Crane_3_GP160-0516-2

Dept. C7250

INSTRUCTION MANUAL

Project No.

Date: 2008-11-27

2/08006.01DAL-3

Page 1(3)

TABLE OF CONTENTS No. of manuals

6 pcs, CD-ROM 2 pcs

Certificate for crane issued by:

DNV

Certificate for foundation issued by:

DNV

IMO No.

L9408683

Name of ship

PROFIT

Newbuilding No.

1022

Shipyard

Jiangsu Rongsheng Heavy Ind.

Owners

Geden

Project No.

2/08006.01DAL-3

Mfg. No.

62509352 - Right crane

Type of crane

GP 160-0516-2

Order specification specification

490 6594-803 /A

Mechanical spec.

490 5435-801 /-

Hydraulic spec.

490 6619-803 /B

Electrical spec.

490 6620-803 /-

Slewing spec.

-

SAFETY DOCUMENTS Document names written with bold letters are documents with safety aspects. INSTRUCTION NO. GENERAL

T EC ECHN. DE SC SCRIP.

FUNCTION

OPERATION

MAINTENANCE

SERVICE

1

2

3

4

5

REV

NAME OF INSTRUCTION

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

2/08006.01DAL-3

-

TECHNICAL DATA

2.007.56 E

c

TECHNICAL DESCRIPTION

3.110.70 E

a

HYDRAULIC FUNCTION

3.142.10 E

c

CRANE CONTROL SYSTEM

PM40 0815-E00

-

OPERATING INSTRUCTION

PM40 1822-E00

d

CREW CHECKLIST BEFORE TAKING CRANE INTO OPERATION

4.620.13 E

b

PARKING THE CRANE, SEA STOWING

5.005.25 E

g

MAINTENANCE CHART

5.019 E

a

INSPECTION OF STRESSED COMPONENTS AND STRUCTURES

PM51 1217-E00

b

LUBRICATING CHART, GP AND HH CRANES

5.302.15 E

e

CRANE HOUSING / HYDRAULIC OIL TANK

5.421.16 E

e

LUBRICANTS FOR DECK MACHINERY

6.000 E

c

HOW TO ORDER SPARE PARTS

6.000.1 E

c

STATEMENT REGARDING DELIVERY OF SPARE PARTS TO SWIVELS, LIFTING

6.000.2 E

c

RETURN FORM

6 6.0

The Original Manufacturer of HÄGGLUNDS Cranes

Dept. C7250

INSTRUCTION MANUAL

Project No.

Date: 2008-11-27

2/08006.01DAL-3

Page 2(3)

TABLE OF CONTENTS 6.0

6.1

6.2

6.3

INSTRUCTION NO.

REV NAME OF INSTRUCTION

6.004.1 E

ba

MacGREGOR GLOBAL SERVICES

6.008.2 E

a

INTRODUCTION

6.100 E

b

MEASURES BEFORE STARTING, DURING AND AFTER COMPLETED SERVICE/M

6.120.15 E

d

SLEWING GEARSET

6.120.62 E

f

HYDRAULIC MOTORS, HOISTING AND SLEWING

6.120.96 E

a

WINCH

6.142.5 E

a

RECOMMENDATION FOR INSPECTION AND REPLACEMENT OF HYDRAULIC H

6.214 E

i

TIGHTENING TORQUES STUDS/SCREWS AND BOLTS

6.216.69 E

d

ROPE REEVING DIAGRAM FOR CRANES TYPE GP AND HH

6.222.1 E

a

HANDLING, INSTALLATION AND MAINTENANCE OF STEEL WIRE ROPES

625/1473 E

b

INDENTATION AND WEAR ON WIRE SHEAVES

625/1560 E

e

LIFTING BLOCK/BEAM

625/1618 E

b

MEASURING PROCEDURE FOR WEAR IN SLEWING BEARINGS FOR CRANE ...

6.305.11 E

-

ELECTRICAL EQUIPMENT, GENERAL MAINTENANCE

6.990.54 E

-

EMERGENCY LOWERING IN CASE OF COMPLETE POWER FAILURE OPERA

EXTRA EXTRA EQUI EQUIPM PMENT ENT 7 APPENDICES SPARE PARTS

8 9

SEE SEPARATE TABLE OF CONTENTS


Dept. C7250

PARTS MANUAL

Project No.

Date: 2008-11-27

2/08006.01DAL-3

Page 3(3)

TABLE OF CONTENTS GROUP DESCRIPTION

PART NUMBER

FIG

9 9.0

HOW TO ORDER SPARE PARTS

9.1

WINCH ASSEMBLY

9.2

9.3

9.4

c

6.000 E

289 3951-801

A/

625-1440.102

WINCH

289 3815-801

B/

625-1450.091

HYDRAULIC MOTOR

188 1769-801

A/

625-2205.016

SLEWING GEAR

289 3822-801

A/

625-3255.022

HYDRAULIC MOTOR

188 1227-801

A/

625-2205.017

PUMP DRIVE

289 0543-801

B/

625-4935.067A

PUMP

188 1097-801

A/

625-4945.012

CYLINDER ASSEMBLY

289 4027-801

-/

625-5882.037

JIB TOP

288 0136-801

A/

625-6244.001B

JIB BEARING ASSEMBLY

287 9974-801

B/

625-6253A

HOOK BLOCK

388 7531-801

E/

625-7013.005D

GENERAL ARRANGEMENT

189 7279-801

A/

189 7279

CRANE ASSEMBLY, RIGHT

189 7315-801

-/

189 7315

SLEWING ASSEMBLY

289 3961-801

-/

289 3961

SLEWING BEARING

388 7097-801

C/

388 7097

LOAD WIRE ROPE; SEE TECHNICAL DATA

390 9790-808

N/

-

DIRECTION VALVE

188 1338-801

-/

625-7322.011

BALANCE VALVE

388 6376-801

B/

625-7330.001

BALANCE VALVE

289 0839-801

B/

625-7330.006A

MOTOR VALVE

388 6358-801

D/

625-7331

LIMIT VALVE

388 6361-801

A/

625-7334

FILTER

287 9463-801

B/

625-7335

BALL VALVE

389 4128-801

-/

625-7620.004

HYDRAULIC HOSES

9.5

9.7

625-7970G

HYDRAULIC CYLINDER

289 3178-801

A/

625-7990.044

HYDRAULIC CIRCUIT DIAGRAM

289 5232

A/

289 5232

HYDR.INST HOUSE JIB, RIGHT

189 5696-801

A/

189 5696

LIMIT ARRANGEMENT VALVES,RIGHT

189 5167-801

B/

189 5167

LIMIT ARRANGEMENT CAMS R

189 7337-801

-/

EL. CENTRAL/STARTER

324 1150-801

A/

625-8630.050A

ELECTRICAL SYSTEM

324 1134

-/

324 1134

HAND PUMP

189 3090-801

D/

624-2494B


GENERAL

1.005 E rev.: e 2003-09-09

Preface This instruction manual covers the MacGREGOR hydraulic deck crane. We hope that it will prove a valuable companion to everyone concerned with the operation of the crane or otherwise in a responsible position.

