23.0
33.0
65.0
114
181
277
386
541
728
935
1350
1840
2480
3210
4120
5110
4.9
9.7
17.0
27.0
40.0
79.0
136
217
333
463
649
874
1120
1620
2210
2980
3850
4940
6140
1 (4)
SERVICE
6.214.1 E rev.: a 2007-03-02
As a rule, always change screws with specified tightening torque on cranes in operation if the joint has to
be opened for some reasons.
If any joint has been opened apply Intertuf after tightening the joint to avoid rust damage.
SAE flange for high pressure hose couplings
Flange
6000 psi
Screw
3/4"
1"
1 1/4"
1 1/2"
2"
M10
M12
M14
M16
UNC 3/4
2 (4)
10 Nm 1 kpm
Class H 10.9 and 12.9
54
94
150
230
377
Stainless bolts and hydraulic pipe couplings

greased with Gleitmo paste
Thread
d
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39
10 Nm 1 kpm
Austenite (A)
50
70
80
3.3
7
9.3
7.8
17
22
15
33
44
27
57
76
43
91
121
65
140
187
91
195
260
127
273
364
171
367
490
220
472
629
318
682
909
434
930
1240
585
1250
1670
755
1620
2160
969
2080
2770
SERVICE
6.214.1 E rev.: a 2007-03-02
Strength of screws and bolts

Strength class
4.6
5.8
6.6
8.8
10.9
12.9
Min. ultimate strength

(kp/mm2)
N/mm2
Min. tensile strength

(kp/mm2)
N/mm2
400
500
600
800
1000
1200
240
400
360
640
900
1080
(40)
(50)
(60)
(80)
(100)
(120)
Corresponding strength
class of nuts
(24)
(40)
(36)
(64)
(90)
(108)
4
5
6
8
10
12
Examples of markings:
Hexagonal screw
Allen screw
Strength class 4.6:
Strength class 12.9:
BH 12 9 M
Strength class 8.8:
Hexagonal nut
Strength class 8:
Strength class 10.9:
M-thread
UNC- and
UNF-thread
Cold forged
UNC- and
UNF-thread
Forged
Strength class 10:
M-thread
UNC- and UNF-thread

Forged
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
coupling
GE 10-LM
GE 10-LR
GE 12-LM
GE 12-LR
GE 15-LM
GE 15-LR
GE 18-LM
GE 18-LR
GE 22-LM
GE 22-LR
GE 28-LM
GE 28-LR
GE 35-LM
GE 35-LR
GE 42-LM
GE 42-LR
Thread
M and R
Tightening
torque in Nm
M 14x1,5
R 1/4
M 16x1,5
R 3/8
M 18x1,5
R 1/2
M 22x1,5
R 1/2
M 26x1,5
R 3/4
M 33x2
R1
R 42x2
R 1 1/4
M 48x2
R 1 1/2
ca 39
ca 39
ca 59
ca 59
ca 69
ca 108
ca 108
ca 108
ca 128
ca 157
ca 216
ca 265
ca 353
ca 392
ca 491
ca 491
Type of
coupling
GE 10-SM
GE 10-SR
GE 12-SM
GE 12-SR
GE 14-SM
GE 14-SR
GE 16-SM
GE 16-SR
GE 20-SM
GE 20-SR
GE 25-SM
GE 25-SR
GE 30-SM
GE 30-SR
Thread
M and R
M 16x1,5
R 3/8
M 18x1,5
R 3/8
M 20x1,5
R 1/2
M 22x1,5
R 1/2
M 27x2
R 3/4
M 33x2
R1
M 42x2
R 1 1/4
Sealing
d = 10
Fitting
Sealing cone
Insert the sealing cone into the 24-degree coupling
fitting, firmly tighten the coupling by hand. Using a
wrench, tighten the coupling nut another 1/4 to 1/2
turn. The O-ring should preferably be oiled.
Hose
Coupling
Tables 1 and 2
Grease
O-ring sealed
4 (4)
ca 59
ca 69
ca 78
ca 69
ca 108
ca 128
ca 128
ca 128
ca 196
ca 206
ca 294
ca 314
ca 491
ca 491
Table 2.
Example: GE 10 - LM
Table 1.
Tiightening
torque in Nm
Sealing
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
always check the condition of the door hinges. Also
make sure that the doors are secured before opening,
see Fig. 1.
A.
Procedure for opening
1. Put on safety belt.

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 position 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).
3
4
Fig. 1. Securing service door to top of crane.
Fig. 2. Opening service door.
1 (2)
SERVICE
B.
6.215.21 E rev.: b 2007-06-08
Procedure for closing
1.
2.
3.
4.
Put on safety belt.

Remove the screw (7), see Fig. 3.
Swing the locking rod (5) back to its parking position.
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
The service door hinges should be lubricated every

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

service door must be open.
D.
Inspection of door hinges
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)
Fig. 3. Locking rod.
SERVICE
6.216.116 E rev.: a 2012-02-16
Rope Reeving Diagram for Cranes Type GLBE-2

Number of reeving parts:
Luffing:
Hoisting:
5 parts
6 parts
Warning!
Make sure that the lockwashers for the wire thimbles
are correctly mounted. Risk of injury. see Fig. 2 on
page 2.
Caution!
It is of utmost importance to grease the wire thimble
according to instructions "Lubricating Chart" and
"Lubricants for Deck Machinery".
Note!
Before rigging slacken the pressure roller on the hoisting winch. See Fig. 4.
Note!
Securing of the luffing and hoisting wires, see instruction "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

and loadcell.
2 (4)
Fig. 3. Rope reeving for Slack wire safety switch,

hoisting and luffing showing correct wire position in
operation.
SERVICE
6.216.116 E rev.: a 2012-02-16
Adjustment of pressure roller on the

hoisting winch
After replacement of wire the pressure roller on the
hoisting winch must be re-adjusted.
- Tighten adjusting nut carefully until the pressure
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
bearings, see Fig. 4.
- Tighten adjusting nut 12 turns to get correct spring

force. Adjustment shall be done at full drum condition.
- Secure with the locking nut.
Empty drum
Full drum
Approx. 2 mm
Approx. 2 mm
Full drum
Empty drum
Pressure roller
Adjusting nut
Frame bearing
Frame
Adjust play by rotating
the washer/bearing.
Frame 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
Unloading steel wire ropes
6.222.1 E rev.: a 1998-04-17
It is advisable to lift a reel by means of a shaft which

is put through its axis bore.
When handling a steel wire rope, the first trouble

often occurs immediately upon receiving it: the fork
of the fork lift truck is either placed under the reel
or inside the coil.
If the fork of the fork lift truck is longer than the

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

rope. The damage may not be discovered until much
later and it could happen that the manufacturer of
the wire rope is held responsible.
If possible, the rope, when recieved on cils or reels,
should not have any contact with a metal hook or
the fork of a fork lift truck.
Instead, it should be lifted by means of a wide textile webbing sling.
Storing steel wire ropes

Steel wire ropes should be stored in a clean, cool,
dry place indoors. The ropes must not be allowed
to rest on the floor. They can be placed on pallets.
2 (12)
SERVICE
If outdoor storage cannot be avoided the ropes must

be covered in a way that moisture cannot create
corrosion problems. Although plastic foil protects
the ropes from rain, condensation from beneath
might not be able to escape and could damage the
ropes permanently. To avoid condensation problems, it is advisable to use breathable water-proof
fabric covers readily available from tarpaulin manufactures.
6.222.1 E rev.: a 1998-04-17
Unwinding steel wire ropes from the reel

An unreeling stand (turnable) should be used to
unwind a wire rope from its reel.
Another accepted unreeling method is to mount the
reel on a shaft supported by two jacks or a stand.
When storing a number of spare ropes, the following rule should be applied: first in - first out. This
means, the ropes should be used in the order of
delivery. In this way it can be avoided that certain
ropes are only put in service after being stored for
many years.
It is self-evident that the different ropes in stock must
be clearly marked to avoid the possibility of
confusion (e.g. if similar ropes of diffferent tensile
strength are stored).
In addition proper records have to be kept which
make it possible to trace the "history" of any rope
back to the manufacturer on the basis of storing
number, specification, date of order and date of
delivery.
Installing steel wire ropes

When installing steel wire ropes, extra care must
be taken that the ropes are unwound from the ring
or reel without torsions and without any outer damage. The same applies to reeving the ropes into
the system.
Rolling the wire rope along the floor, as is sometimes recommended in the relevant literature, does
not work very well in practice because the reel always unwinds less wire than the distance the reel
travels, so that with this method the rope has to be
dragged along the worker.
Unwinding steel wire ropes from the coil

If a rope is delivered on a coil, it is either unwound
on a turntable or the coil is rolled along the ground
like a hoop. In the latter case ensure that the surface is clean; sand or grit that sticks to the lubricant
might damage the wires when the rope travels or
sheaves.
3 (12)
SERVICE
Under no circumstances must the rope be pulled

off a coil while it is lying on the ground or looped
over the head of the reel, because this will inevitably induce one torsion per wrap into the rope.
6.222.1 E rev.: a 1998-04-17
If one end of the ropes has a fitting attached, as it

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

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

and must be discarded.
The spelter socket.
The installation procedure
Typical deck crane example
The most advantageous way of installing a steel

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

where the rope must be spooled from the reel via
sheaves S1 through S9 onto the drum.
With some cranes it may be advisable to discard

the old rope first and to install the new one afterwards. With other cranes, particularly with bigger
ones, it might be better to pull in the new rope attached to the old one. Another possibility is to use
a thinner rope by which the wire rope proper is pulled
into the system. This method is often used with new
equipment.
In every single case careful consideration is necessary as to whether the wire rope should be pulled
through the whole reeving system or whether it
should first be wound from the coil or reel onto the
drum and afterwards be reeved into the system.
4 (12)
SERVICE
Here, special attention must be paid to the hook

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

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

should leave the reel at the buttom and vice versa:
i.e., always reel from top to top or from bottom to
bottom.
If this procedure is not strictly followed, the rope
will either try to twist between reel and drum or it
will later try to regain its preferred position when in
practical service. In both cases structural changes
of the rope may occur.
Installing the rope with the help of the old

one or by a thinner rope
If the new rope is pulled in by the old one or by a
thinner rope one must make sure that the connection between these ropes is absolutely safe. In addition it must be ensured that the thinner rope cannot rotate. Rotation-resistant steel wire ropes or
three-strand ibre ropes for instance, can be recommended for this purpose. When using conven-
6.222.1 E rev.: a 1998-04-17
tional wire ropes one must at least make sure that

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

load capacity, it is flexible and prevents the transfer of twist from the old
rope into the new one. When using
two strands to pull the rope into place,
these will indicate the intensity of twist
in the old rope on the basis of the
number of turns they have made during the installation procedure.
Another possibility is connecting the
rope ends with Chinese fingers. These
are tubes made out of braided
strands, which are pulled over the
rope ends and then secured at their
ends with tape or seizing wire. Under
load the Chinese fingers will contract
and hold the rope ends by friction.
5 (12)
SERVICE
When installing a lang lay rope one must take care

that the Chinese finger cannot unwind from the rope
like the nut from a screw. It is recommended to wrap
a tape around the whole rope length to be held by
the Chinese finger to increase the friction.
6.222.1 E rev.: a 1998-04-17
Under no circumstances should one attempt to generate the tensioning load by jamming the rope, for
instance between two boards. Structural changes
would deform the rope beyond repair.
Installing under load

To achieve perfect spooling of the rope on the drum
it is very important to apply a tensioning load to the
wire ropes during the installation.
This is particularly important with drums spooling
in two or more layers, which, however, is not very
common with deck cranes. If the first layer(s) are
not under tension, they might be too loose, so that
the top layers might be wedged into the bottom layers under load. This could seriously damage the
rope. The unwinding rope might even be clamped,
so that the direction of spooling could suddenly be
reversed during the course of unwinding. The result could be the abrupt lifting of the load that was
actually travelling downwards.
The tensioning load should range from 1% to 2% of
the minimum breaking load of the wire ropes. In
many cases it might suffice to wind the rope quite
normally in order to unwind it and then rewind it
with the help of an outer load.
In other cases, however, the procedure mentioned
above is not possible. In these cases the tensioning
load must already be applied when installing the
rope.
Ample rope tension can be provided by a simple
plank bearing against the reel flanges or by a braking disk attached to the reel.
6 (12)
Attaching the rope termination to the fix

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

After the rope has been installed and before it is
going to do its proper job, several run-throughs of
the normal operational circle should be carried out
under light load. The new rope
should be "broken-in", so that the
component parts can settle and
adjust themselves to the actual
operating conditions. It is most unfortunate that in practice only too
often the exact opposite of this
recommendation is performed:
quite frequently after installing the
rope overload tests are carried out
with loads beyond the safe working load of the system.
6.222.1 E rev.: a 1998-04-17
The rope and this wire end are now wrapped moving away from the location of the intended cut.
The rope is tightly wrapped for a distance of approx.

three rope diameters.
Both ends of the seizing wire are then pulled tight

and twisted together for a length of one rope diameter.
Cutting steel wire ropes

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

gusset between the strands. After preparing the
other side of the intended cut accordingly the rope
can now be cut.
Instead of using one long seizing it is also possible

to apply at least three seizing the size of one rope
diameter each on both sides of the intended cut.
The maintenance of steel wire ropes

Steel wire ropes must be serviced regularly, the kind
of maintenance depending on the lifting device, its
use and the selected rope. Regular maintenance
may considerably increase the service life of a steel
wire rope.
7 (12)
SERVICE
Relubricating steel wire ropes

During production the rope receives intensive lubrication. This in-process treatment will provide the
rope with ample protection against corrosion and is
meant to reduce the friction between the elements
which make up the rope as well as the friction between rope and sheaves or drums. This lubrication,
however, only lasts for a limited time and should be
re-applied periodically.
German Standard DIN 15 020, e. g. specifies: "Steel
wire ropes must be relubricated at regular intervals,
depending on their use, particularly along the zones
subjected to bending. If for operational reasons
relubrication cannot be carried out, shorter service
life of the rope is to be expected and the inspection
intervals have to be arranged accordingly."
When choosing the relubricant, it must be ensured
that it is in accordance with the recommendations
of the rope manufacturer.
6.222.1 E rev.: a 1998-04-17
It is important with all different methods of

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

DIN 15 020 recommends: "From time to time very
dirty steel wire ropes should be cleaned externally".
This applies particularly to ropes operating in extremely abrasive conditions and to those that take
up chemicals.
Effective cleaning without proper tools is quite a
laborious job. For cleaning steel wire ropes the Canadian Rigging Manual recommends an appliance
with three rotating wire brushes and an air blast
drying system to follow. An American manufacturer
offers a "rope porcupine", a sleeve equipped with
brushes, which is drawn along the steel wire rope.
There are several techniques of lubricant application: The most common ones at present are painting or swabbing.
Removing broken wires
Quite often the lubricant is applied at a sheave,

sometimes a continuous drip method is used. If only
a little lubricant is required, pressure spray nozzles
can be applied.
If during an inspection ends of broken wires are

detected which might cross adjacent wires and
destroy them when running over sheaves, these
broken wire ends must be removed.
Maximum penetration of the lubricant into the gaps

of the rope, can only be quaranteed if high pressure lubrication is applied with the help of a pressure lubricator.
Under no circumstances should the broken wire

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

equipped with rubber sealings, are clamped round
the rope and screwed together. While the rope runs
through the lubricator the lubricant is pressed into
the sleeve at a pressure upto about 30 bars.
8 (12)
SERVICE
6.222.1 E rev.: a 1998-04-17
Cutting or shifting steel wire ropes

Very often wire ropes must be discarded although
only short rope sections, e. g. the one that climbs
to the second layer on the drum, are seriously damaged, while the rest of the rope is still in perfect
condition.
In cases such as this the service life of wire ropes
can be enormously increased by shortening, shifting them at the fixing point by a span that removes
the section of the rope which has had most abuse
out of the critical zone.
After this procedure an adjacent section will be subjected to the abuse.
Another typical local damage occurs on the drum
at those sections where the rope rubs against the
adjacent winding (crossover point) and must be
deflected to the side. If the damage caused in these
sections is the main reason for discarding the rope,
several cuttings or shiftings will move the stresses
to different rope zones and possibly multiply the
service life of the rope.
9 (12)
SERVICE
Examples of damage to steel wire ropes

The following pages illustrate some typical examples of damage to steel wire ropes which should
always decree immediate rejection of the rope.
Surfacelayer wires frayed by abrasion; wire ropes
has been running over sharp edges under load.
Localized wear caused by chafing against adjacent

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

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

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

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

open exposing steel wire rope core between strands
that have come apart.
10 (12)
6.222.1 E rev.: a 1998-04-17
SERVICE
6.222.1 E rev.: a 1998-04-17
Some examples of wire rupture
Contraction rupture caused by excessive stress,

(e.g., if a slack line suddenly snaps taut under full
load).
Wear and identations of surface wires also promote

fatigue and lead to premature wire rupture.
Crown wires of outer strands may wear so thin that

the residual cross sectional area of steel in the rope
will not support the normal design load and contraction rupture may ensue.
Corrosion may cause wire ropes to break. As a

safety measure, inspect ropes regularly and carefully to prevent catastrophes; observe manufacturer's instructions
Rupture from fatigue will often occur when undersize sheaves are used. Vibrations and torsional
stress loads in the rope accelerate fatigue rupture.
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
The procedure is general and should be seen as a
guidance only. It is important to read and understand
the instructions below before replacement of wires.
- Rope Reeving Diagram for Cranes Type GLBE-2,
section 6.2.
- Preparation for Rig Mode, section 6.3.
- Handling, Installation and Maintenance of Steel
Wire Ropes, section 6.2.
WARNING!
Rig mode will disable stop and overload limits.
There is a risk of severe damage to the crane and
personal injury.
WARNING!
Jib must be supported, lifting of load is not permitted.
personal injury.
Hoisting winch / wire
For cranes with two fall rigging proceed as follows:
- 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.
- Disengage the slack wire switch by blocking the

spring tensioned roller, which can be done with a
piece of wood, see Fig. 4.
- Loosen the hoisting wire rope socket attached to
the load cell on crane house top with the help of
a shore crane or other suitable crane. Attach the
hoisting wire rope socket to the reel before the
hoisting winch wire is wind from the hoisting winch
drum to the reel. See Fig.13.
- Run the hoisting winch to pay out the hoisting wire,
and at the same time pull on the loose wire end.
- Stop the winch just before it enters into the empty
drum limit.
- Stop the crane. Use pushbutton S13 Start/Stop on
the control panel in cabin.
- 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.
- Remove the cover from the limit switch box.
- Mark the position of the shaft in relation to the limit
switch box. See Fig. 8.
- Remove the limit switch box.
- Measure the empty drum measure AL. See Fig. 2.
AL
AL = Empty drum flange

side/ At least three locking
turns/Tank top
C-00262
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
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!
Rig mode will disable stop and overload limits.
It is not permitted to have any load in the hook.
personal injury.
- Run the hoisting winch to pay out the old (damaged)

wire until it is on the deck.
- Attach the new hoisting wire to the same rope by
using tool 662 0754-000, see Fig. 5.
Preparation for Rig Mode

- Set the key switch RIG/OL Test (inside cabinet CT2)
in position RIG. See Fig.3.
Fig. 5 Tool, wire rigging sock, 662 0754-000.
09
10
19
20
11
12
26
58
49
51
52
57
IO_C1
C2
485.1
SSI
Sp
SSI
IO_C2
SL_C1
C1
A2
A3T
IO_485.1
LU_C1
AU_C1
SL_A1
AU_A1
SL_C2
Input/Output
A1
C2
485.1
Sp
SSI
IO
C1
A2
A3T
IO_A1
A1
AU_C2
LU_C2
SL_A2
LU_485.1
SP
Output
33 36
39 43
34 37
40 45
31
30
32
Sw19
Sw20 55
14 Sw14
56 Sw56
15 Sw15
27
59
29
17
53
18
54
AU Auxiliary
C2
485.1
Sp
MP
Input
08
Com
C1
A3T
SSI
Sp
Error
07
IO_SSI
SSI
SP
Output
33 36
39 43
34 37
40 45
31
30
32
Sw19
Sw20 55
14 Sw14
56 Sw56
15 Sw15
27
59
29
17
53
18
54
A2
485.1
LU_A3
IO_C3
LU_A1
LU_A2
A3T
LU_Sp
SC_C3
SC_C1
HO_C1
SC_A1
HO_A1
SC_C2
Sp
SSI
12
26
58
49
51
52
57
A1
C2
A2
HO_C2
IO_C4
SC_A2
SC_C4
HO_A2
SC_485.1
SC_A3
HO_A3
SC_485.2
IO_485.2
IO_485.3
SC_485.3
Sp
SC_Sp
485.3
09
10
19
20
11
SL Slewing
C1
A1
C2
485.1
A3T
08
Com
LU Luffing
C1
A2
C2
485.1
SC_SSI
485.3
HOHoisting
A1
C1
A2
HO_Sp
A1
A3T
485.2
HO_485.1
SC Supervisory
C4
C4
MP
Input
07
Com
HO_SSI
IO
C3
C3
485.2
Error
IO_A2
Output
33 36
39 43
34 37
40 45
31
30
32
Sw19
Sw20 55
14 Sw14
56 Sw56
15 Sw15
27
59
29
17
53
18
54
AU_A2
09
10
19
20
11
SL_485.1
08
Com
SC
SP
Input
07
12
26
58
49
51
52
57
AU_485.1
Error MP
IO_A3
SP
Output
33 36
39 43
34 37
40 45
31
30
32
Sw19
Sw20 55
14 Sw14
56 Sw56
15 Sw15
27
59
29
17
53
18
54
SL_A3
12
26
58
49
51
52
57
AU_A3
09
10
19
20
11
IO_Sp
08
SL_Sp
MP
Input
07
AU_Sp
Error
SL_SSI
SP
Output
27
28
29
30
31
32
33
34
35
36
37
38
39
40
53
61
LU_SSI
MP
AU_SSI
Error
Input
07 18
08 19
09 20
10 26
11 49
12 51
13 56
14 57
15 58
16 59
17 60
24V
Com
Key switch
RIG/OL Test
Fig. 3. RIG/OL Test key switch in cabinet CT2.

