Instruction Manual Project No. Date:: Dept. C7250

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Baugruppen
1. Hydraulic Symbols
Hydraulische Bildzeichen
Working oil line.

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

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

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

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

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

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

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

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

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

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

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

Filter mit Anzeiger.
Filter with by-pass valve.

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

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

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

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

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

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

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

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

Schieber, Grundzeichen.
Electrically controlled valve.

Schieber, elektromagnetisch gesteuert.
Pressure controlled valve.

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

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

Schieber, vorgesteuert, externer Steuerdruck.
Lever controlled valve.

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

Schieber, mechanisch gesteuert.
Valve with spring return.

Schieber mit Feder-Rückführung.
Valve with detent.

Schieber mit Lagehalter.
4/2 direction valve

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

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

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

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

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

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

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

Druckreduzierventil.
Pressure reducing valve with T-port.

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

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

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

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

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

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

Pumpe für Lastwinde.

13 (30)

Pump for luffing winch.

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

Pumpe für Einziehwinde.
Pump for luffing or slewing.

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

Pumpe für Schwenkantrieb oder Einziehwinde.
Pump for slewing.

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

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

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

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

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

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

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

Ventileinheit für Stabilisierungswinde.
Unloading unit for feed pump.

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

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

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

Leitungsverbindung, fest.
Conductor junction, separable.

Leitungsverbindung, trennbar.
Crossed conductor, no connection.

Kreuzende Leitungen, ohne Verbindung.
Slip ring with brush.

Schleifring mit Bürste.
Fuse, supply side indicated.

Sicherung, Zuführungsseite markiert.
Magnetic relay, contactor.

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

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

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

Kontakt mit Ausschalt-Verzögerung.
Contact with delayed closing.

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

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

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

Temperaturwächter, Thermostat.
Touch free contact.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

nents:
3211 Hydraulic brake

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

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

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

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

principle of operation
Control levers (joysticks)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

electric cabinets
All fans and heaters are labelled in the electrical

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

CT3 Display CT3
Luffing out Lowering

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

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

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

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

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

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

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

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

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

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

3 seconds. See Fig. 3 and 4.
Control lever movement
Start - acceleration Retardation - stop
Empty hook
Speed
Max. load
Time
2 sec. 2 sec.
Fig. 3. Luffing.
4 (6)

Instruction Manual Project No. Date:: Dept. C7250

Uploaded by

Copyright:

Available Formats

Instruction Manual Project No. Date:: Dept. C7250

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Instruction Manual Project No. Date:: Dept. C7250

Uploaded by

Copyright:

Available Formats

How does the crane control acceleration and deceleration?

How does the crane control acceleration and deceleration?

What are the functions of the different control buttons?

What are the functions of the different control buttons?

INSTRUCTION MANUAL Project No.

GENERAL 1 1.000.6 E b SAFETY INSTRUCTIONS

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

FUNCTION 3 3.110.127 E b ELECTRIC FUNCTION

OPERATION 4 PM40 1885-E00 a CREW CHECKLIST

MAINTENANCE 5 5.005.70 E - MAINTENANCE CHART

6.0 6.000 E e HOW TO ORDER SPARE PARTS

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

6.3 6.303.61 E c CARD FRONT MENUS CT2, CC3000

EXTRA EQUIPMENT 7 7.075.11 E - MacHEAVYVISOR RELEASE 3.3

SPARE PARTS 9 SEE SEPARATE TABLE OF CONTENTS

9.0 HOW TO ORDER SPARE PARTS e 6.000 E

9.1 HOISTING WINCH 1212912 -/ 625-1450.212

9.2 BRAKE PUMP UNIT 1219768 A/ 625-4935.245A

9.3 CRANE HOUSE ASSEMBLY 1219977 C/ 625-6102.580

9.4 VALVE UNIT 1204092 A/ 625-7207.018

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

9.5 DRIVERS DESK 1189978 A/ 625-8563.069

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

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

Testing and examination

Improper Use tain measures and procedures must be obeyed.

Functions, Installations and Equipment Safety Functions and Equipment

Specific safety equipment is installed and delivered

Specific service and repair of the electrical, hydraulic

b. Covers and houses:

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

Replacement signs must refer to international and

Principles of Risk Classification

Those risks classified as DANGER sign are pre-

2. WARNING SIGNS are attached to equipment or

The danger does not exist unless protection installa-

3. CAUTION SIGNS are attached to equipment or

Any person should be able to avoid the danger.

4. NOTICE SIGNS are attached to equipment and

Alert / Warning signs

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

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

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

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

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

PM40 7111-E00 ROTATING FAN - KEEP HANDS OFF!

PM40 7112-E00 RIDING ON CARGO FORBIDDEN

PM40 7114-E00 DANGEROUS OIL PRESSURE - BE CAREFUL!

PM40 7115-E00 SLIPPERY SURFACES - WATCH OUT!

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

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

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

The crane operator must stop operation and alert personnel.

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

DANGER SIGN Attached on both sides of the crane jib.

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

PM40 7130-E00 DANGEROUS OIL PRESSURE. BE CAREFUL!

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

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