Spare parts

General advice how to order spare parts; spare parts lists and illustrations.

Every manual belongs to a specific crane or piece of equipment. The identification can be found on the label on the 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 equipment. Appendices

Other information, which cannot be referred to any of the above mentioned sections.


1 (2)

GENERAL

1.005 E rev.: e 2003-09-09

THIS PAGE IS INTENTIONALLY LEFT BLANK

2 (2)


GENERAL

1.009 E rev.: a 1996-05-20

General Instructions Cleanliness in Hydraulic Systems General The fundamental and foremost rule in all work with hydraulic systems and components is absolute cleanliness. Many components, e.g. valves and pumps, have very narrow tolerances, therefore microscopic impurities, invisible to the human eye, may have disastrous effect on the function of a hydraulic system. The hydraulic system installation contains a cleaner with a cartridge designed to stop impurities produced within the hydraulic system during operation. Every care must be taken to prevent external impurities from entering the system when servicin g or repairing it.

Use a brush for cleaning, wipe off with a nonlinting rag, repeat the cleaning if necessary. Finish by spraying the area of operations - hose connections etc. - with the solvent. 4. Mount protective covers immediately after removing a component, a pipe or a hose. Components, shall also be fitted with covers and plugs in order to prevent ingress of dirt. These covers must be kept in clean and closed packages. After use, covers are to be cleaned in the workshop. 5. Observe minute cleanliness when handling all types of quick-release connectors. Spray both connectors with solvent before making up a connection. Clean all covers before reinstallation. Storing and filling up of hydraulic oil

This also applies for components that have been removed and or to be reinstalled. Sooner or later, a component that has been replaced will be inspected in a test equipment somewhere. It is important that the component stays in the same condition as it was when it was removed, as it may otherwise be impossible to decide the real cause of a malfunction. It may also be possible that a component sent in for inspection is not defective at all, and will be returned. Rules when working on the hydraulic system The following fast rules shall be observed during working on the hydraulic system: 1. Carry out a rough general clean-up. 2. Protect the area where work shall be done. Use a sheet of plastic material or similar. 3. Clean well with white spirit or a similar solvent. Remember that it is not enough to clean only the parts immediately concerned, but also their surroundings from where accumulated dirt may be transferred in to the repair area. Do not forget to clean the tools to be used.

1. Store barrels, hoses and pump as clean as possible and best of all in a warm room. The oil viscosity will then be considerably lower, which make the filling through filter easier. 2. Barrels, hoses and pump must be carefully handled and cleaned when necessary. 3. Store barrels horizontally, so plugs (or cocks) are below the liquid level and impurities (e.g., damped air) does not penetrate the barrels. 4. Observe minute cleanliness when filling up oil carelessness is one of the greatest sources when impurities penetrates the hydraulic system. 5. Fill up hydraulic oil. See separate instruction. 6. Never use the last drop in the barrel, as it often consists of water and other impurities dependent on how many times the barrel has been opened.


1 (2)

GENERAL

1.009 E rev.: a 1996-05-20


2 (2)


GENERAL

1.102 E rev.: c 1999-09-14

Conversion Factors

Pressure

Length

1 mm 1m 1 in 1 ft (fot)

= = = =

0,0393701 in (tum) 3,28084 ft (fot) 25,4 mm 304,8 mm

Volume

1 dm 3 = 1 litre = 0,219969 gallon (UK) 1 dm 3 = 1 litre = 0,264172 gallon (US) 1 gallon (UK)= 4,54609 dm3 1 gallon (US)= 3,78541 dm3 Mass

1 kg = 2,20463 lb 1 lb = 0,45359 kg 1 ton (metric) = 1000 kg 1 ton (UK) = 1 longton (US) 1 ton (UK) = 1016,05 kg

1 atm = 1 atm = 1 atm = 1 bar = 1 at = 1 at = 10 lbf/in2 = 10 lbf/in2 = 1 bar = 1 bar = 2 1 kp/cm = 1 bar = 1 Pa = 1 Pa = 1 Pa = 1 Pa = 2 1 kp/cm =

14,6959 lbf/in2 (psi) 1,01325 bar 1,03323 at 0,986923 atm 14,2233 lbf/in2 (psi) 0,980665 bar 0,689476 bar 0,70307 at 1,01972 at 14,5038 lbf/in2 (psi) 14,2233 lbf/in2 100 kPa = 0,1 MPa 1 N/m2 10,2 · 10-6 kp/cm2 0,145 · 10-6 lbf/in2 7,5 · 10-3 mm Hg 98,07 ·103 Pa

Power Force

1 kp 1 kp 1 lbf 1 lbf 1N 1N

= = = = = =

1 kW = 1,35962 hk 1 kW = 1,34102 hp (UK, US) 1 hk = 0,986320 hp (UK, US) 1 hp (UK, US) = 1,01387 hk 1 hk = 0,735499 kW 1 hp (UK, US) = 0,745700 kW

2,20462 lbf 9,80665 N 4,44822 N 0,453592 kp 0 ,101972 kp 0,224809 lbf

Temperature Moment of force

1 kpm= 9,80665 Nm 1 kpm= 7,23301 lbf · ft 1 Nm = 0,737562 lbf · ft 1 lbf · ft = 0,135582 daNm 1 lbf · ft = 1,35582 Nm 1 lbf · ft = 0,13825 kpm 1 daNm = 1,01972 kpm 1 daNm = 7,37562 lbf · ft

0°C 0°C 0°F 0°F 0K 0K

= = = = = =

32°F 2 73,15 K -17,7778°C 2 55,3722 K -273,15°C -459,67°F

°C = 1 (°F - 32) 1,8

°F = 1,8 (K - 273,15) + 32

°F = °C · 1,8 + 32 Moment of inertia

1 kg · m = 3417,17 lb · in 1 lb · in2 = 0,00029264 kg · m2 2

2

K = 1 (°F - 32) + 273,15 1,8

°C = K - 273,15 K = °C + 273,15


1 (2)

1.102 E rev.: c 1999-09-14


2 (2)


GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Hydraulic and Electric Symbols Hydraulische und elektrische Bildzeichen

This section covers a part of the symbols and port markings commonly used in MacGREGOR (SWE) AB, Service Division hydraulic and electric circuits, divided into three parts: Diese Sammlung 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)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Hydraulic symbols and valve assemblies Hydraulische Bildzeichen und VentilBaugruppen

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)


GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Pipe junction. Leitungsverbindung.

Crossed pipes, no connection. Kreuzende Leitungen, ohne Verbindung.

Rotary connection. Dreh-Verbindung.