- Start the crane again.
- A login window will now appear on the cabin display.
See Fig 3.
Fig. 4. Login window.

- Write the password to accept rig mode, use the
software keyboard on the cabin display.
Note!
The password is normally the last four digits of the
Mfg No which can be found in the table of contents.
2 (8)
- Attach the wire rope end to the wire drum with the
wire rope clamps and tighten the bolts. For tightening torques, see instruction "Tightening Torques..."
in section 6.2.
- Run the hoisting winch by pulling in the new hoisting wire, so that the AL measure is the same as
noted earlier and that the winch corresponds to the
position marked earlier.
- Before operating the hoisting winch read preparation 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.
- 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 instruction "Limit Switches in..." in section 6.3, instruction
"Technical Data" in section 2, and calibrate the
encoder according to instruction "Absolute Encoder
Calibration" in section 6.3.
Adjustment of pressure roller on the

hoisting winch
See instruction "Rope Reeving Diagram for Cranes
Type GLBE-2" section 6.1
SERVICE
6.223.26 E rev.: b 2012-02-15
Luffing winch / wire

- Place the jib in the jib rest or move the lifting block
up against the jib top.
- Disengage the slack wire switch by blocking the
spring tensioned roller, which can be done with a
piece of wood, see Fig. 6.
- Mark the position of the wire drum in relation to the

bracket.
- Remove cover from the limit switch box.
Note!
Mark the position of the shaft in relation to the box.
See Fig. 8.
Piece of wood
100 x 200
Piece of wood
100 x 200
Fig. 8. Marking inside limit switch box.
Fig. 6. Disengage of slack wire safety switch.

- Pay out the luffing winch wire and stop just before
it enters into empty drum limit.
- Note how many revolutions of the wire there are
left on the drum at this position. Make a mark on
the drum. Measure the empty drum measure AT,
see Fig. 7.
Wire lock
side
AT
AT = Empty drum flange

side/ Stop lowest position/
At least three locking turns
Fig. 7. Luffing winch.
- 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.
- Secure the wire so that the wire can not pay out
and that the wire clamps that holds the end of the
wire can be removed safely.
- Attach a long rope to the wire end (longer than the
wire rope) and place it 4 to 5 turns around the wire
drum.
- Before operating the luffing winch read preparation
for rig mode, page 2.
- Activate Rig mode.
- Run the winch to pay out the old luffing wire, and
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
top or jib top. See Fig.11,12 and 16.
- Run the winch by pulling in the wire, so that the
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
was disconnected.
3 (8)
SERVICE
- Attach the wire rope end to the wire drum by the

wire rope clamps and tighten the bolts. For tightening torques see instruction "Tightening Torques..."
in section 6.2.
- Exit Rig mode. Set key switch in position Normal.
- Assemble the limit switch box in its correct place.
- Run in the rest of the wire.
- 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 instruction
in section 6.3 and calibrate the encoder according
to instruction "Absolute Encoder Calibration" in
section 6.3.
6.223.26 E rev.: b 2012-02-15
Limit
switch box
Winch drum
Fig.9. Limit switch box, hoisting winch.
Winch drum
Limit switch
box
Tightening torque: See the winch part picture or instruction "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

house top
CAUTION!
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
ropes and loadcell.
Fig.13. How the wire is spooled from the winch drum

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 socket 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
of the wire rope it is important to inspect the condition
of the wire sheaves.
The wear, see Table 1, can certainly occur on every

spot where the wire rope is in contact with the wire
sheave, not only on places shown in Fig. 1.
Wear criterias
Indentation
When the wear on the wire sheave exceeds 3mm, it

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

certain spots, see Fig. 2. After some time the
indentation will have the shape shown in Fig. 3. This
is considered as normal wear.
Fig. 1. Wear on wire sheave.
Fig. 2. Contact spots.
a
max
3
3
2.5
2
1.5
t
16
12
10
8
6
Table 1.
Fig. 3. Good contact between an old wire rope and

the wire sheave.
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 before operations are carried out. Work should only
take place when equipment is supported on a firm
surface.
Maintenance and service

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

enlarged by more than 5%, the part should be
replaced or maybe repaired, see Fig. 4. Contact
MacGREGOR Cranes, Service Division, for
instructions.
Important!
When replacing genuine parts an overload test of
the complete unit must be performed and new certificate must be issued. See Table 1.
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
Fig. 4. Lifting eye.
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, unless 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
PL = (0.933 x WLL) + 27
25 T < WLL < 160 T
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
Below measuring procedure is valid for the crane
types G, TG, GL, TGL, GLB, H, TH, L, and TL.
Note!
The procedure is not valid for measuring the slewing
bearing under the twin platform.
The slewing bearing is an essential part of the crane
and must be well maintained. Over the years the slewing bearing will have some wear, and to be able to
know if there is a need for changing the slewing bearing records of the wear are needed.
The initial measurements should be taken when
the crane is installed at yard or within 2 months
from crane installation.
If the wear measurement shows wear, grease samples
can be taken for analysis.
For slewing bearing grease sampling procedure see
inspection instruction 625/1651 E.
Measuring
The measurements should be taken regularly, every
6 months. Measurements can be sent to Cargotec
Service Organisation for evaluation.
at the reference point in the front of the crane and

"B, C" at the reference point at the back of the crane.
Remove excessive wear (burr) from slewing gear teeth
before measuring.
Measurements shall be taken at four positions of the
slewing bearing, if possible. With the jib pointing:
- Forward to the ship
- Starboard
- Aft
- Port side
It is important to use the same position for all further
measurements to be able to compare the measurements.
With the jib at maximum outreach two measurements
are to be taken, see Fig. 1.
With the jib at minimum position one measurement is
to be taken, see Fig. 2.
Enclosed table can be used to record the measurements.
Allowed play for slewing bearing

Measurements should be recorded with an accuracy
of 0.1 mm.
As a guidence the maximum allowed play is:
- for roller bearings 1.5 mm
- for ball bearings 3.0 mm.
Note!
When measurements are to be taken the ship shall
have as little list/trim as possible.
Contact Cargotec Service Organisation for exact maximum slewing bearing play for your crane.
Neither a load nor cargo handling equipment should

be attached to the hook.
See Slewing Specification spare part picture or Slewing Bearing drawing for type of bearing in your crane,
section 9.3 in spare parts manual.
Procedure
First time a measurement is to be taken two reference
points on the crane's bottom plate must be grinded
and marked. These reference points shall then always
be used at any future measuring, see Fig. 4. Write "A"
Deviation
The deviation is related to differences in production
tolerances and material. For Cargotec a part for a more
accurat evaluation of the bearing play.
1 (4)
625/1579 E rev.: k 2011-10-28
Jib at maximum outreach
Empty hook
Jib direction
Jib direction
Measurement B
(back of crane)
Measurement A
(front of crane)
Fig. 1. Jib in outer position.
Measurement C
(back of crane)
Jib direction
Min. outreach,
empty hook
Fig. 2. Jib at minimum outreach.
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/
reference point
Machined surface/
reference point
Jib
B,C
Fig. 3. Machined surface on crane bottom plate.
Remove excessive
wear (burr) from slewing gear teeth before
measuring.
Reference point
Reference point
B,C
Fig. 4. Reference points, how to measure
3 (4)
625/1579 E rev.: k 2011-10-28
Vessel name: ...........................................................
Fore
IMO No.: ...................................................................

Ps
Stb
Date: .........................................................................
Aft
Crane No.: 1
Measurement (accuracy 0.1 mm)
Jib at max. outreach
A (front of crane)
B (back of crane)
Jib at min. outreach

C (back of crane)
Note!
- If B - C = 0 or negative the
measurement is wrong.
- B - A = deviation bottom plate
crane house + play in bearing.
Play
Deviation
B-C
B-A
Jib direction
Fore
Stb
Aft
Ps
Crane No.: 2
A (front of crane)
B (back of crane)

C (back of crane)
Play
Deviation
B-C
B-A
Jib direction
Fore
Stb
Aft
Ps
Crane No.: 3
A (front of crane)
B (back of crane)

C (back of crane)
Play
Deviation
B-C
B-A
Jib direction
Fore
Stb
Aft
Ps
Crane No.: 4
A (front of crane)
B (back of crane)

C (back of crane)
Play
Deviation
B-C
B-A
Jib direction
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
condition is to analyse the grease samples. The other
is to make play measurements. The grease analysis
can be done in two steps, simplified or in a laboratory.
What method to be used must be decided after the
play measurement is taken. It must be noted that a
single laboratory test of a grease sample gives very
little information. Laboratory tests must be done on
regular basis to see trends.
The play measuring normally tells more about the
bearing condition than a grease sample. Both methods
provide together the best basis for evaluation of the
bearing condition.
Procedure of grease sampling

Following information is necessary in order to give a
correct statement and allow further advice:
- Clean up the seal and the surrounding areas where

the sample will be taken. When cleaning the area
of the seal, prevent the cleaner from contacting the
seals or from entering the raceway's system.
- Push new grease into the grease nipples / bearing
without rotation and collect the first used grease
which will come out at the seal.
Attention: Do not take fresh grease for analysing!
The required quantity of grease for analysing is approximately 3 cm3.
The normal interval for grease sampling is 6 months.
If steel particles are seen when the simplified grease
analysis is done or if the laboratory grease analysis
shows a too high value the grease sampling period
should be increased to each 50 crane operating hours
or every two months.
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

(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

(see below figure)

(see below figure)
Inner seal
Slewing bearing with balls.
Grease sampling
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 recognize the deviations of the used grease.
Recommended analyze limits
Fe
PQ Index = Fe >5 **
Si
Water *
Ok
1500
500
100
1000
Attention
5000
1500
200
2000
Risk
> 5000
> 1500
> 200
> 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

additional cards. On the front of each card
there is a display and three buttons: Select/
Info, Up and Down/Exit.
This instruction describes how to use the

display and buttons on the Micro Processor
Cards (MC- and CC) placed inside the CT2cabinet.
Each crane with CC3000 is equipped with at
least one CC-card and three MC-cards.
Note! Depending on equipment or software

versions the number of alternatives may vary.

1. Error MP (Main Processor) and SP

(Safety Processor)
4. Select/Info
Push the button = Select.
Push and hold the button = Information
will scroll by on the display.
Flashing diode = there are active

errors that have not been
acknowledged.
The diode is on (fixed) = there are
active errors but they have been
acknowledged.
The diode is off = there are no
active errors.
5. Up button
Browse upwards
6. Down/Exit
Push the button - Browse downwards.
Push and hold the button - Exit, back to
top menu.
2. Encoder Calibration button

Used for calibrating encoders
3. Display
See below

SERVICE

6.303.61 E rev.: c
2011-07-14
Display
At power on the software version will appear.
To view that in a later stage, see below
paragraph 6 VER.
For each card there will be two letters
representing the card. When holding the Select
button the complete name will appear.
Standard
view
Sc
Ho
Lu
Sl
Au
Cl
Ec
Ll
Tl
Tr
Io
For more information about errors refer to

Troubleshooting CC3000 in section 6.3 in
the Instruction Manual.
2. CAL - CALIBRATION MODE (LOGIN
REQUIRED)
Complete
name
Supervisor
Hoisting
Luffing
Slewing
Auxiliary
Closing
Eccenter
Lift Line
Tag Line Left
Tag Line Right
Input/Output
Calibration mode makes it possible to

calibrate one or several encoders and
other equipment depending of crane type.
Calibration can only be done if Rig-mode
is on. For more information see Absolute
Encoder Calibration in section 6.3 in the
Instruction Manual.
Each card will be calibrated at a time.
For twin cranes, when in twin mode and
from the master crane and from card Sc:
Ho Ll Tl Tr but not Lu will be calibrated.
3. PLU Plussing Adjustment
Only on Sc card
Only to be used during commissioning of
the crane.
Menu tree
All errors must be acknowledged before you
can move on to other modes. (Diode must not
be flashing). There are seven main modes.
Push Select/Info to enter menu tree.
1.
ERR
2
3
4
5
6
CAL
PLU
CUT
VAL
VER
Error Mode
Calibration Mode (Login
required)
Plussing Adjustment
Cut off valve Adjustment
Value Mode
Software Version
MFG
Manufacturing number
(from version ,
4. CUT Cut off valve Adjustment

Only on Sc card
Only to be used during commissioning of
the crane.
5. VAL - VALUE MODE
Value Mode makes it possible to monitor
different values. How many values that
appear is dependent on equipment and
parameter settings.
Push Down/Exit until the display shows
VAL
Push Select/Info to select Value Mode
Push Down/Exit until the value is on
display.
Push select to see the value.
ERR - ERROR MODE

Error mode shows all active errors in the
respective control card.
Push Select/Info to select Error Mode.
Push Down/Exit or Up to browse
between errors.

6.303.61 E rev.: c 2011-07-14

SERVICE
Values
Sc
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
OUT
Outreach m
FOR
Hook to hook FOR m
AFT
Hook to hook AFT m
AL1
ALM line voltage
AL2
ALM line current
AL3
ALM power
kW
AL4
ALM DC voltage
PW0
PWM0
mA
PW1
PWM1
mA
PW2
PWM2
mA
PW3
PWM3
mA
PW4
PWM4
mA
AI1
"Parameter"
Parameter value
AI2
"Parameter"
Parameter value
AI3
"Parameter"
Parameter value
AI4
"Parameter"
Parameter value
AI5
"Parameter"
Parameter value
CAR
Card Temperature
Degrees
Ho
Lu
Sl
Au
Cl
Ec
LL
TL
TR
IO
MFG.
Push Select/Info to see the MFGnumber
6. VER - SOFTWARE VERSION

Software Version makes it possible to
read the version of the software. This will
also appear at power on.
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.

6.303.61 E rev.: c 2011-07-14

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

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

1.1
General
The
following
description
refers
to
the
microcomputer based crane control system
CC3000 for MacGREGOR hydraulic deck cranes.
Minor variations in the use of control system input
and output signals due to differences in hydraulic
and electric system may occur, the objective of this
description is only to provide a general orientation
concerning the principles of control system
interface signals and of troubleshooting.
For a general description of the principles of the
Crane Control system CC3000 see "Function",
section 3. For detailed information about the control
system a complete electric circuit diagram, relating
2 (10)
specifically to your crane, will be found in the

instruction manual, section "Spare Parts", Group
9.5.
1.2
Power supply, Control system

operation
The power supply transforms the

380/400/440V AC to 24V DC. See Fig. 2.
input
It consists of a three-phase power supply. The

output 24V DC is divided into two supplies, one for
the control system and its output signals (terminal
48) and one for the limit switches, pressure
switches (terminal 42). There are fuses on each
supply in the CT1 cabinet.
SERVICE
6.303.66 E rev.: a
The 0V level for 24V DC is grounded in power

supply unit.
2012-01-10
condensation heating in the crane. A separate

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
Fig. 2. CC3000 Power supply principle.
1.3
Power supply, Control system anticondensation heating
The anti-condensation heating in CT2 cabinet is

powered with 24V DC when the control system is
switched off and the crane is not in operation. A
separate power supply is used for all anti-
Control levers - direction signal

inputs
The control lever for hoisting selects two out of four

24V
direction
signals,
for
selection
of
hoisting/lowering. See Fig. 2. The control lever for
luffing/slewing gives two out of four 24V direction
signals for selecting luffing in/luffing out and
slewing
left/slewing
right.
Fig. 2. Control lever signals, hoisting movement
3 (10)
SERVICE
6.303.66 E rev.: a 2012-01-10
1.7
1.6
Brake release outputs
Each MC card has an output driver for the brake

release signal. The system is capable of detecting
short-circuited output and then giving an errormessage, see sign ERROR MESSAGES.
4 (10)
Lamp output "Control System Error

in CT2"
The LED no 28 on the CC Card are wired to a lamp

in crane operator's cabin. The first time an error
occurs, the lamp flashes. When the error is
acknowledged by pushing the Select/Info pushbutton 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.
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
signals
CT2-X10:48
CT2-X10:50
+24V. 0V, connected to ground.
Power for limit switches, pump servos, etc
CT2-X10:42
CT2-X10:50
+24V. 0V, connected to ground.
CT2-X10:44
CT2-X10:46
Parking of jib
CT2-X10:109
Outputs to control lever potentiometer hoisting
24V AC, powered when crane

stopped.
CT2-X10:201
CT2-X10:202
CT2-X10:203
Ho
+12V from MC "Ho"

+6V from MC "Ho"
0V from MC "Ho".
Control lever potentiometer input hoisting
CT2-X10:204
Ho
Analogue input signal 1.5 to

10.5V with 6V in neutral position
Control lever direction inputs hoisting

Hoisting
Lowering
CT2-X10:207
CT2-X10:208
Ho
Ho
24V when control lever actuated

hoisting
lowering
Outputs to control lever potentiometer

Luffing
CT2-X10:301
CT2-X10:302
CT2-X10:303
Lu
+12V from MC "Lu"

+6V from MC "Lu"
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

Luffing In
Luffing Out
CT2-X10:307
CT2-X10:308
Lu
Lu
Outputs to control lever potentiometer slewing
CT2-X10:401
CT2-X10:402
CT2-X10:403
SL
+12V from MC "SL"

+6V from MC "SL"
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

Slewing Left
Slewing Right
CT2-X10:407
CT2-X10:408
Brake #1 open
Hoisting
Luffing
Slewing
CT2-X10:230
CT2-X10:330
CT2-X10:430
Brake #2 open
Hoisting
Luffing
Slewing
CT2-X10:231
CT2-X10:331
CT2-X10:431
SL
SL
Ho
Lu
SL

luffing in
luffing out

slewing left
slewing right
24V, max. 2A, open circuit gives
error message.
Ho
Lu
SL
Limit switch inputs hoisting

Hoisting
Lowering, slack wire
CT2-X10:214
CT2-X10:215
Ho
24V at normal operation, 0V at

limit. At limit movement is
stopped and brake closed.
Limit switch inputs luffing
CT2-X10:314
Lu
5 (10)
SERVICE
6.303.66 E rev.: a 2012-01-10
Luffing In
Luffing Out, slack wire
CT2-X10:315

Limit switch inputs slewing

Slewing left
Slewing right
CT2-X10:414
CT2-X10:415
SL
Slack wire
CT2-X10:256
CT2-X10:356
Ho
Lu
Output Error in control system CT2
CT2-X110:128
Sc
24V outputs wired together to

error lamp in drivers cabin.
Output for "Hoisting Overload" indication lamp
CT2-X10:255
Ho
Lu
24V when the hoisting pressure

exceeds adjusted value.
Tilt switch, Jack-knife
CT2-X11:351
Lu
24V (Optional)
Klixon High Motor temperature
CT2-X10:259
CT2-X10:359
CT2-X10:459
Ho
Lu
SL
24V
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
Cooling fan #2 (if needed)
CT2-X11:354
CT2-X11:454
Lu
SL
24V
Brake failure lamp
CT2-X10:138
Sc
24V
Derating (Limiting) of high speed movement for

hoisting, luffing and slewing
CT2-X10:217
CT2-X10:317
CT2-X10:417
Sc
Sc
Sc
24V
24V
24V
Backplane Card
Temperature Cabinet CT10
Temperature Cabinet CT13/
Temperature Cabinet CT14/
Temperature Cabinet CT2
Sc:AI3
Ho:AI3
Lu:AI3
Sl:AI3
Absolute encoder
Ho:SSI
Lu:SSI
Sl:SSI
Incremental encoder
Ho:Sp
Lu:Sp
Sl:Sp
FQC
Sc:C1
Ho:C1
Lu:C1
SL:C1
6 (10)
SERVICE
6.303.66 E rev.: a
2012-01-10
3 Troubleshooting the Crane Control system

3.1
or is not corrected by the listed corrective actions,

notify your supervisor.
General
This section provides information for identifying and

correcting malfunctions, which may develop while
operating the cargo crane. Before performing
troubleshooting, read and follow all safety
instructions found in section "General", section 1, of
this manual. This chapter cannot list all
malfunctions that may occur, nor all inspections
and corrective actions. If a malfunction is not listed,
3.2
When troubleshooting a malfunction: Locate the

symptom or symptoms that best describes the
malfunction. If the appropriate symptom is not
listed, notify your supervisor.
Read this section in conjunction with the electrical
and hydraulic diagrams provided in Group 9.5 and
9.4.
Troubleshooting Chart
Troubleshooting the
Crane Control System
CC3000.
Crane movement
malfunction.
Crane movements function but the lamp

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

System Error CT2" in
driver's cabin.
Both lamps
are off.
Check 24V power

supply, see chapter
3.3.
One or both lamps are

flashing or on.
Check the error code in

Control System cabinet
CT2.
Check limit switches,

joysticks, see chapter
3.4.
7 (10)
SERVICE
3.3
Checking Power supply 24V DC in

CT2 cabinet
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 drivers cabin will not flash.
8 (10)
6.303.66 E rev.: a 2012-01-10
With the crane still running, the following steps are

necessary to obtain the error code(s).
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
rnskldsvik.
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
THISPAGEISINTENTIONALLYLEFTBLANK
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

purposes. Each encoder gives an accurate position
feedback to the control system.
WARNING! Always use safety belt when measuring

the MV distance.
The encoder calibration has to be done when the wire

or the absolute encoder has been replaced.
Absolute encoders for hoisting and luffing winches
are installed in the limit switch box or on jib bearing.
For slewing motion the absolute encoder is mounted
under the crane towards the slewing bearing.
To operate the crane in Rig mode see instruction

"Preparation for Rig Mode" in section 6.3.
WARNING!
When the crane is operated in Rig mode the crane has
no software limits.
Inappropriate use may cause severe damage to the
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
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.
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.
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
-
Activate Rig mode.