Tank line, tank. Tankleitung, Tank.

Regulation or variability. Regelbar oder nachstellbar.

Enclosure of component assembly. 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. The Original Manufacturer of HÄGGLUNDS Cranes

3 (30)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

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

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

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

M

Electric motor. Elektromotor.

Filter. Filter.

Filter with contamination indicator. Filter mit Anzeiger.

Filter with by-pass valve. Filter mit Rückschlagventil.

4 (30)


GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Air breather. Luftreiniger.

Pressure electric switch, normally open. Druckschalter, druckgesteuert, normal offen.

Pressure electric switch, normally closed, adjustable. Druckschalter, druckgesteuert, normal geschlossen, regelbar.

Non-return valve. 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)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Quick coupling or gauge connection. Schnellkupplung oder Meßanschluß.

Gauge connection. Meßanschluß.

1

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)


GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

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)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Mechanically controlled valve. Schieber, mechanisch gesteuert.

Valve with spring return. Schieber mit Feder-Rückführung.

Valve with detent. Schieber mit Lagehalter.

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

4/3 direction valve Electrically controlled four-way, three-position valve, spring centred. 4/3-Wegeventil 4-Wegeschieber mit 3 Arbeitsstellungen, federzentriert.

Proportional valve. Proportionalventil.

Servo valve. Servoventil.

8 (30)


A

B

P

T

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

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)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Pressure limiting valve with remote opening or closing. Druckbegrenzungsventil mit ferngesteuerter Öffnung oder Schließung.

Pressure reducing valve. Druckreduzierventil.

Pressure reducing valve with T-port. Druckreduzierventil mit T-Anschluß.

10 (30)


GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-0 2007-06-088

2. Valv Valvee Assemblie Assembliess Ventil-Baugruppen

Filter unit with by-pass valve. Filtereinheit mit Shuntventil.

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

Filter unit with pressure limiting valve. Filtereinheit mit Druckbegrenzungsventil.


11 (30)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Filter unit with pressure limiting valve. Filtereinheit mit Druckbegrenzungsventil.

Filter unit with by-pass valve and electric filter indicaindic ation. Filtereinheit mit Shuntventil und Zustandsanzeige.

12 (30)


GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-0 2007-06-088

Pump for hoisting winch. Pumpe für Lastwinde.



13 (30)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08


Pump for luffing winch. Pumpe für Einziehwinde.

14 (30)


GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Pump for luffing winch. Pumpe für Einziehwinde.

Pump for luffing or slewing. Pumpe für Einziehwinde oder Schwenkantrieb.


15 (30)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Pump for slewing or luffing. Pumpe für Schwenkantrieb oder Einziehwinde.

Pump for slewing. Pumpe für Schwenkantrieb.

16 (30)


GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Hoisting winch with 84-series motor and motor valve. Lastwinde mit Motor Typ 84 und MotorUmschaltventil.

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


17 (30)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Hoisting winch with variable high speed hydraulic motor. Lastwinde mit variabel schnellaufendem hydraulischem Motor.

Luffing winch with 63/64-series motor and motor valve. Einziehwinde mit Motor Typ 63/64 und MotorUmschaltventil.

18 (30)


GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Unloading and flushing valve, slewing. Entlastungs- und Spülventil, Schwenkantrieb.

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

Flushing valve. Spülventil.


19 (30)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Valve unit for stabilizing winch. Ventileinheit für Stabilisierungswinde.

Unloading unit for feed pump. Entlastungsventil für Speisepumpe.

20 (30)


GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

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

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


21 (30)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

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)


GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

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)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

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)


GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Rectifier. Gleichrichter.

Transformer with two windings. Transformator mit zwei Wicklungen.

Transformer with several secondary windings, with screen between primary and secondary windings. Transformator mit mehreren Sekundärwicklungen, mit Schirm zwischen den Primär- und Sekundär-Wicklungen.

Triple-pole thermal relay (overcurrent) circuit breaker. Dreipoliges thermisches Relais (Überstrom-Auslösung).

Frequency converter. Frequenzumformer.


25 (30)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Diode. Diode.



Light emitting diode. Leuchtdiode.

Pilot lamp. Meldeleuchte.

Light. Beleuchtung.

Flood light. Scheinwerfer.

Alarm signal. Alarmsignal.

Alarmsiren. Alarmhupe.

Single-phase outlet. Steckdose, einphasig.

26 (30)


GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Position encoder. Drehfeldgeber.

Puls/speed encoder Geschwindigkeitsgeber

Flexible lead connector. Steckverbindung.

Resistor. Widerstand.

Resistor, non-linear. Widerstand, 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)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Condenser. Kondensator.

Heater, cabin. Heizkörper in der Fahrerkabine.

Air condition. Klimaanlageapparat.

VL . . . . Solenoid valve. Magnetventil.

Oil tank heater. Ölbehälterheizer.

28 (30)


GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08

Controller, hoisting. Steuerknüppel, Lastwinde.

Controller, luffing and slewing. Steuerknüppel, Einziehwinde und Schwenkantrieb.


29 (30)

GENERAL/ALLGEMEINES

1.518.3 ED rev.: d 2007-06-08


30 (30)


TECHNICAL DATA

(2.001.4 E)

Project No.: 2/08006.01DAL-3 rev:- 2008-11-17

GENERAL

TYPE OF CRANE

GP 160-0516-2

WO

2/08006.01DAL-3

SERIAL NUMBER

62509352 – Right crane

WEIGHT

-

TYPE OF FREQUENCY

3 ~ 60 Hz

SUPPLY VOLTAGE

440 V

CONTROL VOLTAGE

230 V

MECHANICAL DATA

SWL

5,0 tonnes

JIB RADIUS

MAX

JIB RADIUS

MIN

16,0 m 3.2 m

LIFTING HEIGHT HOOK TRAVEL HOISTING CAPACITY, NORMAL OPERATION HOISTING SPEED

45 m MAX 5,0 tonnes 10 m/min

LUFFING TIME FROM MAX TO MIN JIB RADIUS SLEWING SPEED

40 sec. MAX 1.6 rev/min

STEEL ROPE

Ø 13 mm L = 110 m No 390 9790-808

ELECTRICAL DATA

EL. MOTOR

289 2428-801

TYPE OF FREQUENCY

3 ~ 60 Hz

RATED POWER, CONT.

63 kW

RATED POWER, S6 40% INT.