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)
6.303.67 E rev.: - 2011-01-18
AL
Fig. 2. Definition of "AL" hoisting winch.
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.
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

Rig Mode" in section 6.3.
To calibrate the encoder on the other cards proceed in

the same way as in items 1, 2, 3, and 4 in above
paragraph except for choosing the corresponding card.
1.
2.
3.
4.
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".
Push the "Down/Exit" button on the Ho-card
front. The display on the Ho-card shows "CAL".
Push the "ENCODER CALIBRATION" button in
cabinet CT2. The display in the Ho-card then
flashes and shows "ANG".
Push the "Select/Info" button on the Ho-card.
Angle encoder is calibrated in this position.
Table 1. Encoder calibration modes

Function/
Mode
Purpose
Calibration position
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)
SIGNAL OVERVIEW
.Colour
Green
Yellow 11,12
Yellow 17,18
Red
2011-11-30
No
Revision
424 0738
Ho Hoisting
CC Card
LED
No
Software
CC3K H01_00
Rev B
Date
1 (2)
LEDs - 24V Input/Output signals are indicated with coloured LEDs

External communication
Indicating
LEDs on
LEDs within the COM box are external communication and
when
communication with Main Processor (MP).
Normal inputs and outputs
+24V
The external communication LEDs are blinking when
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.
Speed reduction switches
+24V
Software
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
Hardware
324 1670-901
Page
Signal Description
07
08
09
10
11
12
13
16
17
18
19
20
26
27
28
29
Overload test
Rigging mode
Parking of jib
30
Twin not synch.
31
32
33
34
35
36
37
38
39
40
49
51
53
56
57
58
59
60
61
24 V
C1
C2
Mode A (Container)
Mode B (Grab)
Mode C (Hatch C.)
Pump Unit 1/ RBTS
Pump Unit 2
Run enable in
Run enable out
Alarm (error in CT2)
Ready to run
ARC Cabin A Lamp

ARC Cabin B Lamp
ARC 180 deg. rotation
ARC Run enable out
Brake Failure lamp
Twin on
Calibration
Twin reset
Em. op. request
Em. op. activated
Power supply +24V
CAN1 (ALM)
CAN2 (Cabin display)
MC Card
Plinth
No
107
108
109
110
111
112
113
116
117
118
119
120
126
127
128
129
LED
No
Hardware
324 1665-901
07
08
09
10
11
12
14
Sw14/15
15
17
18
19
20
Sw20
26
27
130
29
131
132
133
134
135
136
137
138
139
140
149
151
153
156
157
158
159
160
161
30
31
32
33
34
36
37
39
Sc_C1
Sc_C2
Software
CC3K H01_00
Rev B
40
43
45
49
51
52
53
54
55
56
Sw56
57
58
C3 CAN3
Sc_C3
59
C4
R1
R2
R3
MP
Sc_C4
Sc_R1
Sc_R2
Sc_r3
C1
C2
R1
MP
CAN4
RS485_1 (Remote)
RS485_2 (Twin)
RS485_3
Internal communication
Signal Description
Hoisting, input
Lowering, input
Low speed, input
High speed, input
Speed reduce hoisting
Speed reduce lowering
Limit switch hoisting
Speed reduce, stop, block
Limit switch lowering
Speed reduction, ext1
Low pressure switch
Overload switch input
Overload load cell/pressure
Run enable in
Run enable out
Indication Speed
reduce/stop
Hoisting brake, output
Low speed, output
High speed, output
Pump1 hoisting, output
Pump1 lowering, output
Angle Check Cam
VFD Run enable out

Indication Overload
Slack wire
Slack wire from LU
Brake Open Indication
Ext stop 1
Ext stop 2
El.motor high temp
CAN1 (VFD)
CAN2
RS485_1
Plinth
No
207
208
209
210
211
212
214
215
217
218
219
220
226
227
229
230
231
232
233
234
236
237
239
240
243
245
249
251
252
253
254
255
256
257
258
259
Ho_C1
Ho_C2
Ho_R1
SIGNAL OVERVIEW
Page
Date
2 (2)
2011-11-30
No
Revision
424 0738
LEDs - 24V Input/Output signals are indicated with coloured LEDs

External communication
.Colour
Indicating
LEDs on
LEDs within the COM box are external communication and
when
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
LED
No
Hardware
324 1665-901
07
08
11
12
14
Sw14/15
15
17
18
19
20
26
27
29
30
31
32
33
34
36
37
39
40
43
45
49
51
52
53
54
55
56
57
58
Software
CC3K H01_00
Rev B
Signal Description
Luffing in, input

Luffing out, input
Speed reduce luffing in
Speed reduce luffing out
Limit switch luffing in
Speed reduce, stop, block
Limit switch luffing out
Low pressure switch
Overload switch input
Run enable in
Run enable out
Indication Speed
reduce/stop
Luffing brake, output
Unloading, output
Pump1 luff in, output
Pump1 luff out, output
Angle Check Cam
Jack-knife
MC Card
Plinth
No
307
308
Hardware
324 1665-901
311
312
314
315
317
318
319
320
326
327
329
331
333
334
336
337
339
340
343
345
349
351
352
VFD Run enable out

Cooling fan #1
Indication Overload
Slack wire
Ext stop 1 (Jack knife)
353
354
355
356
357
358
(El.motor high temp Klixon)
359
Software
CC3K H01_00
Rev B
Signal Description
07
Left, input
08
Right, input
11
Speed reduce left
12
Speed reduce right
14
Limit switch left
Sw14/15 Speed reduce, stop, block
15
Limit switch right
17
18
19
Low pressure switch
20
26
Run enable in
27
Run enable out
29
30
31
32
33
34
36
37
39
40
43
45
49
51
52
53
54
55
56
57
58
330
Ext stop 2 (High hook)

59
LED
No
59
Slewing brake, output
Plinth
No
407
408
411
412
414
415
417
418
419
320
326
327
329
430
431
432
Pump1 left, output

Pump1 right, output
Pump2 left, output
Pump2 right, output
Angle Check Cam
Remote on
Brake low oil level warning
VFD Run enable out
Cooling fan #2
433
434
436
437
439
440
443
445
449
451
452
453
454
455
Brake low oil level stop

Ext stop 1
(Luffing Slewing limit off)
Ext stop 1
(Luffing Slewing limit off)
456
457
458
459
(El.motor high temp Klixon)
C1
C2
R1
MP
Lu_C1
CAN1 (VFD)
CAN2 (ARC angle swivel) Lu_C2
Lu_R1
RS485_1 (ARC gyro)
C1
C2
R1
MP
Sl_C1
CAN1 (VFD)
CAN2 (ARC Angle Cabin) Sl_C2
RS485_1(Outdoor display) Sl_R1
ERROR MESSAGES
Page
1(2)
No
424 0739
Date
2011-11-27
Revision
F
Error message codes from CC3000
Note!
If the error from the CC3000 has no influence on the performance of the
crane the control system error lamp in the drivers cabin will not flash.
With the crane still running, the following steps are necessary to obtain
the error code(s).
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
card with the flashing LED error MP or error SP on top of the
cards.
Green LED 28 on the Sc-card
Indicate error status in the
whole system (All cards)
Red LED Error MP
Indicate error status from MP in
the local card
Red LED Error SP
Indicate error status from SP in
the local card
Push the Select/Info button once on the card with error LED
flashing. An error code (e.g. E51_11) is shown on the display on the
card.
Hold on pressing Select/Info button, the description of this error will
be rolling on the display. Release the button, the description
disappears and the error code is shown.
Continue to press Select/Info or Down/Exit button once to see the
next error and so on.
Pressing Up button once to show the previous error and so on.
When there are no more error messages, the display shows three
hyphens ---. When all errors have been shown on the display, the
error LED is either on or off.
All errors can be shown round and round if you continue pressing
Select/Info or Down/Exit button or Up button.
LED flashing
New error, not acknowledged
LED on
Error remains, now acknowledged
LED off
No error present at the moment
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
pressed, or holding on pressing Down/Exit button longer than one
second.
If the system is restarted (i. e. 24V power supply is switched off for a
short time) all alarms disappear and only reappear when the error
recurs.
How to see the remaining errors after acknowledging (i.e. error LED is
on)?
Errors can be shown again from normal mode when pressing
Select/Info twice.
Pressing Up or Down/Exit button to see the previous respective
next error, following the same instruction above.
Before reporting to Cargotec (MacGregor) in rnskldsvik, please look

for the error code in the display of the MC or CC card and use the
select/info button to view all error codes. It is essential that all faults to
be corrected to allow the crane to function correctly.
Hardware
324 1670-901
Hardware
324 1665-901
Hardware
324 1665-901
Error MP SP
Display
Select/Info button
Up
Down/Exit
Software
CC3K H01_00
Rev B
Software
CC3K H01_00
Rev B
Error code
01
01_01 to 01_15
01_12
02
02_01 to 02_61
03
03_01 to 03_91
10
10_10
11
11_01 to 11_30
24
24_01 to 24_04
30
30_01
30_02
30_03
30_04
31
31_01
31_02
31_03
Hardware
324 1665-901
Encoder
Calibration
Software
CC3K H01_00
Rev B
Abbreviations:
31_04
31_05
31_11
31_12
31_13
31_51 to 31_53
31_54 to 31_57
32
32_01
Software
CC3K H01_00
Rev B
32_02
VFD = Variable Frequency Drive

ALM = Active Line Module
Description
S ys t e m E r r o r s
Contact Cargotec in rnskldsvik
System Software version mismatch
Check the software version in the cards
MC or CC Card
Restart system or replace the card
Safety processor
MEM card
Replace the MEM card
Parameters
24V Suppl y Voltage
Check 24V supply
J o ys t i c k
Joystick level, normally 1.25 V to 11.75 V.
Check connection to joystick
Check switches/cam in joystick
Measure potentiometers in joystick
Joystick logic error for Lowering, Luffing Out or
Slewing Right movement.
Joystick logic error for Hoisting, Luffing In or
Slewing Left movement.
Joystick is not in zero position when system starts.
An g l e E n c o d e r
Angle encoder communication error
Check angle encoder connection
Replace the angle encoder
Angle shaft coupling
Check angle encoder connection
Angle encoder or speed encoder error
Replace the angle encoder or speed encoder
Angles at CAM control place mismatch.
Check angle encoder cable and connection
Calibrate encoder again.
Contact MacGREGOR Cranes in rnskldsvik
Shaft not connected
Different angle values when more than one encoder
for luffing.
(Only on Sc-card).
Power Swivel angle encoder
ARC angle encoder in cabin
Speed Encoder
No data from speed encoder
Check speed encoder cable and connection
Replace a new speed encoder
Exchange cards
VFD or CC3000 encoder
ERROR MESSAGES
32_03
32_04
32_05, 32_06
32_10
33
33_01
33_02
33_03
33_04
33_07
33_11
33_12
33_13
33_14
33_31
33_32
33_33
33_37
33_41
33_42
35
35_01, 35_02
35_11
35_12
35_13, 35_41
35_14, 35_42
35_15, 35_43
35_16
35_44
35_45
36
36_01, 36_02
36_03
37
37_01 to 37_06
37_10
37_21
37_22
38
38_01
38_02
38_03
38_04
39
39_01, 39_02
40
40_01, 40_02
41
41_01 to 41_03
45
45_01 to 45_36
48
48_01, 48_02
48_11, 48_12
48_21, 48_22
Wrong speed direction

Change speed encoder direction or shift cable
connection (switch A and B)
Replace the speed encoder
Exchange cards
Contact Cargotec (MacGregor) in rnskldsvik
VFD encoder
Encoder error
No data from speed encoder
Weight
Loadcell
Check loadcell cable and connection
Replace the loadcell
Pressure
Loadcell Check
Torque
Load system, in EO
Difference Loadcell
Difference Pressure
Difference Loadcell check
Diffeerence Torque
Outreach, angle Lu
Outreach, angle Sc
Outreach, angle Sc speed
Outreach, in EO
Change to Main not possible
Change to Whip not possible
Temperature
MC card temperature is too high
Power off system
ALM high temp
VFD high temp
Electric motor high temp
Hydraulic oil high temp
High temp
Air intake high temp
Winch oil high temp
Braking resistors overheated
Power
High current
No data from power sensor
Limit
Limit error at stop cam
Check stop cam connection or switch
Limit: Software limits
Limit: Luffing Slewing
Limit: Anticollision
Run Enable
Run enable: No input on terminal X26
Run enable: Terminal X26 is always set
Run enable: No run enable in
Run enable: Team
Low feed pressure
Low feed pressure
Lubrication
Lubrication
Power limitation
Power limitation
External IO
External IO
Motion Sensor
Power swivel
Swing
Ship
49
49_01 to 49_07
50
50_11, 50_21
50_31, 50_41
50_12
50_22, 50_32
50_42
50_13, 50_23
50_33, 50_43
50_24
50_34
51
51_11, 51_21
51_12, 51_22
51_13, 51_23
51_14, 51_24
51_15, 51_ 25
51_31
51_32
51_33
51_34
51_50 to 51_52
52
51_01 to 51_05
51_11 to 51_14
53
53_01 to 53_50
54
54_01 to 54_06
55
55_01 to 55_04
56
56_01 to 56_23
62
62_01
62_02
62_10 to 62_14
62_20 to 62_24
63
63_01 to 63_05
70
70_10
70_20
Page
2(2)
No
424 0739
Date
2011-11-27
Revision
F
External analogue in
A1, A2, A3, A4, A5, A6, A7
Check cable, connection
Check encoder
Replace the MC or CC card
Displacement
Open circuit (Low speed, high speed, unloading,
plussing valve [LC])
Check cable and connection
Short circuit (Low speed, high speed, unloading,
plussing valve [LC]))
Check output cable is not connected to 0V(ground)
Transistor (Low speed, high speed, unloading,
plussing valve [LC]))
High speed valve
No plussing pressure
Brake
Open circuit
Short circuit
Check output cable is not connected to 0V(ground)
Replace the MC card
Transistor
Replace the MC card
Control Circuit
VFD Brake output
Read back (pressure or switch)
Closed (pressure or switch)
Closing failure
Slip
Low oil level or temp error
Pump
Pump PWM current
Check that PWM output is not connected to
0V(ground)
Check that cable is not broken
Replace the MC card
VFD
VFD
AL M
ALM
Stab Winch
Stab winch
Power Swivel
Power Swivel
Twin
No data from Slave
Error in Slave
Angle error Master Ho, Lu, Ll, Tr
Angle error Slave Ho, Lu, Ll, Tr
Team
Team
Speed
Speed control deviation
Variable Frequency Drive zero speed timeout
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
1.2
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.
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.
1.3
Picture 2. Remove X524, X521 and X531
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
Insulation test (megger) Electrical crane
C Hrnfeldt
Deescription (own language)
Drawing No
Isolationstest (megger) Elkran
Year Week
1000004064
10 40
Rev ind
Sheet
1(2)
INSTRUCTION
INSULATION TEST
ELECTRICAL CRANE
1.5
Crane Computer
Disconnect all cables from the computer.
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
Insulation test (megger) Electrical crane
C Hrnfeldt
Deescription (own language)
Drawing No
Isolationstest (megger) Elkran
Year Week
1000004064
10 40
Rev ind
Sheet
2(2)
SERVICE
6.305.19 E rev.: - 2010-12-03
Electrical Equipment, General Maintenance
Introduction
General maintenance of the electric equipment of
the crane is important in order to prevent unexpected
breakdowns. The following general advice may be
useful. Relevant electrical system is placed in section
9, SPARE PARTS.
Portable control boxes

Control panels and remote control boxes may be subjected to abuse an abnormal wear, and should be
inspected after every use. The control boxes must be
stored in a compartment that is well protected against
moisture. Remove moisture that may have collected
in the boxes, and find out how it entered.
Start the crane and try out all combinations of movements that are practicable. This will show if the electric
functions are satisfactory.
Inspect all electrical equipment cabinets, and components. Any defective component must be repaired
or replaced without delay. A detailed inspection and
overhaul at two-year intervals is recommended. Check
that all screws and nuts are securely tightened in the
contactor cabinets, that all switches and pushbuttons
operate correctly, and that cable connections are perfectly tight and all insulating parts intact. Make sure
that inspection door gaskets seal perfectly.
Danger!
Electrical equipment can be alive unless the main
switch and the separate supply is disconnected in
cabinet CT1 and CT2.
C-00108
Dangerous voltage, 700V DC, can remain charged in

the DC-bus up to 5 min. after the power switch Q1 is
switched off.
Fig.1. Electric Cabinet CT1/CT2
Earth connection, hull

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

Check crane system earth connections, and clean
contact surfaces as required.
1 (2)
SERVICE
General maintenance
- Change filter to the ventilation fan in cabinet CT1,
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 "Heating 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 power supplied by separate transformers is switched off
in the ship's engine room. Also check by means of a
voltmeter that the slip-ring unit is not alive.
- Verify that slip-ring contact surfaces are smooth
and even, clean as required.
- Check contact pressure of brushes.
- Replace carbon brushes or entire slip-ring assemblies as required.
- Make sure that cable connections are securely
tightened.
- Make sure that rocker arm mounting screws are
securely tightened.
The removal and installation of the slip-ring unit is the
subject of a separate description.
2 (2)
6.305.19 E rev.: - 2010-12-03
Oil level/temp
See instruction "Control and Indicators" in section 4.
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 equipment", are made in all cranes to get an interlock connection between the external mounted "grab control
equipment" and MacGregor Cranes' safety functions.
Some preparations are done in the cabinet CT1 and
on control panel (CT3) in cabin. The two-position key
switch "Cargo/Grab Handling" which is adaptable to
the "grab control equipment", see instruction "Controls
and Indicators", section 4.
The power supply cable to the "grab control equipment" needs to be connected as shown in Fig. 1. To
protect the "grab control equipment" we recommend
that the power supply cables are connected after the
main switch Q1 and fuse switch disconnector F1 in
the cabinet CT1, see Fig. 1.
K59
Connection of the power supply cables.

Main switch Q1
Fuse switch disconnector F1
Fig. 1. Cabinet CT1.
1 (2)
SERVICE
Contactor relay K59

To energize the contactor relay K59 in cabinet CT1,see
Fig. 1, the two-position key switch "Cargo/Grab Handling" 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 electrical 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)
6.306.7 E rev: a 2011-10-27
SERVICE
6.307.11 E rev.: b 2003-01-08
Slip-Ring Unit
Danger!
Before opening the slip-ring unit, make sure that
power supplied by separate transformers is
switched off in the ship's engine room. Also check
by means of a voltmeter that the slip-ring unit is not
alive. Make sure that the current can not be switched
on again during the maintenance operation.
Use only insulated tools and original spare parts.
Work on a slip-ring assembly may only be carried

out by a qualified electrician or by persons under
the supervision of a qualified electrician and only
according to accepted electrical safety procedures.
1. Park the jib in a suitable manner.