92 kW

SPEED

1772 rev/min

RATED VOLTAGE

440 V

STARTING CURRENT

435 A


1 (2)

TECHNICAL DATA

(2.001.4 E)

Project No.: 2/08006.01DAL-3 rev:- 2008-11-17

HYDRAULIC DATA

PUMP TYPE

188 1108-801 3

DISPLACEMENT

90 cm /rev

MAX. SPEED

1800 rpm

HOISTING CIRCUIT

HYDRAULIC MOTOR

188 1769-801 3

DISPLACEMENT

56.1 cm /rev

LUFFING CIRCUIT

HYDRAULIC CYLINDER

289 3178-801

SLEWING CIRCUIT

HYDRAULIC MOTOR

188 1227-801 3

DISPLACEMENT

28.1 cm /rev

OIL TANK

OIL VOLUME; OIL FILLING

550 litres

SLEWING GEAR, PLANETARY GEAR BOX


6.5 litres

HOISTING WINCH


1.5 litres


2 (2)


2.007.56 E rev.: c 2007-07-21

Technical Description

Hoisting wire rope

Hoisting winch Limit switch box Jib lights (Optional) Hook block Crane jib

Pennant (only HH type) Luffing cylinder Slewing gear Luffing limits (optional) Operator's control panel

Slewing limits (optional)

Oil tank

Heating fan Pump Cardan shaft Main electric motor

Fig. 1. Crane types GP and HH.


1 (4)


The MacGREGOR Cranes hydraulic slewing cranes type GP and HH are delivered as complete units, installed on pedestals, tested electrically, hydraulically and mechanically.

2.007.56 E rev.: c 2007-07-21

The hydraulic oil circuit has a full flow return filter with changeable filter insert. The tank is provided with an oil level indicator, a temperature gauge and an air breather.

Crane control

The crane is controlled from an open platform above the slewing ring. Entrance to the platform is by ladder. All motions have stepless speed control from 0 to max. Two motions can be operated at the same time with full capacity, but with reduced speed.

Electric pump motor

Remote control (optional)

Electric starter

The remote control system allows the crane operator to drive the crane from a position on deck.

A.D.O.L. starter for location in the deck housing will be supplied as a separate item.

Load limiting system

Each hydraulic circuit is provided with equipment for limiting the hydraulic pressure to preset values corresponding to the crane capacity.

The electric pump motor is of a marine type, with class "F" insulation (standardmotor) and provided with an anti-condensation heater for 220V. Motor enclosure IP54. Duty: S6-40% ID.

The starter includes as standard: ammeter, hourmeter, start/stop buttons, main switch and running lamp in the front door. Slewing machinery

Limit switches

Hook Travel Up: The crane is provided with an automatic hook stop at the top position.

The crane is provided with a slewing ring designed for marine application. The gearing is internal. Hoisting machinery

Luffing Up - Down: The luffing cylinder is designed for safe buffering in the extreme positions. Slewing Limits (optional): The crane is provided with limit switches for limiting of slewing angle. Combined Slewing - Luffing Limits (optional): The crane is equipped with an arrangement for reducing allowable outreach through a certain angle. Electro-hydraulic power pack

The crane is provided with a built-in power pack. The electric pump motor is located in the centre of the pedestal with output shaft pointing upwards and driving the hydraulic pump through a cardan shaft.

The winch unit consists of: - Drum with bearing and bracket. - Winch gear with hydraulically operated fail-safe brake. - Hydraulic motor with safety valve to "freeze" movement in case of pressure drop. Wire rope is of the non-rotating type and galvanized. Minimum safety factor is according to classification rules. The wire sheaves are provided with heavy duty roller bearings on steel axles. All bearings have grease nipple lubrication.

The slewing column steel structure is utilized as tank for the hydraulic oil.

2 (4)



2.007.56 E rev.: c 2007-07-21

Fig. 2. Crane system. Main components.

Jib cylinder

Surface treatment

The jib cylinder is designed for marine use and has spherical bronze bearings on steel axles.

All surfaces of the crane are carefully prepared by sandblasting before being given a coat of primer. As standard, the crane is painted with an anticorrosive system based on a two-component epoxy paint and an acrylic finishing coat.

The front part of the piston rod is made of stainless steel to prevent rust formation when the crane is parked.

Heating (valid for cranes working in an ambient temperature below -20°C.)

Steel structure

The steel quality selected is in accordance with classification society recommendations to obtain necessary ductility for the lower temperature design limit.

The crane is equipped with a heating fan located in the foundation to warm up the hydraulic oil tank in case of low ambient temperatures.

All important welds are carried out in accordance with welding pocedures. After welding, a certain number of non-destructive tests are carried out.


3 (4)


2.007.56 E rev.: c 2007-07-21


4 (4)


FUNCTION

3.110.70 E rev.: a 1999-01-07

Hydraulic Function General The following description refers to MacGREGOR service crane type GP/HH.

Three hydraulic work circuits, ie, main hoisting circuit, luffing circuit and slewing circuit make up the complete crane operating system.

the

Minor variations in the hydraulic system may occur in individual cranes of the same type.

All three hydraulic working circuits have a common main pump. The main pump is located inside the hydraulic reservoir which is integrated with the cranehouse.

A complete hydraulic circuit diagram relating specifically to your crane will be found in the instruction manual, “Spare Parts”, Group 9.4.

Hoisting

Luffing

Slewing

Pump

Fig. 1. Identifying hydraulic circuits


1 (8)

FUNCTION

3.110.70 E rev.: a 1999-01-07

The system has also a common main directional valve with three sections, one for each circuit, and one common base shunt section with main pressure limitation. The main directional valve is a pressure compensated valve, which gives load independant speed control. The speed is only depending on the control lever position. The load sensing function in the valve (LS-signal) controls the system pressure to the level just above the highest required momentary pressure. Identifying circuits in the hydraulic diagram Figure 1 shows the arrangement of the three work circuits; main hoisting circuit, luffing circuit and slewing circuit. The circuits appear in the same order in the hydraulic diagram. Symbols Every hydraulic component is represented by a special symbol in the circuit diagram. The meaning of the symbols is explained in Section 1, “Hydraulic and Electric Symbols”. The symbol for the reservoir is shown in several places in the diagram for greater simplicity of drawing; but there is naturally only one reservoir in actual fact.

Hoisting winch circuit Introduction Figure 2 shows a hoisting winch circuit diagram with the following main components: Pump (common) Hydraulic motor Brake unit Main motor valve Main directional valve (common)

The high-speed motor has a fixed displacement in the hoisting circuit and is fitted to the winch via a flange. Transmission of torque to the winch drum is made via planetary gearing. The brake opens by the system pressure via sequence valve 104-2, see Fig. 2.

Component identification The main components are identified by three-digit numbers in the diagram and on the actual components in the crane. The first digit of each number signifies the circuit to which the component belongs, as follows: 1... 2... 3...

Main hoisting circuit Luffing circuit/Luffing cylinder Slewing circuit

Legend MMHO CLU MSL

2 (8)

001 102 103 104 002

Hydraulic motor, main hoisting circuit Hydraulic cylinder, luffing circuit Hydraulic motor, slewing circuit


FUNCTION

3.110.70 E rev.: a 1999-01-07

Fig. 2. Hoisting winch circuit diagram


3 (8)

FUNCTION

3.110.70 E rev.: a 1999-01-07

Safety system

Function

Pressure limiting functions: Main pressure limiting valves 002-6A and 002-7A.