2. Disconnect the ship's power supply at all points
of feed.
3. Disconnect all the cables connection from craneand ship supply.
4. Remove the driver connecting the slip-ring unit
and the foundation. Note the cables mounting
sequence.
5. Remove mounting screw holding the slip-ring unit
on cranehouse bottom. See Fig. 1.
6. Remove the slip-ring unit.
The function of the slip-ring assembly may not be

changed in any way. Especially safety devices must
not be made ineffective. Other than during maintenance and inspection work the housing must always
remain closed.
No responsibility will be assumed for damage to

property or injury to persons caused by improper
use of the slip-ring assembly.
Removal
Mounting screws
Connection crane
Slip-ring unit
Connection box
Connection ship
power
Guide pins
Driver
Rubber protection
Note! Must be
tightened.
Fig. 1. Slip-ring unit.
1 (2)
SERVICE
Any extra equipment such as extra limit switches

fitted on top of the slip-ring unit are removed prior
to removal of the entire slip-ring unit.
Installation
Clean all contact surfaces between slip-ring unit
and cranehouse bottom. Tighten all screws properly. See instruction "Tightening torque".
- Assemble the slip-ring unit under crane bottom
- Assemble the driver to the bottom of the foundation
- Remove the cover around the slip-ring unit
- Fit the slip-ring unit guide pins to the driver's slotted holes by pulling apart the driver and lock it
with help of the through bolt
- Install the cables against the driving bar
- Connect the crane cables from the crane on correct mounting sequence
- Remove the connection box plates
- Connect the cables to the plinths
6.307.11 E rev.: b 2003-01-08
Carbon brushes
- The carbon brushes must never wear down so
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
free, compressed air or with a vacuum cleaner.
No substance containing oil or grease may come
into contact with the brushes or the slip-rings.
Wire brushes
- Check wire brushes.
Debris caused by wear is to be removed with dry,
oil free, compressed air or with a vacuum cleaner.
Afterwards the slip-ring ways and wire brushes
should be lightly sprayed with "Cramolin B" or
equivalent contact spray.
Others
- Check tightness of electric and mechanical
fasteners.
- Check gaskets and cable glands for tightness.
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 brake unit oil tank, an oil level/temperature sensor
is installed, see Fig. 1.
The sensor controls an indicator lamp on the control
panel in the cabin, see fig. 2.
The display on the sensor shows the oil level in cm.

The display can also show oil temperature. If you push
the arrow to the right the display shows, in this order:
1. Max value for oil level
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
show the oil level again.
cm
mode
1. Oil level/temperature sensor

Fig. 1. Brake unit
C-00257
C-00258
Fig. 3. oil level/temperature sensor with display

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
2 (2)
6.311.14 E rev.: - 2012-01-25
SERVICE
6.320.386 E rev.: c 2012-02-09
Limits in Hoisting and Luffing Winch Systems

CC3000
General
The motion and outreaches of the crane jib and hoisting block are controlled by software limits in the crane
control system CC3000 with limit switches as a safety
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,
see paragraph "Limit switches, high hook (optional)".
CAUTION!
Store Keys Safely
When the crane is rigged ready for operation, all keys
for all lockable switches must be stored in a safe place
Check cam
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 corresponding 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

switch boxes, with a 10 mm articulated wrench; the
cams are then easily rotated to their proper settings.
Below measures are stated in the document "Technical

Data" in section 2.
- Use the cam end as measure line when you adjust

the cam(s), see Fig. 1 and 2. The measure between
each hole is 5.
- Adjust the cam(s) according to the table in "Tehnical
Data", section 2.
Measure line
5
Min Outreach Lu
MV distance
Check cam, Lu
Max Outreach Lu
High Hook (optional)
Force Limitation Parking Position Lu
Empty Drum Lu (parking position)
Software Limit Lu
Lifting height, H
Lifting height, K
Check cam, Ho K
Jack-Knife Lu, Min Outreach (optional)
(m)
(mm)
(m)
(m)
(m)
(m)
(degrees)
(m)
(m)
(m)
(m)
(m)
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.
55
30
Lock screw
Fig. 1. Cam.
H
H
Center line
Jib radius
5
Measure line
Measure line
Lock screw
Adjustment
screws
Jib radius
100
245
Adjustment
screws
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 position
BT and BL measures - second layer, from the side of

the full drum flange side to the wire, see Fig. 5 and 6.
- AT and BT - luffing winch

- AL and BL - hoisting winch
Values of AT, BT (luffing) and AL, BL (hoisting) can be

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
three locking turns/
Tank top
AT - Empty drum flange side/

Stop lowest position/ At least
three locking turns
Wirelock
side
BT - Full drum flange

side/second layer
BT
AT
Fig. 4. Luffing winch.
BL - Full drum flange

side/second layer
BL
Wirelock
side
AL
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
the cam adjustments on the luffing winch. Begin at
minimum outreach and luff out to maximum outreach.
Move the cam backwards until there is another "click"

and the cam is now deactivated. (Approximately 1
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
BL5
BL7
Lock screw
Fig. 7. Cam is activated.
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
How to adjust cams and software limits

for luffing winch
WARNING!
When the crane is operated in Rig mode the crane
has no software limits.
To operate in Rig mode see instruction "Preparation
for Rig Mode", section 6.3.
Min Outreach
- To calibrate the angle encoder see instruction
"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.
- Push start button to start the crane.
- 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)
6.320.386 E rev.: c 2012-02-09
Parking position
- Set the key switch "Parking of Jib" in position 1 Parking. See "Control and Indicators", section 4.
Luff out to "Empty Drum, Lu Stop".
- Luff in from the parking area.
- Luff out to make sure that safety cam stops the
parking motion. Make sure that there is at least
"Three locking turns" of the wire on the drum.
switch in position Normal = Exit Rig mode.
- Luff in from the parking area and then luff out to
make sure that software limit stops the parking
motion.
SERVICE
6.320.386 E rev.: c 2012-02-09
Measurement of the minimum jib outreach, 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" (optional)

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
Adjustments of values see "Technical Data", section 2.
Adjust the cam until there is a "click". The cam is

activated. See Fig. 13.
Raise the jib into the Min Outreach Lu, Stop, which is
the correct jib position for adjustment of the limit switch
refer to Fig. 12. Note that the speed reduce switches
are software and operate the speed reduction of the
crane hook.
BH1
Move the cam backwards until there is another "click"

and the cam is now deactivated. (Approximately 1.)
See Fig. 14.
Tighten the cam.
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
How to adjust safety cams and software

limits for hoisting winch
WARNING!
To operate in Rig mode see instruction Preparation
for Rig Mode, section 6.3.
Empty drum
- Luff in to minimum jib outreach.
- Lower the hoisting wire to empty drum, at least
three locking turns.
- To calibrate the angle encoder see instruction "Absolute 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.
6.320.386 E rev.: c 2012-02-09
Full drum
- Luff in to minimum jib outreach.
- Hoist the hoisting wire to full drum (software stop).
- Lower the hoisting wire to come out from the full
drum area.
- Hoist the hoisting wire to full drum to make sure
that the safety cam stops the hoisting motion of the
hoisting winch.
- Lower the hoisting wire to come out from the full
drum area.
- Push the stop button to stop the crane and set the
key switch in position Normal = Exit Rig Mode.
- Push the start button to start the crane.
- Hoist the hoisting wire to make sure that the software limit stops the hoisting motion of the hoisting
winch and not the cams.
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 motion of the hoisting winch.
Adjust Check Cam
- Lower the hook to check cam position see "Technical 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

outreaches
Note!
If the crane is equipped with a high hook function, this
is not applicable.
In a certain area there is a possibility that hook block
and jib top will meet. See Figs. 16 and 17. This will
not cause any problem as the cranes safety system
takes care of it.
A slacking luffing or hoisting wire rope should stop

the luffing out and hoisting movements by use of the
slack wire switch BWL1.
Hook block hoisting the jib:
- This actuates the slack wire switch BWL1 and the
hoisting movement stops.
Jib landed on the hook block:
- Luffing wire slackens and the slack wire switch
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 manufactured 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
c/c
jib
Jib bearing
centre
Outreach (m)
Min. jib
outreach
Max. jib
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

respective winch movement before the spooling of
the rope on the drum has been damaged. The
adjoining figures show the arrangement of the wire
sensing device with built-in switch. When the wire
slackens the motion is stopped by means of a short
ramp time. The spring-loaded pressure roll forces the
wire towards the wire drum, at the same time swinging
the arm to actuate the built-in switch.
Run the hoisting wire block/swivel slowly against the

jib top and lift the jib, to cause the luffing wire to slacken.
The hoisting winch shall then stop. Some cranes are
equipped with safety switches to prevent the block
from touching the jib. This safety switch must be made
inoperative. Lower the hoisting wire block/swivel so
that the luffing wire rope is taut. Check that the switch
returns properly.
The slack wire function is approved as long as the

wire is spooling properly on the drum.
Functional test, hoisting
Lower the hook block on to the deck to slacken the
hoisting wire rope. Hoist the hook in order to check
that the switch returns properly.
Note! The slackwire device is not designed to detect

slack in the rope at the position of the lifting block. It
will only detect slack at winch.
The lifting block may lay flat on the ground/deck and
the slack wire device may still not be activated.
This is most evident at minimum outreach. In these
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.
Note! The surveyor has to fill in and undersign the
form on page 2.
- Start the crane with pushbutton S13, START/STOP.

- 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"
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.
09
10
19
20
11
IO_C1
SL_C1
AU_C1
SL_A1
AU_A1
IO_A1
485.1
SSI
Sp
SSI
IO_C2
AU_C2
SL_C2
C2
IO_A2
AU_A2
C1
A2
A3T
IO_485.1
SL_485.1
Input/Output
A1
C2
485.1
Sp
SSI
IO
C1
A2
A3T
AU_485.1
SL_A2
Sp
SP
Output
36
43
37
45
33
39
34
40
31
30
32
Sw19
Sw20 55
14 Sw14
56 Sw56
15 Sw15
27
59
29
17
53
18
54
A1
485.1
SL_A3
IO_C3
LU_A1
LU_A2
LU_A3
SSI
Sp
MP
Input
08
AU Auxiliary
C2
A3T
SL_Sp
SSI
Error
07
12
26
58
49
51
52
57
Com
C1
A2
485.1
LU_Sp
SC_C3
SC_C1
HO_C1
SC_A1
HO_A1
SC_C2
Sp
SSI
HO_C2
IO_C4
SC_A2
SC_C4
HO_A2
SC_485.1
SC_A3
HO_A3
SC_485.2
IO_485.2
Sp
IO_485.3
SC_485.3
485.3
A1
C2
A2
A3T
SP
31
30
32
Sw19
Sw20 55
14 Sw14
56 Sw56
15 Sw15
27
59
29
17
53
18
54
SL Slewing
C1
A1
C2
485.1
A3T
09
10
19
20
11
Output
36
43
37
45
33
39
34
40
08
Com
LU Luffing
C1
A2
C2
485.1
SC_Sp
485.3
HOHoisting
A1
C1
A2
HO_Sp
A1
A3T
485.2
MP
Input
07
Com
HO_485.1
SC Supervisory
C4
C4
SC_SSI
IO
C3
C3
485.2
Error
12
26
58
49
51
52
57
IO_A3
31
30
32
Sw19
Sw20 55
14 Sw14
56 Sw56
15 Sw15
27
59
29
17
53
18
54
AU_A3
09
10
19
20
11
Output
36
43
37
45
33
39
34
40
08
Com
SC
SP
Input
07
IO_Sp
Error MP
12
26
58
49
51
52
57
IO_SSI
SP
Output
36
43
37
45
31
30
32
Sw19
Sw20 55
14 Sw14
56 Sw56
15 Sw15
27
59
29
17
53
18
54
AU_Sp
09
10
19
20
11
SL_SSI
33
39
34
40
08
AU_SSI
MP
Input
07
LU_C1
Error
12
26
58
49
51
52
57
LU_C2
SP
Output
27
28
29
30
31
32
33
34
35
36
37
38
39
40
53
61
LU_485.1
MP
Input
07 18
08 19
09 20
10 26
11 49
12 51
13 56
14 57
15 58
16 59
17 60
24V
Com
LU_SSI
Error
HO_SSI
WARNING!
During the overload test the load limits increase and
the crane can lift a specified per cent more than the
safe working load. Inappropriate use may cause severe
damage to the crane and bodily injury.
Key switch
Fig. 1. Key switch in cabinet CT2.
Fig. 2. Login window overload test.
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
2 (2)
Date
Classification
Signatur
Clarification of signature
SERVICE
6.324.2 E rev.: - 2010-11-10
Preparation for Rig Mode

WARNING!
WARNING!
Operation in Rig mode is only permitted together with
below intructions:
- Absolute Encoder Calibration, CC3000
- Rope Reeving Diagram
- Limit Switches and Software Limits
- Replacement of Wires
NOTE! The password is the last four digits of the

crane's manufacturing No., which can be found in
the instruction manual or on 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 "RIGGING" and the
diagram shows only a red line. See Fig. 3.
NOTE! Motions are speed reduced in Rig mode. To
exit Rig mode the crane has to be stopped and the
key switch must be set to position "Normal".
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.
Key switch
Fig. 1. Key switch in cabinet CT2.
Fig. 2. Login window.
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!
Make sure that no persons are within the working
area of the crane when the crane is emergency
operated.
WARNING!
You must only use the specified emergency hand
pump.
For reference see hydraulic circuit diagram in section

9.4 in the parts manual. All hydraulic components in
this instruction can be found in the diagram.
The brake opens at approximately 6 - 13 bar (0.6 - 1.3
MPa). The pressure is changing because of the load
in the hook.
3
2
CAUTION!
After an emergency operation, slewing motion, hoisting 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 emergency operation.
6
IMPORTANT!
- This work has to be done with great care by skilled
personnel.
- You can only operate one motion at a time.
- Valves 1663, 2661 and 3661 must not be operated
except in an emergency brake release situation.
Introduction
This instruction describes how to do an emergency
operation in case of a complete power failure. The
slewing, luffing and hoisting motion may be operated
to a limited extent by releasing their respective brakes
with the hand pump.
1.
2.
3.
4.
5.
6.
7.
8.
9.
7
8
Handle
Pressure relief valve
Safety valve
Air filter, oil filling
Pressure gauge
Oil tank
Plug with o-ring, in holder
Pressure relief valve (must be closed)
Quick coupling
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

o-ring must be removed from the oil filling connection
and be replaced by the plastic air filter from holder,
see Fig. 1. The plug with the o-ring can be placed in
the holder.
When lowering with hand pump there is risk for

overheating the brake discs. That can cause loss of
brake force. The winch drums must not be turned
more than one revolution in one minute.
Wait for five minutes for the brake discs to cool down
before starting the next turn of the winch drum.
To have control of the turn of the winch drum, the
winch frame and drum flange can be marked with
tape, see Fig. 2.
During transportation the plastic air filter must be replaced with the plug with the o-ring and installed at
oil filling connection to avoid oil leakage and filter
contamination.
2
The pressure relief valve must be closed during
emergency operation, see Fig. 1. If the valve is open
it is not possible to get hydraulic pressure to open
and close the brakes during the emergency operation.
Function test of the hand pump
C-00253
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 decrease. Continue with pump strokes until the pressure 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.
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
WARNING!
Risk of bodily injury. May only be operated by authorized personnel. Operate with great care.
CAUTION!
If the crane tilts, release the brakes with great caution.
- Turn the crane in low speed.
- Make sure that the brake closes between each
pump stroke.
Operation
- Push safety valve, see Fig. 1. Release the safety
valve to quickly brake the slewing gears at any time.
- Release the brake by pumping oil from the hand
pump. The crane may now be slewed to position
with the help of another crane. Be careful.
After operation
- Open ball valve 3661 and remove the hose from the
quick coupling 3662.
Connection
- Connect the hose from the hand pump to quick
coupling 3662. See Fig. 3.
- Close ball valve 3661.
C-00250
2
1
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
WARNING!
WARNING!
The hoisting winch drum must only be emergency
operated/lowered for one minute, then it must be
stopped for five minutes. The brake discs can be
overheated and loss of brakeforce can cause load
drop.
Connection
coupling 1662 on the hoisting winch, see Fig. 4.
Lower the load

To prevent overheated brake discs and loss of brake
force the emergency lowering of the load must be

stopped in intervals of five minutes.
In tropical conditions the stops must be longer than
five minutes. The brake discs can be cooled down with
compressed air.
valve to quickly brake the winch at any time.
- Carefully pump with the handle until the hoisting
winch drum moves. The load must be lowered slowly and the brake must close between each pump
stroke.
- Lower the load by turning the hoisting winch drum
one revolution during minimum one minute, see Fig.
2.
- After one revolution wait for five minutes for the
brake discs to cool down, then continue lowering.
After operation
- Open ball valve 1661.
- Remove the hose from the quick coupling 1662.
C-00251
2
1
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
WARNING!
WARNING!
The luffing winch drum must only be emergency
operated/lowered for one minute, then it must be
stopped for five minutes. The brake discs can be
overheated and loss of brakeforce can cause load
drop.
Connection
coupling 2662 on the luffing winch, see Fig. 5.
Lower the jib

To prevent overheated brake discs and loss of brake
force the emergency lowering of the load must be

stopped in intervals of five minutes.
In tropical conditions the stops must be longer than
five minutes. The brake discs can be cooled down
with compressed air.
valve to quickly brake the winch at any time.
- Carefully pump with the handle until the luffing
winch drum moves. The load must be lowered
slowly and the brake must close between each
pump stroke.
- Lower the load by turning the hoisting winch drum
one revolution during minimum one minute, see
Fig. 2.
- After one revolution wait for five minutes for the
brake discs to cool down, then continue lowering.
After operation
- Open ball valve 2661.
- Remove the hose from the quick coupling 2662.
1
C-00252
2
1
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.
- Log
information about
allowing future analysis.
crane
Three examples
equipments.
of
different
cranes
and
operations,
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.: -
Icons
2010-11-10
If an arrow goes yellow the motion is speed

reduced by CC3000.
Standard crane
GLH crane operating Main
Hoist
GLH crane operating Whip
Hoist
The small white ball on the hoisting joystick

indicates the speed of the hoisting winch. During
operation, the ball will move along the hoisting
circle, to indicate the direction and movement when
hoisting or lowering. Hoisting is indicated by a
clockwise
rotation
and
lowering
by
a
counterclockwise rotation.
Crane with ELCCL

Different modes depend on type of crane and
equipment. If there is a mode it shows centered on
top level of the screen.
Ton in hook
The current date and time is displayed in UTC

time.
The current load in the hook. If the value exceeds

the overload limit the box background will flash in
red and an audio warning is also given. The
overload information is indicated by CC3000.
The MacGREGOR logo is displayed. When

touching the logo, version information will be
displayed.
Optional
Visual warning with or without alarm sound can be
configured by CC3000 parameter. This warning
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.
Joystick, hoisting with high and low

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

operating the crane. When an operation is not
permitted by CC3000 a white cross will over cross
the corresponding arrow.
The current jib outreach
When reached the limit the box will flash in yellow.