Hoisting circuit Neutral/idling With the control lever in neutral and the pump running, the hoisting winch performs no actual work. The speed is controlled by the hand lever (direct connected) integrated with the main directional valve. The control lever can be moved in two directions, backwards or forwards, see Fig. 3. Hoisting and lowering To hoist, move the control lever backwards from neutral position. This will move the spool for hoisting 002-1A and connect the pump to the motor. The system pressure increases up to the needed level for the current load and the winch brake will open at a certain system pressure level and the winch starts to move in hoisting direction. Increased movement of the lever increases the amount of flow from the pump through the spool and to the winch motor and the speed increases in the same manner. The speed is controlled by the control lever and increases continously in proportion to the lever position. To lower the load the lever has to be moved forwards in similar way as for hoisting.

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

Slewing

Luffing

Hoisting

Safety system Pressure limiting functions: Main pressure limiting valves 002-6B and 002-7B.

Fig. 3. Control lever movements

4 (8)


F UNC T IO N

3 . 1 10 . 7 0 E r e v. : a 1 9 9 9 - 0 1- 0 7

002

Fig. 4. Luffing circuit diagram


5 (8)

F UN CT I ON

3 .1 1 0 .7 0 E r e v . : a 1 9 9 9 - 0 1 - 0 7

Slewing circuit Introduction Fig. 5 shows a slewing circuit diagram with the following main components: Hydrau Hydr auli lic c mo moto torr Br ak e Ba l an c e va l ve

302 302 3 03 304

Pump (common) 001 and main directional valve (common) 002, see Fig. 2. Slewing To slew left, move the control lever backwards from neutral position. This will move the spool for slewing 002-1C and connect the pump to the motor. The system pressure increases up to the needed level for the current load and the slewing brake will open at a certain system pressure level and the crane starts to move in slewing left direction. Increased movement of the lever increases the amount of flow from the pump through the spool and to the winch motor and the speed increases in the same manner. The speed control is controlled by the control lever and increases continously in proportion to the lever position. To slew right the lever has to be moved forwards in similar way as for slewing left. Safety system Pressure limiting functions: Main pressure limiting valves 002-6C and 002-7C.

6 (8)


F UNC T IO N

3 . 1 10 . 7 0 E r e v. : a 1 9 9 9 - 0 1- 0 7

002

Fig. 5. Slewing circuit diagram


7 (8)

F UN CT I ON

3 .1 1 0 .7 0 E r e v . : a 1 9 9 9 - 0 1 - 0 7


8 (8)


FUNCTION

3.142.10 E rev.: c 2008-09-22

Crane Control System

The control system is based upon three control levers (main direction valve) operated from the outside crane housing/oil tank. The right lever controls the hoisting winch, the middle controls the luffing and the left lever controls the slewing movement. All movements except for the luffing movement are driven by hydraulic motors. The luffing movement is driven by a hydraulic cylinder.

Hydraulic motors The hydraulic motors may be reversed by changing the direction of the oil flow. They deliver constant torque over their entire speed range. Limit switch box, hoisting Controls stop for full drum.

The brake releases and closes in the correct sequence when the hydraulic motor is started and stopped. Hydraulic pump The pump is a fixed displacement pump. The speed of the winch is depending on the lever movement.

Fig. 1. Crane system. Main components.


1 (2)

FUNCTION

3.142.10 E rev.: c 2008-09-22


2 (2)


OPERATION

PM40 0815-E00 rev.: - 2008-02-18

OPERATING INSTRUCTION Notify responsible officer onboard before taking crane into operation. Make sure that there is nobody in the crane working area who might be injured.

START - STOP BEFORE STARTING

START

REMOTE START/STOP

Set main switch, placed on starter box, in position "1". The white indicator lamp for main supply illuminates. The yellow lamp for anti condensation heater illuminates.

Press the green "I" button on starter box. The green indicator lamp for crane running illuminates. The yellow indicator lamp for anti condensation heater goes out.

Press green "Start" button or red "Stop" button on remote start/stop box, placed on the crane foundation.

START START

Main switch should be switched on approx. 10 hours before the crane is taken in operation.

STOP

STOP

Press the red "0" button on Starter box. The green indicator lamp for crane running goes out. The yellow lamp for anti condensationheater illuminates.

AFTER STOPP ING

Set main switch in position "0".

STOP

Emergency stop

STARTER BOX

A. Main switch B. Stop button A

200 150

100

50

00000250 h

0

C. Start button D. Crane running lamp

B

C

D

E

F E. Main supply lamp

A

F. Anti condensation heater lamp


1 (2)

OPERATION

PM40 0815-E00 rev.: - 2008-02-18

CRANE OPERATION If more than one crane movement are activated at the same time the speed of the crane will be reduced. Notice! The movements of the crane are activated directly by the movements of the control levers. Notice! Always check that the wire runs correctly on the drum.

1. Control lever Slewing Moving the control lever forwards or backwards will operate the slewing movements.

1

2

2. Control lever Luffing Moving the control lever forwards or backwards will operate the luffing movements.

3

3. Control lever Hoisting

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

4

EMERGENCY STOP

Turn Emergency stop lever (4) to stop crane movements.

Fig. 1. Operator's control panel.

1. Slewing

2. Luffing

3. Hoisting

Fig. 2. Sign on operator's control panel

2 (2)


OPERATION

PM40 1822-E00 rev.: d 2008-09-22

Crew Checklist before Taking Crane into Operation

List

Verify that ship does not list more than 5 degrees.

Wires and sheaves

Max. 5°

Verify that wires run correctly in the sheaves and that the wire ends are securely clamped.

Jib and hook release

Oil level

Loosen hook and jib from its parking position manually before raising jib from its parking support.

Verify that hydraulic oil level is between min. and max. on oil level dipstick.

MAX MIN


1 (2)

OPERATION

PM40 1822-E00 rev.: d 2008-09-22


2 (2)


OPERATION

4.620.13 E rev.: b 2008-09-24

Parking the Crane, Sea Stowing Sea stowing Prior to sea voyage, the crane jib should be put on its parking support, see Fig. 1. If the hook is to be stowed to deck, fibre strops with low ultimate load or manual "stretching screw" are to be used, see Fig. 3. Tighten hook attachment manually to make sure that the wire rope does not slack between the winch and the jib top. Maximum tightening force between hook and deck is dependent on work load and reeving, see Table 1.

Caution! The wire ropes must not be tightened by the winch. The wire ropes, sheaves, and winches are subject to heavy stress during sea voyage. Note! Before operation release hook from sea stowing position manually. Make sure that hook and crane jib are loose before raising the jib from its parking support.

Fig. 1. Crane in sea stowing position.

Fig. 2. Wire rope must not slack between winch and jib top.


1 (2)

OPERATION

4.620.13 E rev.: b 2008-09-24

Recommendation for parking the hook Hand-tighten only to the extent that the wire rope is not slack. Maximum tightening force (kN) between hook and deck, see Table 1.

Reeving

) T ( L W S

0≤5 5≤8 8 ≤ 20 20 ≤ 25

1-part

2-part

3-part

4-part

5

5

-

-

5

10

-

-

5

10

15

15

-

-

-

15

Rope connection Stretching screw turnbuckle Deck

Fig. 3. Recommendation for parking the hook.

Table 1. Maximum tightening force (kN).

Cranes equipped with stainless steel wire ropes (optional) Caution! Stainless steel wire ropes must be strapped to the metal bars on jib during sea voyage. See Fig. 4. Stainless steel wire ropes have lower tolerance for impacts than galvanized wire ropes and can be damaged if not tightened and strapped according to instruction.

Fig. 4. Stainless steel wire rope attachment.

2 (2)


MAINTENANCE

5.005.25 E rev.: g 2007-01-15

Maintenance Chart

Lubricate crane according to LUBRICATING CHART.

Every time before taking crane into operation

slacken, tighten all screws with a torque wrench. See drwg. "Slewing assembly", section 9.3.

After 200 operating hours (running in period)

Crane housing/Hydraulic oil tank Slewing gear case

- Check oil level

- The first oil change. Oil filter - Check oil pressure. See "Lubricating Chart", section 5.

Winch - The first oil change.

Slewing gear case - Check oil level. See instruction "Slewing Gearset", section 6.1. The oil quantity is marked on the name plate and in "Technical Data", section 2. - Check visually all sides. Check for leakage, particularly on the bottom shaft seal ring. Winch - Check oil level. See instruction "Winch", section 6.1. The oil quantity is marked on the name plate and in "Technical Data", section 2.

Every six months or every 500 working hours Wire ropes, wire rope clamps - Inspect for wear. See instruction "Handling and Checking Steel Wire Ropes" under section 6.2. - Wire ropes are inspected according to stipulations issued by Classification Associations and National Bodies. Bottom plate - Check for leakage.

Loose gear - Check that block, beam, hook, swivel and shackle are intact. Check according to instruction "Lifting Block/Beam", section 6.2.

Wire sheaves - Inspect for wear Loose gear - Check that hook and swivel are intact.

Every two months or every 200 operating hours Slewing rim screws - Inspect visually the slewing rim screws from the deck. If any screw shows any tendency to

Electrical equipment - Inspect according to “Electrical Equipment, General Maintenance” under section 6.3, Service.


1 (4)

MAINTENANCE

5.005.25 E rev.: g 2007-01-15

Crane house, foundation and jib welding joints - Inspect for any sign of crack. See "Inspection of Stressed Components and Structures", section 5.

Every two years or every 2000 hours of operation Crane housing/Hydraulic oil tank; oil change and cleaning

Hydraulic system - Measure the pressures according to the hydraulic circuit diagram’s adjoining list, section 9.4. - Reset as required. Oil analysis - Sample oil and analyse every six months. - If no oil analysis is done the oil must be changed every two years or every 2000 hours of operation. See separate instruction section 5. Slewing rim - Check seals.

- Drain oil and clean the reservoir. (See “Hydraulic Oil Tank”, section 5.) - Top up with fresh oil according to “Lubricants for Deck Machinery”, section 5. - Change oil filter cartridge. - Change air filter. Multiple disc brake, winch - Check for leakage. - Check discs. Check according to instruction "Hoisting Winch" under section 6.1. Multiple disc brake, slewing gearset

Slewing gear, pinion

- Check for leakage. - Check discs. Check according to instruction "Slewing Gearset" under section 6.1.

- Check backlash.

Every 1000 operating hours or at least every year

Hydraulic hoses and couplings outside crane house - Inspect for damage and leakage.

Slewing gear case - Change oil. Gear box. - Change oil. Disc-room. - Check motor spline shaft for deformations or wear. See instruction "Slewing Gearset", section 6.1. Winch - Oil analysis. - Change oil. Gear box. - Change oil. Room between motor and gear. See instruction "Hoisting Winch", section 6.1.

Every four years Slewing rim studs/screws - Tighten all studs/screws with a torque wrench. Tightening torque, see separate drawing, "Slewing assembly", section 9.3 - Consult MacGREGOR (SWE) AB, Service Division before replacing studs/screws with any other specifications than recommended.

Air filter - Check and change air filter.

2 (4)


MAINTENANCE

5.005.25 E rev.: g 2007-01-15

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

Every ten years Hydraulic hoses inside crane house - Replace all hydraulic hoses.


3 (4)

MAINTENANCE

5.005.25 E rev.: g 2007-01-15


4 (4)


MAINTENANCE

5.019 E rev.: a 2007-01-12

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

This inspection should be performed at inter vals according to the Maintenance Chart. Note! Rust on a painted surface does not necessarily mean that there is a crack in the underlying material. Remedy When rust is found on top of or near a weld, grind the topmost surface layer away to expose the crack clearly. When in doubt, use a liquid penetrant to identify the crack. Before repairing of a crack in a stressed part, always contact MacGREGOR (SWE) AB, Service Division for advice.

Fig. 1. Crane Structure.


1 (2)

MAINTENANCE

5.019 E rev.: a 2007-01-12


2 (2)


LUBRICATING CHART

PM51 1217-E00 rev.: b 2007-02-06

GP- and HH-cranes Key to symbols

a

PART OF CRANE

a Daily or before taking crane into operation. b Every 50 working hours (item 7 and 14*). After more than 48 hours off duty (item 14*). c Every 100 working hours. d Every two months or every 200 working hours. e Every six months or every 500 working hours. f Every year or every 1000 working hours. g Every two years or every 2000 working hour.

b

c

d

e

f

g

1 WIRE SHEAVES AND THIMBLE, JIB TOP, 3-4 NIPPLES 2 WIRE ROPE 3 LIFTING EQUIPMENT, 1-3 NIPPLE(S) 4 HOISTING WINCH BEARING, 1 NIPPLE 5 AIR BREATHER 6 OIL DRAIN PLUG (IN PUMP BRACKET)

1)

BEARING, SLEWING RIM, 3-8 NIPPLES, SEE DRWG. PARTS MANUAL SEC. 9.3

2)

7

8 SLEWING RIM TEETH

Key to symbols

9 JIB BEARINGS, 2 OR 4 NIPPLES

Grease for ball and roller bearings Grease for wire ropes

10 OIL LEVEL TEMPERATURE GAUGE

Grease for open spur gears Check oil level Cylinders Oil filter, check/change Check air breather Hydraulic oil tank, oil change Sample oil and analyse every six months. If necessary change oil and clean tank Slewing gear case, oil change The first oil change after 200 working hours. Winch, oil change The first oil change after 200 working hours. Winch + slewing gear Motor flange/shaft coupling; oil change.