The current
hoisting/lowering speed
The current lifting height
The current
hoisting/lowering speed
together with current
lifting height
2 (6)
7.075.11 E rev.: List
2010-11-10
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.
Anti-collision (optional)
Standard mode
Buttons to switch different modes.
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 anticollision 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
When a dialog box needs input, a keyboard shows
on the screen.
Date, time and the copy logs. This is the same

diaolog box that shows for users.
Second button
4 (6)
7.075.11 E rev.: -
2010-11-10
Eighth button
2. User (bottom left corner)
Third button
Tap the bottom left corner and a password dialog

box shows. Enter the user password (set to 1111)
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
COMPATIBILITY .............................................................................................................................................. 2
THE INSTALLATION AND SERVICE .............................................................................................................. 2
THE CONNECTION OF PERIPHERAL DEVICES........................................................................................... 2
CODE DATA ..................................................................................................................................................... 2
THE SERVICE AND PROTECTION INSTRUCTIONS..................................................................................... 2
DISPLAY UNIT ................................................................................................................................................. 3

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

8.1
8.2
8.3
THE DISPLAY IS DARK OR DIM ........................................................................................................................ 4

SERIAL PORT FAULTS ................................................................................................................................... 4
LED IS BLINKING RED BUT PROGRAM DOESNT START .................................................................................... 4
TECHNICAL DATA .......................................................................................................................................... 4
1 (4)
7.076.2 E rev.: c 2009-06-29
Compatibility
The display is compatible with Windows CE and Linux.
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.
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.
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.
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, rnskldsvik,
Sweden.
2 (4)
7.076.2 E rev.: c
2009-06-29
Display unit
1
2
3
4
5
X1
X2
X8
X5
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
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
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.
Technical Data
This display is especially developed for use of heavy machinery, which guarantees system durability and flexible
expandability to the different applications.
Kernel
Processor Intel XScale, 533 MHz
Compact Flash 32 MB -> commercially available
Kernel Flash 32/ 64 MB
RAM -> 256 MB SDRAM
Graphic controller Silicon motion, 8 MB RAM
Interfaces
2 x CAN 2.0B, ISO 11898 24V,1 Mbit
2 x Ethernet 10/100 Base-T
2 x USB 2.0
RS232 OPTION. 115000 baud, replaces
Keyboard & Mouse Via USB
Display
10.4 SVGA 800x600 TFT
Backlight CCFL ~400 nit
Touch screen Resistive
Mechanical
Enclosure Aluminum
Mounting Stand
Connectors DIN M12
4 (4)
Power
Voltage 10 - 36 VDC
Current < 500 mA at 24 VDC (6.5)
Environment
IP-class IP65
Temperature range -40 C - +65 C (operating)
-40 C - +70 C (storage)
EMC conformity In accordance with 89/336/EEC:
EN 50081-2: 1993
Software
Operating system: Windows CE 5.0
Internal control
Status LED In front panel
Photo diode Automatic backlight control
Internal temperature protection against overheating
in abnormal ambient conditions.
Dimensions
Screen size:
Depth:
Height:
Width:
10.4
40 mm
217 mm
285 mm
EXTRA EQUIPMENT
7.082.1 E rev.: - 2009-01-15
Installation of Maintenance Platform on Foundation

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

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)
Cargotec Sweden AB
MacGregor Cranes
Sjgatan 4G
Telephone: 46 - 660 - 29 40 00
Telefax:
46 - 660 - 139 77
www.cargotec.com
Spare Parts Manual
9.0
How to order
spare parts
9.1
Machinery
9.2
Pump unit
Oil cooler
9.3
Mechanical
equipment
9.4
Hydraulic
components
9.5
Electric
components
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.: ......................................................
M/V ........................................................
IMO /Lloyd's no.: ..............................................
Crane type: .............................................
Serial no: .........................................................
Crane place: ...........................................
Our ref.: ..........................................................
Re:
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
HOISTING WINCH
1212912
625-1450.212
Weight 3.300 kg
Date
Group
Fig.
Page
2012-01-18
9.1
625-1450.212
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2012-01-18
9.1
625-1450.212
2 (2)
HOISTING WINCH
Item
000
Qty
Article no
1212912
Description
HOISTING WINCH
Supplementary data
PARTS MANUAL
LUFFING WINCH
1187739
625-1450.184 /0
Weight 1.490 kg
Date
Group
Fig.
Page
2010-12-16
9.1
625-1450.184
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2010-12-16
9.1
625-1450.184
2 (2)
LUFFING WINCH
Item
Qty
000
Article no
1187739
Description
LUFFING WINCH
Supplementary data
PARTS MANUAL
Date
Group
Fig.
Page
2008-05-14
9.1
625-2250.022
1 (2)
WINCH MOUNTING SET
10
800 Nm
3
9
800 Nm
10
5
6
9
289 5365-801
625-2250.022
800 Nm
PARTS MANUAL
Date
Group
Fig.
Page
2008-05-14
9.1
625-2250.022
2 (2)
WINCH MOUNTING SET

Item
Qty
Article no
Description
Supplementary data
000
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
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.
PARTS MANUAL
Date
Group
Fig.
Page
2010-12-17
9.1
625-1440.195
1 (2)
ASSEMBLY SET
2
1
277 Nm
1192483
625-1440.195
PARTS MANUAL
Date
Group
Fig.
Page
2010-12-17
9.1
625-1440.195
2 (2)
ASSEMBLY SET
Item
Qty
Article no
Description
000
1192483
ASSEMBLY SET
001
2121 2030-629
. SCREW
002
487 2826-002
. WASHER
Supplementary data
M6S 16 x 45 -10.9; DIN 933
PARTS MANUAL
Date
Group
Fig.
Page
2010-12-17
9.1
625-1440.196
1 (2)
ASSEMBLY SET
2
1
277 Nm
1192647
625-1440.196
PARTS MANUAL
Date
Group
Fig.
Page
2010-12-17
9.1
625-1440.196
2 (2)
ASSEMBLY SET
Item
Qty
Article no
Description
000
1192647
ASSEMBLY SET
001
2121 2030-630
. SCREW
002
487 2826-002
. WASHER
Supplementary data
M6S 16 x 50 -10.9
PARTS MANUAL
Date
Group
Fig.
Page
2010-09-22
9.1
625-3254.029
1 (2)
ASSEMBLY SET
275 Nm
1
2
1 dl
1192648
625-3254.029
PARTS MANUAL
Date
Group
Fig.
Page
2010-09-22
9.1
625-3254.029
2 (2)
ASSEMBLY SET
Item
Qty
Article no
Description
000
1192648
ASSEMBLY SET
001
2121 2030-628
. SCREW
002
487 2826-002
. WASHER
003
1263 2078-001
. MOLYKOTE 1000
Supplementary data
M6S 16 x 40 - 10.9; DIN 933
Solid lubricant paste
PARTS MANUAL
Date
Group
Fig.
Page
2010-09-28
9.1
625-3256.016
1 (2)
DRIVE IN, COMPLETE
46 Nm
19
1000000279439
312
22
20
311
10
11
26
25
16
15
80 Nm
321 322
15
27
21
12
46 Nm
28
30
6
Disc arrangement,
item 321 + 322
Center line
Inner discs
Outer discs
Motor side
Gear side
9
875 13004-157
625-3256.016 /0
Weight 50 kg
13
14
PARTS MANUAL
Date
Group
Fig.
Page
2010-09-28
9.1
625-3256.016
2 (2)
DRIVE IN, COMPLETE

Item
Qty
Article no
Description
Supplementary data
000
875 13004-157
. DRIVE IN, COMPLETE
003
875 13027-056
. MOTOR FLANGE
004
12
2121 2532-513
. SCREW
005
875 13011-002
. BEARING
006
875 13012-003
. CIRCLIP
007
875 13012-004
. CIRCLIP
008
875 13012-019
. CIRCLIP
009
875 13007-003
. SHAFT SEALING
010
875 13014-037
. SHIM
011
875 13003-001
. PRESSURE UNIT
012
875 13028-002
. DISC CARRIER
013
875 13007-001
. SEALING
014
875 13006-002
. PLUG
015
875 13007-008
. SEALING
016
875 13006-004
. PLUG
M18
019
875 13008-011
. VENTILATION FILTER
M10
020
875 13010-020
. COUPLING
021
875 13005-001
. OIL SIGHT GLASS
M22
022
875 13008-016
. VENTILATION FILTER
M12; 0.2 bar
025
875 13023-014
. COVER
026
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
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
875 13001-001
. MULTIPLE DISC, OUTER
Change all 16 discs at the same time.
322
875 13001-002
. MULTIPLE DISC, INNER
Change all 16 discs at the same time.
MC6S 10x110 -8.8 FZB; DIN 912
M22
PARTS MANUAL
Date
Group
Fig.
Page
2007-11-23
9.1
625-3254.023B
1 (2)
1
3
391 0246-801
625-3254.023
275 Nm
PARTS MANUAL
Date
Group
Fig.
Page
2007-11-23
9.1
625-3254.023B
2 (2)

Item
Qty
000
001
002
24
003
Article no
391 0246-801
Description
Supplementary data
. SLEWING GEAR
See mechanical specification
2121 2030-632
. SCREW
M6S 16 x 60 -10.9
24
487 2311-005
. WASHER
005
487 7218-002
. NIPPLE
006
2152 2151-178
. SEALING
PARTS MANUAL
Date
Group
Fig.
Page
2010-09-24
9.1
625-3255.040
1 (2)
SLEWING GEAR
109 110
1189838
625-3255.040 /0
Weight 225 kg
PARTS MANUAL
Date
Group
Fig.
Page
2010-09-24
9.1
625-3255.040
2 (2)
SLEWING GEAR
Item
Qty
000
003
Article no
Description
Supplementary data
1189838
SLEWING GEAR
MODULE 14
875 13004-157
. DRIVE IN, COMPLETE
SEE FIG. 625-3256.016
109
875 13007-001
. SEALING
110
875 13006-001
. PLUG, MAGNETIC
M22
PARTS MANUAL
Date
Group
Fig.
Page
2012-01-19
9.2
625-4935.245A
1 (2)
BRAKE PUMP UNIT
2
1
1219768
625-4935.245 /A
PARTS MANUAL
Date
Group
Fig.
Page
2012-01-19
9.2
625-4935.245A
2 (2)
BRAKE PUMP UNIT

Item
Qty
Article no
Description
000
1219768
BRAKE PUMP UNIT
001
1224554
. LEVEL AND TEMP. SENSOR
002
1224683
. OIL FILTER
003
1224684
. PRESSURE SWITCH
004
1224690
. DIRECTIONAL VALVE
Supplementary data
PARTS MANUAL
Date
Group
Fig.
Page
2012-01-19
9.3
625-6102.580
1 (4)
30 22
23
29
35
12
35
CT14
CT13
17 18 19 40
110 109
36 37
4
33
14
35
5
CT2
31
13
CT1
35
7
CT10
16 39
38 15
31
1219977
625-6102.580
PARTS MANUAL
Date
Group
Fig.
2012-01-19
9.3
625-6102.580

Item
Qty
000
003
004
005
Article no
1219977
Description
Supplementary data
. SLEWING BEARING MOUNTING
SEE SLEWING SPECIFICATION
. WINCH MOUNTING SET
SEE FIG. 625-2250.022
. HOISTING WINCH ASSEMBLY
SEE MECHANICAL SPECIFICATION
006
. LUFFING WINCH ASSEMBLY
007
. JIB BEARING MOUNTING
012
1189584
. CABIN ASSEMBLY CRANE HOUSE
SEE FIG. 625-6540.042
013
289 5323-801
. LIMIT SWITCHES BOX
SEE FIG. 625-6245.635
014
289 5449-801
. LIMIT SWITCHES BOX
SEE FIG. 625-6245.643
015
1192647
. ASSEMBLY SET
SEE FIG. 625-1440.196
016
1192483
. ASSEMBLY SET
SEE FIG. 625-1440.195
017
1192648
. ASSEMBLY SET
SEE FIG. 625-3254.029
018
. SLEWING GEAR ASSEMBLY
SEE HYDRAULIC SPECIFICATION
019
. SLEWING GEAR ASSEMBLY SET
SEE FIG. 625-3254.023
022
. CRANE TOP MOUNTING
023
390 7581-801
. PROTECTIVE PLATE MOUNT.
SEE FIG. 625-6459.051
029
390 3274-801
. COVER MOUNTING
SEE FIG. 625-6169.005
031
1191997
. ENCODER ASSEMBLY
SEE FIG. 624-2180.018
033
. OIL TANK ASSEMBLY
SEE HYDRAULIC SPECIFICATION
035
. ELECTRICAL CABINET
SEE TABLE OF CONTENCE SECTION
036
. VENTILATION FAN ASSEMBLY
SEE FIG. 625-6625.027
037
. VENTILATION FAN
SEE TABLE OF CONTENTS SECTION
038
. ELECTRIC MOTOR
039
. ELECTRIC MOTOR
289 5365-801
391 0246-801
1192902
Page
2 (4)
PARTS MANUAL
Date
Group
Fig.
Page
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
36 37
4
33
14
35
5
CT2
31
13
CT1
35
7
CT10
16 39
38 15
31
1219977
625-6102.580
PARTS MANUAL
Date
Group
Fig.
2012-01-19
9.3
625-6102.580

Item
Qty
Article no
Description
Supplementary data
040
. ELECTRIC MOTOR
109
289 3393-801
. SLACK WIRE DEVICE, MOUNT.
110
289 3396-801
.. SLACK WIRE DEVICE
SEE FIG. 625-6250.023
Page
4 (4)
PARTS MANUAL
Date
Group
Fig.
Page
2011-11-21
9.3
625-6122.029A
1 (2)
CRANE
FOUNDATION
490 6432-801
625-6122.029
PARTS MANUAL
Date
Group
Fig.
Page
2011-11-21
9.3
625-6122.029A
2 (2)
Item
Qty
Article no
Description
Supplementary data
000
490 6432-801
001
289 5663-801
. SLEWING BEARING
10 x greasing nipples. Ball bearing
004
391 0032-801
. SLEWING BEARING MOUNTING
SEE FIG. 625-6123.003
005
391 0033-801
. SLEWING BEARING YARD MOUNTING
SEE FIG. 625-6124.003
PARTS MANUAL
391 0032-801
625-6123.003
Date
Group
Fig.
Page
2011-11-18
9.3
625-6123.003
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2011-11-18
9.3
625-6123.003
2 (2)

Item
Qty
Article no
Description
Supplementary data
000
391 0032-801
002
99
390 9268-010
. STUD
M30x265: Special requirements
003
99
2121 2039-130
. NUT
M6M 30; Special requirements
PARTS MANUAL
391 0033-801
625-6124.003
Date
Group
Fig.
Page
2011-11-18
9.3
625-6124.003
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2011-11-18
9.3
625-6124.003
2 (2)

Item
Qty
Article no
Description
000
391 0033-801
001
100
390 9268-011
. STUD
002
100
1205600
. WASHER
003
100
2126 2039-130
. NUT
Supplementary data
M30x300; Special requirements.
M6M 30; Special requirements.
PARTS MANUAL
COVER MOUNTING
Date
Group
Fig.
Page
2010-05-24
9.3
625-6169.005A
1 (2)
PARTS MANUAL
Date
Group
Fig.
2010-05-24
9.3
625-6169.005A
COVER MOUNTING
Item
Qty
Article no
Description
Supplementary data
000
390 3274-801
COVER MOUNTING
001
390 3282-801
. COVER ASSEMBLY
SEE FIG. 625-6169.006
002
2121 2034-455
. SCREW
M6S 8 x 30 -A4 -80
003
2151 2027-164
. WASHER
RB 8.4 x 16 -A4
004
2126 2634-118
. LOCKING NUT
M6M 8 -A4-80
Page
2 (2)
PARTS MANUAL
COVER ASSEMBLY
Date
Group
Fig.
Page
2003-01-30
9.3
625-6169.006
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2003-01-30
9.3
625-6169.006
2 (2)
COVER ASSEMBLY
Item
Qty
Article no
Description
Supplementary data
000
390 3282-801
COVER ASSEMBLY
001
390 3282-001
. COVER
002
389 1581-802
. HANDLE
003
1856 2160-001
. SEAL STRIP
004
389 1903-004
. HINGE
005
2121 2034-451
. SCREW
M6S 8 x 20 -A4-80
006
2151 2027-164
. WASHER
RB 8.4 x 16 -A4
007
2126 2634-118
. NUT
M6M 8 -A4-80
L= 2010
PARTS MANUAL
Date
Group
Fig.
Page
2010-04-21
9.3
625-6170.082
1 (2)
JIB BEARING HOUSING
10
2
12
5
3
11
1
6
11
3
12
2
1184754
625-6170.082
PARTS MANUAL
Date
Group
Fig.
Page
2010-04-21
9.3
625-6170.082
2 (2)
JIB BEARING HOUSING

Item
Qty
Article no
Description
Supplementary data
000
1184754
JIB BEARING HOUSING
001
1184753
. BEARING HOUSING
002
388 9574-001
. RING
003
388 9575-001
. WASHER
004
24
487 2826-002
. WASHER
005
489 3362-001
. CLIP
006
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
2152 2115-543
. O-RING
012
2186 2187-170
. V-RING
PARTS MANUAL
Date
Group
Fig.
Page
2010-07-17
9.3
625-6170.085
1 (2)
Notice!
Shaft must be mounted correctly,
grease holes towards jib in 45.
See punchmark on shaft.
45
2
Punchmarks
235 Nm
6
3
4
5
7
7
1
1191812
625-6170.085
PARTS MANUAL
Date
Group
Fig.
Page
2010-07-17
9.3
625-6170.085
2 (2)

Item
Qty
Article no
Description
000
1191812
001
1191825
. JIB BEARING SHAFT
002
1184754
. JIB BEARING HOUSING
003
12
487 2826-002
. WASHER
004
1191826
. PLATE
005
490 3578-001
. SPACER
006
12
2121 2030-630
. SCREW
007
2152 2115-529
. O-RING
008
2545 2110-003
. GREASE NIPPLE
Supplementary data
SEE FIG. 625-6170.082
M6S 16 x 50 -10.9
AM 10 x 1 -A2-50
PARTS MANUAL
Date
Group
Fig.
Page
2011-02-17
9.3
625-6244.077
1 (2)
JIB TOP MOUNTING
18
22
10
10
10
10
10
10
12
22
8
9
18
1195433
625-6244.077
PARTS MANUAL
Date
Group
Fig.
Page
2011-02-17
9.3
625-6244.077
2 (2)
JIB TOP MOUNTING

Item
Qty
Article no
Description
Supplementary data
000
1195433
JIB TOP MOUNTING
006
390 4860-001
. SHAFT
008
1185110
. DISTANCE
009
489 5334-002
. LOCK WASHER
010
490 4086-801
. WIRE SHEAVE
012
1185111
. DISTANCE
018
2121 2034-628
. SCREW
M6S 16 x 40 -A2-70
022
2545 2110-003
. GREASE NIPPLE
AM 10 x 1 -A2-50
PARTS MANUAL
Date
Group
Fig.
Page
2011-12-07
9.3
625-6245.635B
1 (2)
LIMIT SWITCHES BOX
22
26
27
23 24
31
14 15
1
2
3
4
5
6
16 17
32
18 19 20 21
25
289 5323-801
625-6245.635 /B
PARTS MANUAL
Date
Group
Fig.
Page
2011-12-07
9.3
625-6245.635B
2 (2)
LIMIT SWITCHES BOX

Item
Qty
Article no
Description
Supplementary data
000
289 5323-801
LIMIT SWITCHES BOX
001
875 15017-012
. CAM DISC WITH ARM, COMPLETE
30 - 55
002
875 15017-012
30 - 55
003
875 15017-012
30 - 55
004
875 15017-012
30 - 55
005
875 15017-013
55 - 100
006
875 15017-013
55 - 100
014
875 15001-001
. MICRO SWITCH
1A
015
875 15001-002
. THREADED STUD WITH NUTS
M3. Cut to right length.
016
875 15003-023
. COVER, COMPLETE
Incl. screws and sealing.
017
875 15003-002
.. SEALING
L = 2000 mm
018
2121 2034-457
.. SCREW
M6S 8 x 35 -A2-70
019
2126 2034-118
.. NUT
M6M 8 - A2-70
020
2151 2027-164
.. WASHER
BRB 8.4 x 16 -A2
021
2126 2432-118
.. CAP NUT
MHM 8 -6 FZB
022
875 15012-013
. WORM GEAR, COMPLETE
Incl. screws. Ratio 50:1.
023
875 15006-008
. SHAFT COUPLING, COMPLETE
024
875 15008-005
. KEY
025
875 15002-003
. CABLE GLAND WITH NUT
026
875 15009-003
. SCREW
027
875 15006-013
. SHAFT
031
ENCODER
Ordered separately.
032
ENCODER
Ordered separately.
4 x 4 x 16
T6SS 4 x 6 -A2
PARTS MANUAL
Date
Group
Fig.
Page
2007-12-13
9.3
625-6245.643
1 (2)
LIMIT SWITCHES BOX
22
33
23 24
32
1
14 15
2
3
4
16 17
5
6
7
8
18 19 20 21
9
289 5449-801
625-6245.643 /0
25
31
10
PARTS MANUAL
Date
Group
Fig.
Page
2007-12-13
9.3
625-6245.643
2 (2)
LIMIT SWITCHES BOX

Item
Qty
Article no
Description
Supplementary data
000
289 5449-801
LIMIT SWITCHES BOX
001
875 15017-008
30 - 55
002
875 15017-009
55 - 100
003
875 15017-009
55 - 100
004
875 15017-008
30 - 55
005
875 15017-008
30 - 55
006
875 15017-010
100 - 175
007
875 15017-010
100 - 175
008
875 15017-010
100 - 175
009
875 15017-011
175 - 290
010
875 15017-011
175 - 290
014
10
875 15001-001
. MICRO SWITCH
1A
015
875 15001-002
. THREADED STUD WITH NUTS
M3. Cut to right length.
016
875 15003-028
. COVER, COMPLETE
Incl. screws and sealing.
017
875 15003-002
.. SEALING
L = 2000 mm
018
2121 2034-457
.. SCREW
M6S 8 x 35 -A2-70
019
2126 2034-118
.. NUT
M6M 8 - A2-70
020
2151 2027-164
.. WASHER
BRB 8.4 x 16 -A2
021
2126 2432-118
.. CAP NUT
MHM 8 -6 FZB
022
875 15012-005
. WORM GEAR, COMPLETE
Incl. screws. Ratio 50:1.
023
875 15006-008
. SHAFT COUPLING, COMPLETE
024
875 15008-002
. KEY
025
875 15002-002
. CABLE GLAND WITH NUT
031
875 15018-001
. PLAIN BEARING
032
ENCODER
Ordered separately.
033
ENCODER
Ordered separately.
4 x 4 x 20
PARTS MANUAL
Date
Group
Fig.
Page
2009-06-15
9.3
625-6248.001B
1 (2)
PARTS MANUAL
Date
Group
Fig.
2009-06-15
9.3
625-6248.001B

Item
Qty
Article no
Description
Supplementary data
000
489 6415-801
002
2122 2519-378
. SCREW
MSK6SS 6 x 40 -A4
003
2151 2027-156
. WASHER
BRB 6.7 x 14 -A2
004
2126 2034-116
. NUT
NYLOC - M6M 6 -A4-80
Page
2 (2)
PARTS MANUAL
SLACK WIRE DEVICE
Date
Group
Fig.
Page
2004-10-13
9.3
625-6250.023
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2004-10-13
9.3
625-6250.023
2 (2)
SLACK WIRE DEVICE

Item
Qty
Article no
Description
Supplementary data
000
289 3396-801
SLACK WIRE DEVICE
001
288 2344-801
. SUPPORT
002
288 2345-801
. BRACE
003
288 2346-801
. BRACE
004
388 3290-004
. LIMIT SWITCH PART
005
489 5947-001
. SPRING
006
489 4601-001
. SCREW
007
489 4604-001
. SPACER
008
18
490 4586-001
. ROLLER
009
490 4587-001
. WASHER
010
490 4591-001
. SCREW
011
20
488 8518-014
. WASHER
012
489 6172-001
. SHAFT
013
2184 4024-546
. LINK SCREW
M12 x 80 FZB
014
2121 2032-544
. SCREW
M6S 12 x 60 -8.8 FZB
015
2121 2532-339
. SCREW
MC6S 5 x 40 -8.8 FZB
016
2121 2032-331
. SCREW
M6S 5 x 20 -8.8 FZB
017
2126 2032-122
. NUT
M6M 12 -8 FZB
018
2126 2636-124
. LOCKING NUT
M6M 16 -8 FZB; DIN 982
019
2151 2022-185
. WASHER
BRB 17 x 30 FZB
020
2151 2022-196
. WASHER
BRB 23 x 40 FZB
021
2114 2014-201
. SPLIT PIN
SP 4 x 40 -A4
022
5661 4116-512
. LIMIT SWITCH, HOISTING
023
5661 4126-001
. LIMIT SWITCH
PARTS MANUAL
Date
Group
Fig.
Page
2006-03-06
9.3
625-6275.004C
1 (2)
PARTS MANUAL
Date
Group
Fig.
2006-03-06
9.3
625-6275.004C

Item
Qty
Article no
Description
000
489 5409-801
001
388 7147-009
. SCREW
002
490 3816-008
. WASHER
Supplementary data
M6S 30 x 210 -10.9 spec.
Page
2 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2003-01-29
9.3
625-6404.001
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2003-01-29
9.3
625-6404.001
2 (2)

Item
Qty
Article no
Description
Supplementary data
000
390 3374-801
001
389 3943-001
. SHAFT
002
489 4345-003
. LOCKING PLATE
003
489 5334-002
. LOCK WASHER
17 SSt
006
2121 2034-624
. SCREW
M6S 16 x 30 -A4-80
PARTS MANUAL
Date
Group
Fig.
Page
2011-12-20
9.3
625-6404.003
1 (2)
7
1
6
3
1184729
625-8751.005
PARTS MANUAL
Date
Group
Fig.
Page
2011-12-20
9.3
625-6404.003
2 (2)

Item
Qty
Article no
Description
Supplementary data
000
1184729
001
389 3943-002
. SHAFT
002
489 4345-003
. LOCKING PLATE
003
489 5334-002
. LOCK WASHER
006
2121 2034-624
. SCREW
M6S 16 x 30 -A2-70
007
2545 2110-003
. GREASE NIPPLE
AM 10 x 1 -A2-50
PARTS MANUAL
Date
Group
Fig.
Page
2011-12-20
9.3
625-6404.004
1 (2)
LOAD CELL ASSEMBLY
1223123
625-6404.004
PARTS MANUAL
Date
Group
Fig.
Page
2011-12-20
9.3
625-6404.004
2 (2)
LOAD CELL ASSEMBLY

Item
Qty
Article no
Description
000
1223123
LOAD CELL ASSEMBLY
001
1190251
. LOAD CELL
002
1184729
. MOUNT. WIRELOCK JIB TOP
Supplementary data
SEE FIG. 625-6404.003
PARTS MANUAL
CRANE JIB MOUNTING
1195432
625-6408.120
Date
Group
Fig.
Page
2011-02-16
9.3
625-6408.120
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2011-02-16
9.3
625-6408.120
2 (2)
CRANE JIB MOUNTING

Item
Qty
Article no
Description
000
1195432
CRANE JIB MOUNTING
003
1195433
. JIB TOP MOUNTING
004
390 3374-801
. MOUNTING WIRE LOCK JIB TOP
Supplementary data
SEE FIG. 625-6404.001
PARTS MANUAL
Date
Group
Fig.
Page
2011-01-28
9.3
625-6459.074
1 (2)
CRANE TOP MOUNTING
18
25
15
13
2
19
16
7
7
7
9
16
19
10
17
12
20
25
25
14
7
1
16
11
25
1195405
625-6459.074
19
PARTS MANUAL
Date
Group
Fig.
Page
2011-01-28
9.3
625-6459.074
2 (2)
CRANE TOP MOUNTING

Item
Qty
Article no
Description
Supplementary data
000
1195405
CRANE TOP MOUNTING
001
289 1841-001
. SHAFT
002
289 1842-001
. SHAFT
007
490 4086-801
. WIRE SHEAVE
009
1184786
. SPACER
010
1184788
. SPACER
011
490 3620-001
. COVER
012
490 3621-001
. COVER
013
489 5223-001
. SPACER
014
489 4345-004
. LOCKING PLATE
015
489 5334-001
. LOCK WASHER
016
489 5334-002
. LOCK WASHER
017
2154 2233-192
. LOCK WASHER
018
2121 2034-495
. SCREW
M6S 10 x 30 -A2-70
019
2121 2034-628
. SCREW
M6S 16 x 40 -A2-70
020
2121 2034-672
. SCREW
M6S 20 x 40 -A2-70
025
2545 2110-003
. GREASE NIPPLE
A-M 10 x 1 -A2-50
PARTS MANUAL
390 7581-801
625-6459.051
Date
Group
Fig.
Page
2007-01-17
9.3
625-6459.051
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2007-01-17
9.3
625-6459.051
2 (2)

Item
Qty
Article no
Description
Supplementary data
000
390 7581-801
001
390 7582-001
. PROTECTIVE PLATE
002
2121 2034-542
. SCREW
M6S 12 x 50 -A2 -70
003
2151 2054-178
. WASHER
TBRSUB 13 x 36 FZB
004
2126 2634-122
. NUT
M6M 12 -A2 -70
PARTS MANUAL
INCLINOMETER, C
Date
Group
Fig.
Page
92-02-19
9.3
625-6509A
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
92-02-19
9.3
625-6509A
2 (2)
INCLINOMETER, C
Item
Qty
Article no
Description
Supplementary data
000
388 0176-801
INCLINOMETER, C
001
488 7233-001
. INCLINOMETER
002
2121 2254-378
. SCREW
MCS 6 x 40 -5.8 G
003
11
2126 2032-116
. NUT
M6M 6 -8 FZB
004
488 7511-001
. BRACKET
005
2151 2022-153
. WASHER
BRB 6.4 x 12 G
006
2121 2034-370
. SCREW
M6S 6 x 20 -A2-70
007
2151 2025-153
. WASHER
BRB 6.4 x 12 SSt
PARTS MANUAL
1189584
625-6540.042
Date
Group
Fig.
Page
2010-11-15
9.3
625-6540.042
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2010-11-15
9.3
625-6540.042
2 (2)

Item
Qty
Article no
Description
Supplementary data
000
1189584
001
1189585
. CABIN ASSEMBLY
002
489 5395-801
. BRACKET
003
489 5154-003
. SHAFT
004
488 9225-001
. WASHER
005
1189615
. RUBBER STRIP
007
2151 2027-192
. WASHER
RB 21 x 37 -A4
008
2114 2014-201
. SPLIT PIN
SP 4 x 40 A4
010
1234 2413-050
. LOCKING FLUID
243
SEE FIG. 625-6545.072
PARTS MANUAL
Date
Group
Fig.
Page
2010-09-27
9.3
625-6545.072
1 (2)
CABIN ASSEMBLY
48
16
57
39
4
42
5
59
56
50
47
35
16
41
20
21
24
13
1189585
625-6545.072
PARTS MANUAL
Date
Group
Fig.
Page
2010-09-27
9.3
625-6545.072
2 (2)
CABIN ASSEMBLY
Item
Qty
Article no
Description
Supplementary data
000
1189585
CABIN ASSEMBLY
004
289 2251-801
. CAB CUPOLA ASSEMBLY
SEE FIG. 625-6560.007
005
390 8573-801
. CAB DOOR ASSEMBLY
SEE FIG. 625-6546.008
013
390 4053-801
. EMERGENCY DOOR ASSY
SEE FIG. 625-6546.001
016
488 3152-801
. VENTILATOR, C
020
490 3825-001
. PLATE
021
12
489 3492-001
. SHIM
024
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
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
2151 2027-156
. WASHER
RB 6.7 x 14 -A4
059
39
2151 2027-173
. WASHER
RB 10.5 x 20 -A4
PARTS MANUAL
EMERGENCY DOOR ASSY
Date
Group
Fig.
Page
2002-06-26
9.3
625-6546.001
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2002-06-26
9.3
625-6546.001
2 (2)
EMERGENCY DOOR ASSY

Item
Qty
Article no
Description
Supplementary data
000
390 4053-801
EMERGENCY DOOR ASSY
001
390 4054-001
. WINDOW
002
389 1581-801
. HANDLE
003
489 5392-801
. HINGE
004
2121 2636-331
. SCREW
MFS 5 x 20 -A4-80
005
2126 2634-114
. NUT
M6M 5 -A4 -80
006
2151 2027-146
. WASHER
BRB 5.3 x 10 -A4
007
489 2006-801
. EYE BOLT WITH WIRE
008
1236 2135-021
. SEALING COMPOUND
PARTS MANUAL
CAB DOOR ASSEMBLY
Date
Group
Fig.
Page
2006-10-30
9.3
625-6546.008
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2006-10-30
9.3
625-6546.008
2 (2)
CAB DOOR ASSEMBLY

Item
Qty
Article no
Description
000
390 8573-801
CAB DOOR ASSEMBLY
001
289 4337-001
. DOOR
003
390 8574-801
. DOOR LOCK
004
1856 2141-006
. RUBBER MOULDING
Supplementary data
L = 5310 mm
PARTS MANUAL
CAB CUPOLA ASSEMBLY
Date
Group
Fig.
Page
2009-06-29
9.3
625-6560.007A
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2009-06-29
9.3
625-6560.007A
2 (2)
CAB CUPOLA ASSEMBLY

Item
Qty
Article no
Description
Supplementary data
000
289 2251-801
. CAB CUPOLA ASSEMBLY
001
189 2327-001
. CAB CUPOLA
002
387 6167-803
. SLIDE WINDOW
003
388 0223-001
. GLASS
004
388 0145-002
. GLASS
005
388 0145-003
. GLASS
006
388 0145-004
. GLASS
007
289 2251-007
. RUBBER MOULDING
008
289 2251-008
. LOCKING LIST
009
488 7400-001
. HOLDER
010
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
1236 2273-001
. SEALING
PARTS MANUAL
WINDSCREEN CLEANER
Date
Group
Fig.
Page
2005-05-10
9.3
625-6561.001C
1 (2)
PARTS MANUAL
Date
Group
Fig.
2005-05-10
9.3
625-6561.001C
WINDSCREEN CLEANER
Item
Qty
Article no
Description
Supplementary data
000
387 6227-802
WINDSCREEN CLEANER
010
6179 2151-280
. WIPER MOTOR
011
387 6227-920
.. MOUNTING SET
For shaft 20
012
387 6227-916
.. MOUNTING SET
For shaft 16
030
6179 2153-700
. WIPER BLADE
L = 700 mm
090
6179 2152-600
. ARM
L = 600 mm
101
2126 2032-118
. NUT
M6M 8 -8 FZB
102
2154 2016-164
. SPRING WASHER
FBB 8,2 FZB
Page
2 (2)
PARTS MANUAL
VENTILATION FAN
390 2115-801
625-6625.014
Date
Group
Fig.
Page
2010-10-22
9.3
625-6625.014A
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2010-10-22
9.3
625-6625.014A
2 (2)
VENTILATION FAN
Item
Qty
000
Article no
390 2115-801
Description
VENTILATION FAN
Supplementary data
PARTS MANUAL
Date
Group
Fig.
Page
2010-09-30
9.3
625-6625.027
1 (2)
1192902
625-6625.027
PARTS MANUAL
Date
Group
Fig.
Page
2010-09-30
9.3
625-6625.027
2 (2)

Item
Qty
Article no
Description
Supplementary data
000
1192902
001
288 0945-801
. TUB FOR FAN
002
2121 2032-459
. SCREW
M6S 8 x 40 -8.8 FZB
003
20
2126 2636-118
. LOCKING NUT
M6M 8 -8 FZB; DIN 982
004
20
2151 2058-165
. WASHER
TBRSB 8.4 x 26 FZB
005
1236 2296-020
. SEAL STRIP
19 x 2
PARTS MANUAL
Date
Group
Fig.
Page
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
5
16
14
9
9
11
10
1205161
625-7013.126
Weight 1170 kg
PARTS MANUAL
Date
Group
Fig.
Page
2011-12-12
9.3
625-7013.126
2 (2)
LIFTING BLOCK
Item
Qty
Article no
Description
Supplementary data
SWL 36 tonnes.
000
1205161
LIFTING BLOCK
001
875 12401-022
. SHEAVE, COMPLETE
002
875 12054-004
.. BEARING
003
875 12062-003
.. LOCK RING
004
875 12009-007
. SPACER
005
875 12404-013
. SHAFT, COMPLETE
006
2545 2011-025
.. GREASE NIPPLE
007
875 12413-010
. SWIVEL, COMPLETE
008
2545 2011-025
.. GREASE NIPPLE
009
875 12073-007
. SHACKLE
010
875 12001-027
. HOOK, COMPLETE
Incl.safty latch kit.
011
875 12064-003
.. SAFETY LATCH KIT
Incl. spring, screw, nut.
012
1227187
. PROTECTION CAP, COMPLETE
Incl. screws
013
875 12406-001
. SPACER, COMPLETE
Incl. spacer tube, screw, nut.
014
875 12409-011
. CABLE LEADER, COMPLETE
016
2183 2022-126
. LIFTING EYE BOLT
A-M10 x 1 FZB; DIN 71412
A-M10 x 1 FZB; DIN 71412
M20 FZV; DIN 580
PARTS MANUAL
Date
Group
Fig.
Page
2011-03-09
9.4
625-7207.018
1 (2)
VALVE UNIT
18
18
1
1204092
625-7207.018
PARTS MANUAL
Date
Group
Fig.
Page
2011-03-09
9.4
625-7207.018
2 (2)
VALVE UNIT
Item
Qty
Article no
Description
000
1204092
VALVE UNIT
001
187 8727-001
. VALVE BLOCK
002
1204093
. DIRECTIONAL VALVE
003
387 7053-803
. PRESSURE SWITCH, C
006
2121 2541-378
. SCREW
018
2541 4129-113
. BALL VALVE
Supplementary data
SEE FIG. 625-7322.082
MC6S 6 x 40 -12.9
PARTS MANUAL
Date
Group
Fig.
Page
2011-03-10
9.4
625-7322.082
1 (2)
DIRECTIONAL VALVE
1204093
625-7322.082
PARTS MANUAL
Date
Group
Fig.
Page
2011-03-10
9.4
625-7322.082
2 (2)
DIRECTIONAL VALVE
Item
Qty
Article no
Description
000
1204093
DIRECTIONAL VALVE
001
489 6335-801
. COIL
002
489 6334-801
. GASKET SET
Supplementary data
PARTS MANUAL
PRESSURE SWITCH, C
Date
Group
Fig.
Page
87-02-19
9.4
625-7444
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
87-02-19
9.4
625-7444
2 (2)
PRESSURE SWITCH, C
Item
Qty
Article no
Description
000
387 7053-803
PRESSURE SWITCH, C
001
2152 2151-204
. SEAL RING
002
488 4933-001
. PLUG
Supplementary data
TM 130
PARTS MANUAL
Date
Group
Fig.
Page
2011-11-23
9.4
625-7951.007
1 (2)
ACCUMULATOR
1219345
625-7951.007
PARTS MANUAL
Date
Group
Fig.
Page
2011-11-23
9.4
625-7951.007
2 (2)
ACCUMULATOR
Item
Qty
Article no
Description
Supplementary data
Preload pressure 20 bar.
000
1219345
ACCUMULATOR
001
1226037
. REPAIR KIT
PARTS MANUAL
Date
Group
Fig.
Page
2003-06-10
9.4
625-7970G
1 (2)
HYDRAULIC HOSES
When ordering hydraulic hoses, see marking on each

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

Pressure - temperature - bending radius - damage caused by outside factors.
Sunlight and artificial light are also harmful to hydraulic hoses.
PARTS MANUAL
Date
Group
Fig.
Page
2012-01-23
9.4
625-7994.004
1 (2)
TUBING BRAKE
2
18
1219586
625-7994.004
PARTS MANUAL
Date
Group
Fig.
Page
2012-01-23
9.4
625-7994.004
2 (2)
TUBING BRAKE
Item
Qty
Article no
Description
Supplementary data
000
1219586
TUBING BRAKE
002
1204092
. VALVE UNIT
SEE FIG. 625-7207.018
003
1219345
. ACCUMULATOR
SEE FIG. 625-7951.007
018
2152 2151-178
. SEALING
PARTS MANUAL
Date
Group
Fig.
Page
2010-09-27
9.5
625-8563.069
1 (2)
DRIVERS DESK
14 72 73
9 10
15
11 12
4
2
3
13
6
1189978
625-8563.069
PARTS MANUAL
Date
Group
Fig.
Page
2010-09-27
9.5
625-8563.069
2 (2)
DRIVERS DESK
Item
Qty
Article no
Description
Supplementary data
000
1189978
DRIVERS DESK
002
390 8558-001
. DRIVER SEAT
003
1189898
. CONTROL PANEL
SEE FIG. 625-8597.057
004
414 6792-801
. CONTROLLER
SEE FIG. 625-8596
006
314 3980-801
. SIREN
007
5915 4262-002
. ARMATURE
60 W
008
5911 4145-060
. LAMP BULB
220 V 60 W E27
009
387 6227-802
. WINDSCREEN CLEANER
SEE FIG. 625-6561.001
010
388 9799-001
. COVER
011
5217 4837-240
. SCREW CONNECTION
012
5217 4838-240
. BULKHEAD HOUSING
013
314 4244-801
. CABIN HEATER
014
287 4867-002
. ARM REST
015
288 1058-001
. ARM REST
072
488 7461-001
. SIGN
073
488 6906-001
. SIGN
PARTS MANUAL
Date
Group
Fig.
Page
2011-11-27
9.5
625-8564.023
1 (2)
EL.INST.CRANE HOUSE
53 54
52
1212847
625-8564.023
PARTS MANUAL
Date
Group
Fig.
Page
2011-11-27
9.5
625-8564.023
2 (2)
EL.INST.CRANE HOUSE
Item
Qty
Article no
Description
Supplementary data
000
1212847
EL.INST.CRANE HOUSE
001
324 1408-801
. ABSOLUTE SINGLETURN ENCODER
002
324 1409-801
. INCREMENTAL ENCODER 5000
SEE FIG. 624-2180.025
004
390 9852-801
. MOUNTING ENCODER
SEE FIG. 624-2180.015
005
390 9851-801
. MOUNTING ENCODER
SEE FIG. 624-2180.014
008
324 1353-801
. HEATING FAN
052
5375 4231-024
. SWITCH
053
5912 4102-020
. FLUORESCENT TUBE
18 W
054
5915 4315-001
. ARMATURE
2 x 18 W
PARTS MANUAL
124 0647-801
625-8567.045
Date
Group
Fig.
Page
2010-12-23
9.5
625-8567.045A
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2010-12-23
9.5
625-8567.045A
2 (2)

Item
Qty
Article no
Description
Supplementary data
000
124 0647-801
001
1684 2126-301
. CABLE
MPRX 3 x 1.5 L=7m
002
2121 2550-370
. SCREW
MC6S 6 x 20 -A2-70
003
2126 2634-116
. LOCKING NUT
M6LM 6 - A2-70
004
2151 2027-156
. WASHER
BRB 6.7 x 14 -A2
005
2166 2051-823
. CABLE GLAND
Pr 22.5
007
5388 4121-002
. CONNECTION BOX
PARTS MANUAL
Date
Group
Fig.
Page
2011-10-05
9.5
625-8567.046C
1 (2)
25 26
124 0648-801
625-8567.046
14
13
12
PARTS MANUAL
Date
Group
Fig.
Page
2011-10-05
9.5
625-8567.046C
2 (2)