12 WINCH GEAR BOX, OIL CHANGE.

11 SLEWING GEAR CASE, OIL CHANGE

13 WINCH + SLEWING GEAR 14 LUFFING CYLINDER BEARINGS, 4 NIPPLES (INNER) 15

12 13

14

3)

16 PISTON SEALING, 1-3 NIPPLE(S)

4)

17 OIL FILTER 18 CARDAN SHAFT, 2 NIPPLES 19 OPEN GEAR 20 DRAIN COCK, HYDRAULIC OIL DRAIN 21

ELECTRIC MOTOR, UPPER AND LOWER BEARING, NIPPLES

22 OIL FILLING

Maintenance intervals: See "Maintenance Chart", section 5. Lubricants: See "Lubricants for Deck Machinery", section 5. Oil volumes: See tables page 2. * Four times a year if the crane is off duty for a longer period (item 14).

LUFFING CYLINDER BEARINGS, 4 NIPPLES (OUTER)

1) Open oil drain plug after oil tank is drained through drain cock. 2) Relubrication should be performed under slewing motion. If that is not possible relubricate bearing through all grease fittings, than turn bearing approx. 200 mm and relubricate again. Repeat this procedure until overlap of greasing is achieved and the whole bearing circumference is filled with new grease at the gaps and seals. (Five rotations/greasings should be sufficient.) 3) Cylinder to be lubricated only at assembly/replacement. 4) Check pressure on the manometer every time before taking crane into operation. The pressure must not exceed 1.5 bar (0.15 MPa). If necessary, change filter.

4

(1. Alternative to central lubrication.)

2 9 5 1 22 10

(14. Alternative to central lubrication.)

17 14 15

11

16 15

8 20

7

6

18 21

t r o p p u s b i J

1

3 19

3 (1. Alternative to central lubrication.)

CAUTION! Filling of oil and checking oil level in oil tank and winch to be made at horizontal jib and/or cylinder in bottom position.


1 (2)

MAINTENANCE

PM51 1217-E00 rev.: b 2007-02-06

Oil volumes Crane size

63 100 160 250 320 400 500 630 800

Oil volume (litres) Total hydraulic system 250 500 600 750 1050 1100 1250 1250 2050

Oil volume (litres) Oil tank 200 450 550 700 950 950 1100 1100 1800

Oil volume (litres) Slewing gear 2.2 NA 6.5 8.0 8.0 16.0 16.0 2 x 8.0 2 x 8.0

Table 1.

SWL (tonnes) >0 to 3 >3 to 5 >5 to 8 >8 to10 >10 to15 >15 to 20 >20 to 25

Winch* (litres) 1.5 1.5 2.0 NA 2.5 NA NA

* For exact volume, oil filling, see Technical Data in section 2.

Table 2.

NA = Not applicable.

2 (2)


MAINTENANCE

5.302.15 E rev.: e 2003-09-11

Crane Housing / Hydraulic Oil Tank General

Cleaning the crane housing/oil tank

The crane housing, with the pump situated inside, functions as an oil tank.

Before cleaning the crane housing/oil tank, immobilise the crane jib in a suitable manner and stop the electric motor. Open the drain cock and drain off the oil into clean empty barrels or drums then open the oil drain plug on pump bracket and drain off oil left.

Checking oil level The crane housing/oil tank has an oil sight glass. Check that oil level is between min. and max. See Fig. 1. Filling oil

Remove the tank cover. Scrape off sediment, if any, from the tank bottom and sides using a rubber scraper. Flush the tank with white spirit.

Oil is filled into the crane housing/oil tank. When filling oil the hydraulic machinery must be at rest, crane jib in parking position (cylinder not projected) and the electric main switch open. Fill oil to just under the MAX mark, see Fig. 1. Use oil according to instruction ”Lubricants for Deck Machinery". Caution! Oil filled in the tank must be filtered to ISO 16/13 or better. Filling of oil to be made at horizontal jib and/or cylinder in bottom position.

Wipe the tank dry with clean rags. DO NOT USE COTTON WASTE, or other linting material. Apply new sealing compound and reinstall the tank cover. If the drained oil is in good condition and can be used anew, it should be filtered before refilling. Pump and hoses used for filling must be perfectly clean. Fill oil to just under the MAX mark. Use oil according to instruction ”Lubricants for Deck Machinery".

Inspection Oil sight Oil filling

Max

Drain cock

Drain plug on pump bracket

Min

Fig. 1. Crane housing / Hydraulic oil tank.


1 (2)

MAINTENANCE

5.302.15 E rev .: e 2003-09-11


2 (2)


MAINTENANCE

5.421.16 E rev.: e 2007-01-03

Lubricants for Deck Machinery

B. GREASES

A. OILS The oil shall be refined oil containing additives against oxidation, rust and foaming, as well as wear inhibitor and/or EP additives. Hoisting winch gear box, slewing gear case Oils with oil film reinforcing additives. Viscosity approx. 220 cSt/40o C (ISO VG 220 HM). Solidification point -15o C or better. Example: SHELL OMALA 220

Roller bearings. Crane jib bearing Grease with EP additives. NOTE! MUST NOT contain molybdenum disulphide. Must withstand wet conditions. Example: SHELL Alvania EP (LF) 2 (-20 to +130 °C) Arctic climate: SHELL Albida PPS2. Ropes

Hoisting winch; motor flange Slewing gear; motor flange Half the motor flange should be filled with hydraulic oil to prevent wear/rust on motor shaft/coupling. NOTE! When replacing brake discs the new discs should be slightly wet with ATF-oil. Crane hydraulic system Viscosity approx. 46 cSt/40o C (ISO VG 46 HV). Viscosity index (VI) approx. 150. Solidification point -45o C or better. Example: SHELL TELLUS T46.

Please contact MacGREGOR (SWE) AB, Service Division, when choosing lubricants for extreme temperatures.