Item
Qty
Article no
Description
Supplementary data
000
124 0648-801
002
490 5473-001
. SCREW
005
1190048
. CABLE
L = 40m
012
2126 2634-122
. LOCKING NUT
M6LM 12 - A2-70
013
2151 2027-178
. WASHER
BRB 13 x 24 -A2
014
2151 2027-185
. WASHER
BRB 17 x 30 -A2
025
5911 4529-410
. HALOGEN LAMP
1000W
026
5921 2141-101
. FLOOD LIGHT
PARTS MANUAL
CONTROLLER, C
Date
Group
Fig.
Page
92-11-03
9.5
625-8595
1 (2)
PARTS MANUAL
Date
Group
Fig.
92-11-03
9.5
625-8595
CONTROLLER, C
Item
Qty
Article no
Description
000
314 2721-802
CONTROLLER, C
001
414 5396-801
. POTENTIOMETER WITH CARD
002
414 2081-801
BELLOWS WITH BRACE
Supplementary data
SPARE PART NO: 662 0034-000
Page
2 (2)
PARTS MANUAL
Date
Group
Fig.
Page
91-11-14
9.5
625-8592C
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
91-11-14
9.5
625-8592C
2 (2)
Item
Qty
Article no
Description
000
314 2006-802
001
414 5396-801
. POTENTIOMETER WITH CARD
002
414 2081-801
BELLOWS WITH BRACE
Supplementary data
SPARE PART NO: 662 0034-000
PARTS MANUAL
CONTROLLER
Date
Group
Fig.
Page
1997-10-07
9.5
625-8596
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
1997-10-07
9.5
625-8596
2 (2)
CONTROLLER
Item
Qty
Article no
Description
Supplementary data
000
414 6792-801
CONTROLLER
001
414 7054-001
. COVER
002
314 2006-802
. CONTROLLER, LUFFING/SLEWING
003
2152 2067-018
. COVER PLATE
004
2121 2550-331
. SCREW
MC6S 5 x 20 A4-80
005
2126 2634-114
. NUT
M6M 5 -A4 -80
006
2151 2027-146
. WASHER
RB 5.3 x 10 -A4
SEE FIG. 625-8592
PARTS MANUAL
CONTROL PANEL
1189898
625-8597.057
Date
Group
Fig.
Page
2010-09-23
9.5
625-8597.057
1 (4)
PARTS MANUAL
Date
Group
Fig.
2010-09-23
9.5
625-8597.057
CONTROL PANEL
Item
Qty
Article no
Description
000
1189898
CONTROL PANEL
001
224 0206-001
. COVER
002
314 2721-802
. CONTROLLER, C
006
424 0641-801
. SWITCH WITH HANDLE
011
424 0643-001
. LENS WITH SYMBOL
012
424 0643-004
. LENS WITH SYMBOL
013
1190001
. LENS WITH SYMBOL
015
424 0643-002
. LENS WITH SYMBOL
016
424 0643-006
. LENS WITH SYMBOL
028
424 0646-001
. SIGN
030
424 0644-002
. SIGN
032
424 0644-005
. HEADLINE SIGN
033
424 0644-006
. HEADLINE SIGN
038
5298 2070-100
. PILOT LAMP
045
5372 2206-003
. CONTACT BLOCK
046
5372 2206-002
. CONTACT BLOCK
048
5372 2203-001
. PUSH BUTTON
049
5372 2204-102
. PUSH BUTTON
050
5372 2202-101
. EMERGENCY STOP
053
5375 4340-102
. SWITCH
056
5375 4341-112
. SWITCH WITH KEY
058
5672 4245-002
. CIRCUIT BREAKER
061
13
2152 2069-225
. BLANKING PLUG
062
5372 2205-122
. PUSH BUTTON
Supplementary data
RED
Page
2 (4)
PARTS MANUAL
CONTROL PANEL
1189898
625-8597.057
Date
Group
Fig.
Page
2010-09-23
9.5
625-8597.057
3 (4)
PARTS MANUAL
Date
Group
Fig.
2010-09-23
9.5
625-8597.057
CONTROL PANEL
Item
Qty
Article no
Description
Supplementary data
063
2152 2067-018
. COVER PLATE
064
2121 2550-331
. SCREW
MC6S 5 x 20 -A2-70
066
2126 2634-114
. LOCKING NUT
M6LM 5 - A2-70
068
2151 2027-146
. WASHER
BRB 5.3 x 10 -A2
069
5372 2207-004
. CONTACT BLOCK
Page
4 (4)
PARTS MANUAL
EL. INST JIB LIGHT (CABIN)
324 2043-801
625-8597.061
Date
Group
Fig.
Page
2011-01-26
9.5
625-8597.061
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2011-01-26
9.5
625-8597.061
2 (2)

Item
Qty
Article no
Description
000
324 2043-801
001
5372 2207-011
. CONTACT BLOCK
003
5372 2205-142
. PUSH BUTTON
Supplementary data
PARTS MANUAL
Date
Group
Fig.
Page
2011-01-27
9.5
625-8597.062
1 (2)
14 15
324 1722-801
625-8597.062
PARTS MANUAL
Date
Group
Fig.
Page
2011-01-27
9.5
625-8597.062
2 (2)

Item
Qty
Article no
Description
000
324 1722-801
002
5372 2205-143
. PUSH BUTTON
003
5372 2207-011
. CONTACT BLOCK
014
5921 2141-101
. FLOOD LIGHT
015
5911 4529-410
. HALOGEN LAMP
Supplementary data
1000W
PARTS MANUAL
324 1724-801
625-8597.063
Date
Group
Fig.
Page
2011-01-27
9.5
625-8597.063
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2011-01-27
9.5
625-8597.063
2 (2)

Item
Qty
Article no
Description
000
324 1724-801
001
5375 4340-131
. SWITCH
002
424 0644-014
. SYMBOL
Supplementary data
PARTS MANUAL
Date
Group
Fig.
Page
2011-03-28
9.5
625-8597.069
1 (2)
EL.INST. VENTILATION FAN (CAB)
1, 2
324 2098-801
625-8597.069
PARTS MANUAL
Date
Group
Fig.
Page
2011-03-28
9.5
625-8597.069
2 (2)

Item
Qty
Article no
Description
000
324 2098-801
001
5375 4340-102
. SWITCH
002
424 0644-008
. SIGN
003
414 4354-002
. VENTILATOR
Supplementary data
PARTS MANUAL
Date
Group
Fig.
Page
2011-03-30
9.5
625-8597.074
1 (2)
EL INST AIR CIRCUL FAN (CABIN)
1 12
324 1848-801
625-8597.074
PARTS MANUAL
Date
Group
Fig.
Page
2011-03-30
9.5
625-8597.074
2 (2)

Item
Qty
Article no
Description
000
324 1848-801
001
5375 4340-102
. SWITCH
004
6480 2150-024
. FAN
012
424 0644-008
. SIGN
Supplementary data
PARTS MANUAL
Date
Group
Fig.
Page
2011-06-27
9.5
625-8597.081
1 (2)
1182879
625-8597.081
PARTS MANUAL
Date
Group
Fig.
Page
2011-06-27
9.5
625-8597.081
2 (2)

Item
Qty
Article no
Description
000
1182879
004
1183160
. CABLE
Supplementary data
PARTS MANUAL
1213177
625-8598.140
Date
Group
Fig.
Page
2012-01-18
9.5
625-8598.140
1 (6)
PARTS MANUAL
Date
Group
Fig.
2012-01-18
9.5
625-8598.140

Item
Qty
Article no
Description
000
1213177
001
1189718
. TEMPERATURE SENSOR
002
1188839
. THERMOSTAT
003
1188840
. HEATER
004
5349 2021-102
. KNOB
005
1190324
. ENCLOSURE
006
5692 4740-024
. HOUR METER
007
1188132
. POWER SUPPLY
008
1188133
. POWER SUPPLY
009
1188414
. CABINET
010
1189715
. TRANSFORMER
011
1212929
. FUSE
012
2611 3109-104
. COLLECTOR RAIL
013
2611 3130-116
. CONN. LINK
014
1196903
. CONNECTING LINK
015
2663 4383-102
. TERMINAL BLOCK
016
16
2669 4160-015
. END HOLDER
017
2669 4180-060
. FUSE TERMINAL
018
324 1165-801
. TRANSFORMER 1-PHASE
019
424 0644-013
. SIGN
020
1193301
. RESISTOR
021
5340 2011-501
. CIRCUIT BREAKER
022
1190309
. CIRCUIT BREAKER
023
5347 4262-202
. CIRCUIT BREAKER
Supplementary data
Page
2 (6)
PARTS MANUAL
1213177
625-8598.140
Date
Group
Fig.
Page
2012-01-18
9.5
625-8598.140
3 (6)
PARTS MANUAL
Date
Group
Fig.
2012-01-18
9.5
625-8598.140

Item
024
Qty
Article no
Description
Supplementary data
1187547
. COMPACT FLASH CARD
Must be ordered separately
026
5354 4130-400
. CONTACTOR RELAY
027
1196887
. RELAY
028
5354 4273-009
. CONTACTOR
029
5354 4273-012
. CONTACTOR
030
5372 2202-101
. EMERGENCY STOP
031
5381 4280-001
. ELECTRICAL OUTLET
032
5572 4105-063
. MOTOR SWITCH
033
5572 4105-160
. MOTOR SWITCH
034
5572 4105-916
. MOTOR SWITCH
035
5638 1000-230
. SAFETY RELAY
036
5639 4161-202
. IMPULSE RELAY
037
1211917
. CONTROL UNIT
038
1187548
. SENSOR MODULE
039
7635 4113-200
. THERMOSTAT
040
7426 4200-050
. SURGE SUPPRESSOR
041
1187859
. CIRCUIT BREAKER
042
5672 4212-140
. FUSE
043
5672 4212-120
. FUSE
044
5347 4262-206
. CIRCUIT BREAKER
045
1190312
. CIRCUIT BREAKER
047
5354 4137-501
. AUXILIARY CONTACT BLOCK
5x20 2A
Page
4 (6)
PARTS MANUAL
1213177
625-8598.140
Date
Group
Fig.
Page
2012-01-18
9.5
625-8598.140
5 (6)
PARTS MANUAL
Date
Group
Fig.
2012-01-18
9.5
625-8598.140

Item
Qty
Article no
Description
048
5572 4105-400
. MOTOR SWITCH
049
1187549
. COMMUNICATION CARD (CAN)
053
10
1190937
. CABLE CLAMP
054
1189943
. CABLE
056
324 0089-801
. RELAY CARD WITH LEDS
057
5349 2002-105
. CONNECTOR
058
5349 2011-105
. COVER
059
10
1190938
. CABLE CLAMP
061
1197848
. CABLE PROTECTION
062
5354 4137-510
. AUXILIARY CONTACT BLOCK
063
1202852
. CONTACTOR
065
1190527
. CIRCUIT BREAKER
066
5347 4262-106
. CIRCUIT BREAKER
067
5375 4340-122
. SWITCH
068
1196427
. CABINET CONTROL
069
2166 2058-004
. MOUNTING BASE
070
2124 2550-228
. SCREW
071
2638 3100-544
. COPPER BRAID
072
5218 3107-111
. AUXILIARY CONTACT
073
5347 4262-306
. CIRCUIT BREAKER
074
1196599
. DRIVECLIQ CABLE 0.6m
075
1191510
. MOTOR SWITCH
076
2663 4382-025
. TERMINAL BLOCK
077
2669 4106-025
. PARTITION PLATE
Supplementary data
SEE FIG. 625-8599.020
SEE FIG. 625-8600.020
Page
6 (6)
PARTS MANUAL
EL.CABINET (CT10)
1213017
625-8598.141
Date
Group
Fig.
Page
2012-01-18
9.5
625-8598.141
1 (4)
PARTS MANUAL
Date
Group
Fig.
2012-01-18
9.5
625-8598.141
EL.CABINET (CT10)
Item
Qty
Article no
Description
Supplementary data
000
1213017
EL.CABINET (CT10)
004
1189578
. ASSEMBLY PLATE
005
12
2121 2032-449
. SCREW
006
1188842
. HEATER
007
1189614
. TERMINAL STRIP
008
2166 2058-004
. MOUNTING BASE
009
1189718
010
1193301
. RESISTOR
011
1189100
. BUSBAR CU
013
1189895
. CABLE
014
12
1189825
. WASHER
015
1190046
. CABLE
017
1192689
. CABLE CLAMP
018
1192690
. CABLE CLAMP
019
2641 2101-505
. CABLE TERMINAL
020
2641 2101-920
. CABLE TERMINAL
021
1186625
. CABLE
022
20
1189888
. CABLE
023
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
026
24
2126 2636-118
. LOCKING NUT
M6M 8 -8 FZB; DIN 982
027
1187539
. ACTIVE INTERFACE MODULE
028
1214628
. ACTIVE LINE MODULE
M6S 8 x 16 -8.8 FZB
0,2m
Page
2 (4)
PARTS MANUAL
EL.CABINET (CT10)
1213017
625-8598.141
Date
Group
Fig.
Page
2012-01-18
9.5
625-8598.141
3 (4)
PARTS MANUAL
Date
Group
Fig.
2012-01-18
9.5
625-8598.141
EL.CABINET (CT10)
Item
Qty
Article no
Description
101
1188819
. CABINET BASIC
102
1196389
.. FILTER MAT
220
1188837
. FILTER
221
1196388
.. FILTER MAT
230
1188838
. FILTER
231
1196387
.. FILTER MAT
Supplementary data
Incl. filter mat
Incl. filter mat
Page
4 (4)
PARTS MANUAL
1213018
625-8598.142
Date
Group
Fig.
Page
2012-01-18
9.5
625-8598.142
1 (4)
PARTS MANUAL
Date
Group
Fig.
2012-01-18
9.5
625-8598.142

Item
Qty
Article no
Description
Supplementary data
000
1213018
004
2121 2034-495
. SCREW
005
1188842
. HEATER
006
1189655
. ASSEMBLY PLATE
007
25
1189888
. CABLE
008
1189890
. CABLE
010
1190283
. CABLE
011
48
2154 2033-009
. WASHER
012
1189100
. BUSBAR CU
014
2166 2058-004
. MOUNTING BASE
015
1189718
016
1189614
. TERMINAL STRIP
017
1193301
. RESISTOR
018
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
1189895
. CABLE
0,2m
022
24
2126 2636-118
. LOCKING NUT
M6M 8 -8 FZB; DIN 982
023
2121 2032-449
. SCREW
M6S 8 x 16 -8.8 FZB
024
1189825
. WASHER
025
1197830
. CABLE PIT
026
1189891
. CABLE
027
1194728
. CABLE
028
2641 2101-705
. CABLE SOCKET
M6S 10 x 30 -A2-70
BRIF 8.4 G
Page
2 (4)
PARTS MANUAL
1213018
625-8598.142
Date
Group
Fig.
Page
2012-01-18
9.5
625-8598.142
3 (4)
PARTS MANUAL
Date
Group
Fig.
2012-01-18
9.5
625-8598.142

Item
Qty
Article no
Description
029
2641 2101-505
. CABLE TERMINAL
030
1192689
. CABLE CLAMP
031
1192690
. CABLE CLAMP
032
1214531
. SINGLE MOTOR MODULE
101
1188821
. CABINET
102
1196390
.. FILTER MAT
220
1188838
. FILTER
221
1196387
.. FILTER MAT
230
1188837
. FILTER
231
1196388
.. FILTER MAT
Supplementary data
Incl. filter mat
Incl. filter mat
Page
4 (4)
PARTS MANUAL
EL. CABINET (CT14)
1189233
625-8598.110
Date
Group
Fig.
Page
2011-11-29
9.5
625-8598.110A
1 (4)
PARTS MANUAL
Date
Group
Fig.
2011-11-29
9.5
625-8598.110A
EL. CABINET (CT14)

Item
Qty
Article no
Description
000
1189233
EL. CABINET (CT14)
004
1188842
. HEATER
005
1189614
. TERMINAL STRIP
006
1193301
. RESISTOR
007
1189718
008
1189095
. END COVER
009
1189099
. CONNECTION ADAPTOR 250A
010
1189098
. CONNECTION ADAPTOR 800A
011
1189094
. BUSBAR SUPPORT
012
1189100
. BUSBAR CU
013
1189097
. BASE TRAY
014
1189096
. COVER SECTION
015
2166 2058-004
. MOUNTING BASE
016
1189890
. CABLE
018
12
2121 2032-368
. SCREW
019
12
1190082
. WASHER
020
2166 2304-806
. CABLE PIT
021
1189888
. CABLE
022
1186625
. CABLE
023
1190283
. CABLE
024
2121 2034-497
. SCREW
025
2126 2634-120
. LOCKING NUT
026
2154 2033-010
. WASHER
027
1189891
. CABLE
Supplementary data
M6S 6 x 16 -8.8 FZB; DIN 933
M6LM 10 - A2-70
Page
2 (4)
PARTS MANUAL
EL. CABINET (CT14)
1189233
625-8598.110
Date
Group
Fig.
Page
2011-11-29
9.5
625-8598.110A
3 (4)
PARTS MANUAL
Date
Group
Fig.
2011-11-29
9.5
625-8598.110A
EL. CABINET (CT14)

Item
Qty
Article no
Description
Supplementary data
028
1186617
. CABLE
029
2641 2101-103
. TUBE TERMINAL
030
2641 2101-104
. CABLE TERMINAL
031
1192689
. CABLE CLAMP
032
1192690
. CABLE CLAMP
033
1194728
. CABLE
034
1187543
Must be ordered separately.
035
1187544
. DC ADAPTER
036
1187545
. 24V PLINTH ADAPTER
037
1187575
038
1187550
. SHIELD CONNECTION
039
1187577
. SHIELD CONNECTION
101
1188823
. CABINET
102
1196391
.. FILTER MAT
220
1188838
. FILTER
221
1196387
.. FILTER MAT
230
1188843
. FILTER FAN
231
1196387
.. FILTER MAT
Incl. filter mat
Incl. filter mat
Page
4 (4)
PARTS MANUAL
RELAY CARD WITH LEDs
Date
Group
Fig.
Page
2000-03-28
9.5
625-8599.020
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2000-03-28
9.5
625-8599.020
2 (2)

Item
Qty
Article no
Description
Supplementary data
000
324 0089-801
006
414 4667-007
. SPACER
007
2121 2254-220
. SCREW
MCS 3 x 6 -5.8 FZB
008
2126 2636-110
. NUT
NYLOC-M6M 3 -8 FZB
009
2154 2022-124
. WASHER
AZ 3.2 FZB
PARTS MANUAL
Date
Group
Fig.
Page
2010-02-2
9.5
625-8600.020
1 (2)
CABINET CONTROL
11
50
50
50
459
Hardware
Hardware
xxx xxxx-xxx
Error
MP
Input
Error
Output
MP
07
18
27
08
19
28
09
20
29
10
26
30
11
49
31
09
08
33
36
39
43
34
37
40
45
31
51
32
10
32
13
56
33
19
Sw19
Encoder
14
57
34
20
Sw20
calibration
15
58
35
11
16
59
36
60
37
12
17
30
MP
Input
Error
Output
07
08
33
36
39
43
34
37
40
45
31
09
10
32
19
Sw19
55
20
Sw20
14
Sw14
11
56
Sw56
15
Sw15
12
27
26
30
MP
SP
Input
Output
07
08
45
418
30
412
411
408
407
404
403
402
401
32
19
Sw19
55
20
Sw20
14
Sw14
11
14
Sw14
56
Sw56
56
Sw56
15
Sw15
12
15
Sw15
27
26
59
58
59
58
59
49
17
29
49
17
29
49
17
29
51
18
53
51
18
53
51
18
53
C3
R3
61
52
54
52
54
52
R1
57
R1
57
C1
C2
Sc
Normal
OL-Test
27
54
C1
MP
R1
C2
Com
MP
Com
MC
Ho
415
55
58
MP
MC
Lu
425
40
10
Com
427
420
26
C2
430
37
53
C1
432
431
34
40
MC
434
433
426
38
57
436
435
36
39
MP
449
438
437
43
R2
CC
451
448
39
R1
C4
453
33
31
09
457
455
429
C2
24V
Rigg
xxx xxxx-xxx
SP
C1
Com
Em.Op.
Error
Output
07
Hardware
xxx xxxx-xxx
SP
Input
12
Normal
Hardware
xxx xxxx-xxx
SP
458
Sl
Select / Info
Select / Info
Select / Info
Select / Info
Up
Up
Up
Up
Down / Exit
Down / Exit
Down / Exit
Down / Exit
50
50
42
359
357
355
353
349
348
338
337
336
335
334
333
332
331
330
329
327
326
325
320
319
318
317
315
314
312
311
308
307
304
303
302
301
50
P118
C17
1
AU_C1 1
IO_C1 1
IO_485.1 1
SSI
C22
C23
1
Sp
IO_SSI
AU_485.11
IO_A3
P1110
P1118
P107
P106
1196427
625-8600.020
P207
P206
P307
P306
P407
P406
P507
P506
P1107
P1106
50
50
256
255
254
253
252
251
249
248
247
245
243
241
240
239
238
237
236
235
234
233
232
231
230
229
227
226
225
220
219
218
217
215
214
212
211
210
209
208
207
204
203
202
201
50
50
42
50
42
42
42
161
160
158
157
153
151
149
143
141
137
136
135
134
133
132
28
258
257
50
485.1
P1103
AU_SSI
C57
C58
SSI
A3T
IO_Sp
1
AU_A3
P510
Sp
IO_C2 1
C18
1
AU_C2 1
C2
P1109
P1102
485.1
AU_Sp
SL_485.11
SL_A3
SL_Sp
C49
C50
A3T
P503
SSI
A2
IO_A2
C53
AU_A2
C2
P509
P410
Sp
P1108
P1101
P502
485.1
C1
IO_A1
C52
1
AU_A1
C44
1
C45
1
SL_A2
A2
SL_SSI
LU_485.11
LU_A3
C41
SSI
A3T
A1
Input/Output
P508
SL_C2 1
C2
P403
P310
C42
Sp
SL_C1 1
SL_A1
C36
1
LU_C1 1
LU_A1
C37
1
LU_A2
A2
IO
P501
P402
485.1
C1
P409
C33
C34
SSI
A3T
HO_485.11
HO_A3
SC_485.11
LU_C2 1
C2
P303
Sp
C11
SSI
P210
P203
SC_SSI
C12
1
Sp
P110
SC_Sp
485.3
IO_485.3 1
SC_485.3 1
485.3
P1117
A2
A1
Auxiliary
P408
P302
485.1
HO_Sp
P103
P117
A3T
C1
P309
P202
485.1
A1
AU
P401
P209
A3T
P102
SC_A3
SC_485.2 1
P1116
485.2
IO_485.2 1
P116
HO_C1 1
C28
C29
1
C2
P109
485.2
C1
Slewing
P308
HO_C2 1
A2
SL
P301
HO_A2
SC_C2 1
C7
1
C2
A1
Luffing
P208
P201
SC_A2
A2
IO_C4
SC_C4
C4
P108
P101
C4
C1
LU
Software
LU_Sp
P1115
A1
Hoisting
HO_A1
C6
C1
IO_C3 1
A1
HO
Software
HO_SSI
P115
C3
SC_A1
SC_C3 1
C3
Supervisory
SC
SC_C1 1
IO
SC
Software
PC COM
LU_SSI
Software
PC COM
29
414
356
259
PC COM
417
358
50
PC COM
419
131
130
128
127
126
125
119
118
117
116
115
114
113
112
111
110
109
108
107
104
103
102
101
50
50
42
42
50
42
50
42
50
42
98
97
96
95
94
93
92
91
90
89
88
87
86
85
84
83
82
81
80
79
78
77
76
75
74
73
72
71
70
69
68
67
66
65
64
63
62
61
60
23
22
21
20
19
18
17
16
15
14
13
12
11
10
PARTS MANUAL
Date
Group
Fig.
Page
2010-02-2
9.5
625-8600.020
2 (2)
CABINET CONTROL
Item
Qty
Article no
1196427
Description
Supplementary data
000
CABINET CONTROL
003
. MC-CARD
See table of contents section 9.5
004
. CC-CARD
006
324 1663-X
. MEMORY CARD
X = Crane manufacturing No.
011
5245 4507-003
. POWER RESISTOR
028
1202073
. SWITCH
029
1202072
. SWITCH
PARTS MANUAL
Date
Group
Fig.
Page
2010-09-30
9.5
625-8635.007
1 (2)
ELECTRIC MOTOR
1
2
1188770
625-8635.007 /0
PARTS MANUAL
Date
Group
Fig.
Page
2010-09-30
9.5
625-8635.007
2 (2)
ELECTRIC MOTOR
Item
Qty
Article no
Description
000
1188770
ELECTRIC MOTOR
001
5692 4607-101
. INCREMENTAL ENCODER
002
1197621
. FAN WITH MOTOR
Supplementary data
PARTS MANUAL
Date
Group
Fig.
Page
2010-09-30
9.5
625-8635.008
1 (2)
ELECTRIC MOTOR
1
2
1188769
625-8635.008 /0
PARTS MANUAL
Date
Group
Fig.
Page
2010-09-30
9.5
625-8635.008
2 (2)
ELECTRIC MOTOR
Item
Qty
Article no
Description
000
1188769
ELECTRIC MOTOR
001
5692 4607-101
. INCREMENTAL ENCODER
002
1197622
. FAN WITH MOTOR
Supplementary data
PARTS MANUAL
ELECTRIC MOTOR
1188771
625-8635.011
Date
Group
Fig.
Page
2012-01-19
9.5
625-8635.011
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2012-01-19
9.5
625-8635.011
2 (2)
ELECTRIC MOTOR
Item
000
Qty
Article no
1188771
Description
ELECTRIC MOTOR
Supplementary data
PARTS MANUAL
Date
Group
Fig.
Page
2010-10-08
9.5
625-8650.001
1 (2)
EL. INST. IMPULS RELAY
224 0116-801
625-8650.001
PARTS MANUAL
Date
Group
Fig.
Page
2010-10-08
9.5
625-8650.001
2 (2)

Item
Qty
Article no
Description
000
224 0116-801
002
5639 4161-202
. IMPULSE RELAY
Supplementary data
PARTS MANUAL
Date
Group
Fig.
Page
2011-02-02
9.5
625-8650.005
1 (2)
1, 2
4
224 0547-801
625-8650.005
PARTS MANUAL
Date
Group
Fig.
Page
2011-02-02
9.5
625-8650.005
2 (2)

Item
Qty
Article no
Description
000
224 0547-801
001
5354 4133-221
. CONTACTOR RELAY
002
7426 4200-050
. SURGE SUPPRESSOR
004
2669 4160-015
. END HOLDER
Supplementary data
PARTS MANUAL
5
1, 2
3
224 0506-801
625-8650.010
Date
Group
Fig.
Page
2011-03-28
9.5
625-8650.010
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2011-03-28
9.5
625-8650.010
2 (2)

Item
Qty
Article no
Description
000
224 0506-801
001
2669 4180-060
. FUSE TERMINAL
002
5672 4212-140
. FUSE
003
4762 4201-100
. POWER SUPPLY
005
2669 4160-015
. END HOLDER
Supplementary data
PARTS MANUAL
Date
Group
Fig.
Page
2011-02-03
9.5
625-8655.001
1 (2)
CABIN DISPLAY
424 0715.801
625-8655.001
PARTS MANUAL
Date
Group
Fig.
Page
2011-02-03
9.5
625-8655.001
2 (2)
CABIN DISPLAY
Item
Qty
Article no
Description
000
424 0715-801
CABIN DISPLAY
001
5730 1003-101
. DISPLAY
002
424 0632-801
. USB CABLE
003
424 0786-801
. BUZZER CABLE
Supplementary data
PARTS MANUAL
Date
Group
Fig.
Page
2010-10-05
9.5
625-8750.023
1 (2)
SLIPRING DEVICE
196
196 8
52
Earth
52
11
9
1192979
625-8750.023 /0
Weight 54 kg
52
PARTS MANUAL
Date
Group
Fig.
Page
2010-10-05
9.5
625-8750.023
2 (2)
SLIPRING DEVICE
Item
Qty
Article no
Description
Supplementary data
000
1192979
SLIPRING DEVICE
003
875 17206-001
. CABLE TERMINAL
008
30
875 17202-001
. SIGNAL BRUSH, COMPLETE
009
875 17205-001
. RUBBER BELLOW
011
875 17205-003
. CLAMP
052
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.
20 A
PARTS MANUAL
Date
Group
Fig.
Page
2008-10-30
9.7
624-2180.014
1 (2)
MOUNTING ENCODER
390 9851-801
624-2180.014
PARTS MANUAL
Date
Group
Fig.
Page
2008-10-30
9.7
624-2180.014
2 (2)
MOUNTING ENCODER
Item
Qty
Article no
Description
000
390 9851-801
MOUNTING ENCODER
001
490 4982-001
. TORQUE ARM
002
2121 2550-220
. SCREW
Supplementary data
MC6S 3 x 6 -A2-70
PARTS MANUAL
Date
Group
Fig.
Page
2008-10-30
9.7
624-2180.015
1 (2)
MOUNTING ENCODER
390 9852-801
624-2180.015
PARTS MANUAL
Date
Group
Fig.
Page
2008-10-30
9.7
624-2180.015
2 (2)
MOUNTING ENCODER
Item
Qty
Article no
Description
000
390 9852-801
MOUNTING ENCODER
001
490 4982-001
. TORQUE ARM
002
2121 2550-220
. SCREW
Supplementary data
MC6S 3 x 6 -A2-70
PARTS MANUAL
Date
Group
Fig.
Page
2010-12-20
9.7
624-2180.018
1 (2)
ENCODER ASSEMBLY
18
6 10 12
19
5
22
17
11 13
2
7
1191997
624-2180.018
9 14
PARTS MANUAL
Date
Group
Fig.
Page
2010-12-20
9.7
624-2180.018
2 (2)
ENCODER ASSEMBLY
Item
Qty
Article no
Description
Supplementary data
000
1191997
ENCODER ASSEMBLY
001
390 4817-001
. LOCKING PLATE
002
1192022
. SHAFT
004
390 7664-801
. JIB
005
490 4056-001
. BUSHING
006
490 4982-001
. TORQUE ARM
007
2186 2111-118
. SEALING
008
1192056
. TUBE
009
2121 2034-540
. SCREW
M6S 12 x 40 -A2-70
010
2121 2550-220
. SCREW
MC6S 3 x 6 -A2-70
011
2121 2550-370
. SCREW
MC6S 6 x 20 -A2-70
012
2151 2027-124
. WASHER
BRB 3,2 x 7 -A2
013
2151 2027-156
. WASHER
BRB 6.7 x 14 -A2
014
2151 2054-178
. WASHER
TBRSUB 13 x 36 FZB
017
2545 2110-001
. GREASE NIPPLE
G 1/4 A2-50
018
2154 2421-114
. CIRCLIP
019
2151 2027-178
. WASHER
BRB 13 x 24 -A2
022
. ABSOLUTE ENCODER
PARTS MANUAL
324 1408-801
624-2180.023
Date
Group
Fig.
Page
2011-07-07
9.7
624-2180.023
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2011-07-07
9.7
624-2180.023
2 (2)

Item
000
Qty
Article no
324 1408-801
Description
Supplementary data
PARTS MANUAL
324 1409-801
624.2180-025
Date
Group
Fig.
Page
2011-09-12
9.7
624-2180.025
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2011-09-12
9.7
624-2180.025
2 (2)

Item
000
Qty
Article no
324 1409-801
Description
Supplementary data
PARTS MANUAL
Date
Group
Fig.
Page
2010-12-13
9.7
624-2196.001
1 (2)
20 = Electrical System
13 14
13 14
13 14
13 14
12
11
30
10
31
1196430
624-2196.001
PARTS MANUAL
Date
Group
Fig.
Page
2010-12-13
9.7
624-2196.001
2 (2)

Item
Qty
Article no
Description
Supplementary data
000
1196430
010
1196673
. ELECTRICAL OUTLET
011
1200949
. SWITCH
012
5375 4231-024
. SWITCH
013
5915 4315-001
. ARMATURE
2 x 18 W
014
5912 4102-020
. FLUORESCENT TUBE
18 W
020
1202034
. ELECTRICAL SYSTEM
030
1196543
. JUNCTION BOX, X71A
SEE FIG. 624-2196.002
031
1196773
. JUNCTION BOX, X71B
SEE FIG. 624-2196.003
PARTS MANUAL
JUNCTION BOX, X71A
1196543
624-2195.002
Date
Group
Fig.
Page
2010-12-10
9.7
624-2196.002
1 (4)
PARTS MANUAL
Date
Group
Fig.
2010-12-10
9.7
624-2196.002
JUNCTION BOX, X71A

Item
Qty
Article no
Description
Supplementary data
000
1196543
JUNCTION BOX, X71A
001
224 0348-801
. CASING
002
1189895
. CABLE
003
2641 2101-505
. CABLE TERMINAL
004
1201763
. SIGN
005
16
2121 2032-451
. SCREW
006
2124 2550-228
. SCREW
007
1201609
. DISTANCE
008
16
2126 2032-118
. NUT
009
414 3662-002
. CLAMP
010
2121 2550-329
. SCREW
011
1201817
. SHEET
012
2154 2033-006
. WASHER
013
2166 1904-140
. CABLE GLAND
014
2151 2022-146
. WASHER
BRB 5.3 x 10 FZB; DIN 125
015
2121 2550-325
. SCREW
MC6S 5 x 10 -A2-70
016
2175 4115-025
. MOUNTING RAIL
019
1196590
. CONNECTION BAR
023
2663 4386-120
. TERMINAL BLOCK
025
2669 4107-120
. PARTITION WALL
026
2669 4160-025
. END HOLDER
028
2940 4108-999
. MARKING
030
5237 4101-210
. COVER
031
5237 4150-340
. CABLE FLANGE
0,2m
M6S 8 x 20 -8.8 FZB; DIN 933
M6M 8 -8 FZB
MC6S 5 x 16 -A2-70
KSB 5.3 x 11 FZM
Page
2 (4)
PARTS MANUAL
JUNCTION BOX, X71A
1196543
624-2195.002
Date
Group
Fig.
Page
2010-12-10
9.7
624-2196.002
3 (4)
PARTS MANUAL
Date
Group
Fig.
2010-12-10
9.7
624-2196.002
JUNCTION BOX, X71A

Item
Qty
033
Article no
Description
5239 2102-210
. GASKET
Supplementary data
Page
4 (4)
PARTS MANUAL
JUNCTION BOX, X71B
1196773
625-2196.003
Date
Group
Fig.
Page
2011-02-28
9.7
624-2196.003A
1 (4)
PARTS MANUAL
Date
Group
Fig.
2011-02-28
9.7
624-2196.003A
JUNCTION BOX, X71B

Item
Qty
Article no
Description
Supplementary data
000
1196773
JUNCTION BOX, X71B
001
224 0348-801
. CASING
002
1190527
. CIRCUIT BREAKER
003
1190312
. CIRCUIT BREAKER
004
1196822
. CIRCUIT BREAKER
005
2121 2032-451
. SCREW
006
1201763
. SIGN
007
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
1201609
. DISTANCE
011
414 3662-002
. CLAMP
012
2121 2550-329
. SCREW
013
1201817
. SHEET
014
2166 1904-132
. CABLE GLAND
015
1189937
. BRACKET
016
2121 2550-325
. SCREW
017
2175 4115-027
. MOUNTING RAIL
018
2151 2022-146
. WASHER
019
1197148
. TERMINAL
020
2647 4155-040
. EARTH TERMINAL
021
1197150
. TERMINAL
022
68
2663 4382-025
. TERMINAL BLOCK
023
2154 2033-006
. WASHER
M6S 8 x 20 -8.8 FZB; DIN 933
MC6S 5 x 16 -A2-70
MC6S 5 x 10 -A2-70
BRB 5.3 x 10 FZB; DIN 125
KSB 5.3 x 11 FZM
Page
2 (4)
PARTS MANUAL
JUNCTION BOX, X71B
1196773
625-2196.003
Date
Group
Fig.
Page
2011-02-28
9.7
624-2196.003A
3 (4)
PARTS MANUAL
Date
Group
Fig.
2011-02-28
9.7
624-2196.003A
JUNCTION BOX, X71B

Item
Qty
Article no
Description
024
2669 4106-025
. PARTITION PLATE
025
1197806
. CABLE
026
2669 4160-015
. END HOLDER
027
1186615
. CABLE
028
80
2940 4108-999
. MARKING
029
1192204
. CABLE
030
5237 4101-210
. COVER
031
1196857
. CONNECTOR BAR
032
5237 4150-632
. CABLE FLANGE
033
5239 2102-210
. GASKET
034
2152 2270-132
. STOP PLUG
035
2641 2101-165
. CABLE TERMINAL
Supplementary data
L=3m
Page
4 (4)
PARTS MANUAL
CABINET ADD. COMPONENTS, X71B
1201179
624-2196.005
Date
Group
Fig.
Page
2011-01-25
9.7
624-2196.005
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2011-01-25
9.7
624-2196.005
2 (2)

Item
Qty
Article no
Description
000
1201179
001
5639 4161-204
. IMPULSE RELAY
002
1196857
. CONNECTOR BAR
003
1196822
. CIRCUIT BREAKER
004
2647 4155-040
. EARTH TERMINAL
005
2669 4160-015
. END HOLDER
006
10
2663 4382-025
. TERMINAL BLOCK
007
12
2940 4108-999
. MARKING
008
1192204
. CABLE
Supplementary data
L=3m
PARTS MANUAL
Date
Group
Fig.
Page
2012-01-20
9.7
624-2196.015
1 (2)
PEDESTAL PUSHBUTTON
1202077
624-2196.015
PARTS MANUAL
Date
Group
Fig.
Page
2012-01-20
9.7
624-2196.015
2 (2)
PEDESTAL PUSHBUTTON
Item
Qty
Article no
Description
000
1202077
PEDESTAL PUSHBUTTON
001
414 6713-801
. SWITCH
Supplementary data
PARTS MANUAL
Date
Group
Fig.
Page
2007-04-11
9.7
624-2498
1 (2)
HAND PUMP
Oil
150
10
11
560
570
189 6211-801
624-2498
500
20
130
30
140
PARTS MANUAL
Date
Group
Fig.
Page
2007-04-11
9.7
624-2498
2 (2)
HAND PUMP
Item
Qty
Article no
Description
Supplementary data
000
189 6211-801
HAND PUMP
010
875 29031-011
. PUMP
011
875 29031-012
. HANDLE
020
875 29031-006
. PRESSURE RELIEF VALVE
030
875 29031-015
. SAFETY VALVE, COMPLETE
130
2522 2105-012
. PLUG WITH SEAL
G 1/2"
140
875 29031-005
. MANOMETER
60 bar
150
875 29031-013
. OIL CAP WITH AIR FILTER
G 1/2"
500
875 29031-014
. HYDRAULIC HOSE WITH COUPLINGS
3/8" L = 3000
560
2529 2458-111
.. QUICK COUPLING
G 3/8"
570
2528 2512-612
.. PIPE COUPLING
G 3/8"
D = 45 cc
Setting 25 bar, seal-locked
PARTS MANUAL
Date
Group
Fig.
Page
2010-08-13
9.7
624-2524A
1 (2)
490 4074-801
624-2524
PARTS MANUAL
Date
Group
Fig.
Page
2010-08-13
9.7
624-2524A
2 (2)

Item
Qty
Article no
Description
000
490 4074-801
003
6956 2020-060
. FIRE EXTINGUISHER POWDER
Supplementary data

Deck Crain

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6 pcs:1 pcs CD rom

62512724-Crane 1, 62512725-Crane 2, 62512726-Crane 3, 62512727-Crane 4

490 8998-801 - 804 /G

490 8999-801 - 804 /B

490 9001-801 - 804 /A

490 9000-801 - 804 /A

GENERAL INSTRUCTIONS, CLEANLINESS IN HYDRAULIC SYSTEMS

HYDRAULIC AND ELECTRIC SYMBOLS

HYDRAULIC BRAKE FUNCTION, ELECTRIC CRANE

CRANE CONTROL SYSTEM CC3000

THERMOSTATIC CONTROLLED VENTILATION FAN AND HEATER ELEMENTS

HEATING AND COOLING OF CABINETS IN ELECTRIC CRANES

OPERATION, START AND STOP

CONTROLS AND INDICATORS

EMERGENCY ESCAPE INSTRUCTIONS

EMERGENCY ESCAPE INSTRUCTIONS, ROPE LADDER/FIXED LADDERS

PARKING THE CRANE, SEA STOWING, GENERAL INSTRUCTION

HANDLING HATCHES BY DECK CRANE

EMERGENCY OPERATION OF HATCH COVERS BY DECK CRANE

REV NAME OF INSTRUCTION

INSPECTION OF STRESSED COMPONENTS AND STRUCTURES

SLEWING BEARING STUDS

SAMPLING OF OIL TO VERIFY THE CLEANLINESS IN HYDRAULIC SYSTEM

LUBRICANTS FOR DECK MACHINERY

HOW TO ORDER SPARE PARTS

STATEMENT REGARDING DELIVERY OF SPARE PARTS TO SWIVELS, LIFTING B

WORLDWIDE SERVICE NETWORK

MEASURES BEFORE STARTING, DURING & AFTER COMPLETED SERVICE/MAIN

RECOMMENDATION FOR INSPECTION AND REPLACEMENT OF HYDRAULIC HO

HYDRAULIC PISTON ACCUMULATORS

TIGHTENING TORQUES, STUDS/SCREWS AND BOLTS

SERVICE DOOR (OPENING AND CLOSING), SERVICE AND LUBRICATION OF DO

ROPE REEVING FOR CRANE TYPE GLBE-2

HANDLING, INSTALLATION AND MAINTENANCE OF STEEL WIRE ROPES

REPLACEMENT OF WIRES, ONE OR TWO FALL RIGGING

INDENTATION AND WEAR ON WIRE SHEAVES

MEASURING PROCEDURE FOR WEAR IN SLEWING BEARINGS FOR ROPE LUFF

SLEWING BEARING GREASE SAMPLING PROCEDURE

CARD FRONT MENUS CT2, CC3000

TROUBLESHOOTING FOR CRANE CONTROL SYSTEM CC3000, ELECTRIC CRAN

ABSOLUTE ENCODER CALIBRATION, CC3000

SIGNAL OVERVIEW, CRANE CONTROL SYSTEM CC3000

ERROR MESSAGES, CRANE CONTROL SYSTEM CC3000

INSULATION TEST, ELCTRICAL CRANE

ELECTRICAL EQUIPMENT, GENERAL MAINTENANCE

INSTALLATION OF POWER SUPPLY CABLE AND CABLE FOR "GRAB...

OIL LEVEL TEMPERATURE SENSOR, BRAKE UNIT

LIMIT SWITCHES AND SOFTWARE LIMITS IN HOISTING AND LUFFING WINCH ..

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PREPARATION FOR OVERLOAD (OL) TEST MODE

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EMERGENCY OPERATIONIN CASE OF COMPLETE POWER FAILURE, OPERA

MacHEAVYVISOR RELEASE 3.3

USER MANUAL DISPLAY, CC PILOT XS

INSTALLATION OF MAINTENANCE PLATFORM ON FOUNDATION, (CUSTOMER D

REV NAME OF INSTRUCTION

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WINCH MOUNTING SET

DRIVE IN, COMPLETE

SLEWING GEAR ASSEMBLY SET

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CRANE HOUSE ASSEMBLY