Grease resistant to salt water and with antirust properties. (Very thin.) Temperature range -30 to +100°C. Viscosity 9.8 cSt/40°C Example: FUCHS CEDRACON Arctic climate: FUCHS Ceplattyn Open spur gear units Grease with good adhesion properties. Example: SHELL MALLEUS GL95 (-15 to +150 °C) SHELL MALLEUS GL65 (-30 to +150 °C) Cylinder (Only for cranes with cylinder luffing) A lithium/calcium-based grease with base oil viscosity 150 - 200 cSt/40°C. NOTE! MUST NOT contain molybdenum disulphide. Example: SHELL CALITHA EP T2


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MAINTENANCE

5.421.16 E rev.: e 2007-01-03


2 (2)


How to order spare parts

6.0

Hydraulic system

6.1

Mechanical equipment

6.2

Electrical equipment

6.3

SERVICE

2 0 5 0 7 0 0 2 E

Address: MacGREGOR (SWE) AB SE-891 85 ÖRNSKÖLDSVIK, Sweden Telephone: 46 - 660 - 29 40 00 Telefax: 46 - 660 - 139 77 (Spare Parts, Technical Services & Technical Documentation Services) www.macgregor-group.com/cranes


SERVICE

6.000 E rev.: c 2007-01-02

How to Order Spare Parts

Important details when enquiring or ordering spare parts To speed up the process we request you to provide us with below information:

State name of company as well as your name Vessel's name and IMO number (and/or Lloyd's number) Crane type (see manual or name plate in operator's cabin) Crane place on the vessel. No. 1 counted from the fore Crane serial number (see manual or name plate in operator's cabin) Spare part figure or drawing number. To be found in section 9 in the manual Part description Item number from spare part figure or drawing respectively Part number, if available, from spare part figure or drawing respectively Quantity required Deadline - when or where in the world do you need the parts? Delivery details such as: consignee as well as phone and fax numbers Terms of delivery: by DHL, air freight direct or consignment, by truck or shipping freight

The more you can provide us with above details the faster and more reliable replies and deliveries will be made.

Address: MacGREGOR (SWE) AB, Service Division SE-891 85 ÖRNSKÖLDSVIK, Sweden Telephone: 46 - 660 - 29 40 00 Telefax: 46 - 660 - 139 77 The Original Manufacturer of HÄGGLUNDS Cranes

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6.000 E rev.: c 2007-01-02 page 2 (2)

SE-891 85 ÖRNSKÖLDSVIK, SWEDEN

Tel: 46 - 660 - 29 40 00 Direct: Fax: 46 - 660 - 139 77

Date: ................................................

Spare parts/Service specification Please use this form whenever assistance is needed.

Service request Confirmation of phone call/conv.

From: .. .............................................................

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

Fax no:

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

Tlx no:

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

.............................................................. Re:

M/V ........................................................

IMO /Lloyd's no.: ..............................................

Crane type:.............................................

Serial no: .......................................................

Crane place: .........................................

Our ref.: .......................................................

For following spares we would like to:

have your quotation place order, deadline for arrival :..............................

Part no.

Qty Description

Fig./Drwg.

Item

1. ..........................................

.....

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

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

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

2. ...........................................

.....

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

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

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

3. ...........................................

.....

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

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

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

4. ...........................................

.....

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

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

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

5. ...........................................

.....

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

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

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

6. See enclosure Delivery/Agent's address:

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

Name/

Title/


SERVICE

6.000.1 E rev.: c 2007-01-08

Statement Regarding Delivery of Spare Parts to Swivels, Lifting Block, Lifting Beams etc. Reference is made to ILO regulations, SAFETY AND HEALTH IN DOCK WORK, section A, B and D.

Section D

Section A

Due to the difficulties for the shipowner to perform adequate proof load test certified by a competent person, in general MacGREGOR (SWE) AB, Örnsköldsvik, cannot supply separate spare parts to hook blocks, swivels, lifting beams etc. to the owner or managers. However, it is possible to deliver such parts to the MacGREGOR service organization, if they can guarantee that the proof load test and appreciate inspection according to ILO will be performed under their responsibility.

Paragraph A.1.1 stipulates that every lifting appliance should be with the provisions of section D.1: (a) before taking in to use the first time (b) after the renewal or repair of any stress bearing part; and (c) at regular four-year intervals, after the date on which the appliance was first taken in to use. Paragraph A.1.2 stipulates that the following exceptions to the requirements of paragraph A.1.1 may nevertheless be allowed: (a) where any part is renewed or repaired, it should be considered sufficient to subject that part, by separate means, to the same stress as would have been imposed on if it had been tested in-situ during the testing of the

Section D stipulates the Test loading is needed.

MacGREGOR (SWE) AB, Örnsköldsvik Quality Department

Gunnar Tjärnström Quality Manager

complete appliance.

Section B

Paragraph B.1.2 stipulates that every item of loose gear, including cargo blocks, lifting beams and lifting frames, should be tested: (a) before it is taken in to use the first time (b) after any renewal or repair of a stress-bearing part.


1 (2)

SERVICE

6.000.1 E rev.: c 2007-01-08


2 (2)


SERVICE

6.000.2 E rev.: c 2007-05-16

RETURN FORM How to return parts from deck crane manufacturing, installation or guarantee exchange

Delivery address:

MacGREGOR (SWE) AB Att.: Mr Daniel Lundberg Björnavägen 2 SE-891 41 ÖRNSKÖLDSVIK SWEDEN

Transport means, if necessary: Advised by us on request. Phone no.: 46-660-29 40 00 Fax no.: 46-660-124 55 E-mail: [email protected] Identification:

Absolutly necessary is a paper inside the return shipment, shortly describing: 1) the part 2) from where it has been taken and 3) why it is returned.

Claim:

Detailed claim can be sent separately and does not have to be enclosed. The above refers only to the return shipment as such.


1 (2)

SERVICE

6.000.2 E rev.: c 2007-05-16

RETURN FORM To be packed inside return box or parcel Date:

Sent by:

Newbuilding no.: Ship’s name: IMO no.:

Crane place on board: Crane serial no.: Returned part’s drawing or article no, serial no.: Part description: Serial no. of unit from which the part is taken: Unit description:

Reason for return: *

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

2 (2)


SERVICE & PARTS

6.004.1 E rev.: ba 2008-05-08

MacGREGOR Global Services

CHINA

BELGIUM

Hong Kong, (P) MacGREGOR (SGP) Pte Ltd.

Antwerpen, (S) (P) MacGREGOR (NLD) B.V.

Unit 3119, 31/F, Tower 1, Millennium City 1, 388 Kwun Tong Road, Kowloon HONG KONG Phone: (+852) 2394 1008 Telefax: (+852) 2787 7652 Telefax: (+852) 2787 9878 (cranes)

Luithagen-Haven 2E B-2030 ANTWERPEN Phone: (+32) 3-546 46 40 Telefax: (+32) 3-542 4772

BRAZIL Rio de Janeiro, (S) MacGREGOR Brasil Ltda

Shanghai, (S) (P) MacGREGOR (SHA) Trading Co. Ltd.

Avenida Rio Branco 31 salas 1913 & 1914 Edif. Julio Lima CEP 20090-003 Centro RIO DE JANEIRO R.J. Phone: (+55) 21-2516 1790 Telefax: (+55) 21-2516 1743

Room 1701, Cross Tower 318 Fu Zhou Road 200001 SHANGHAI Phone: (+86) 21-6391 2798 Telefax (+86) 21-6391 2276

CANADA

CROATIA

Vancouver, (S) Nagesco Ltd.

Rijeka, (S) (P) MacGREGOR (HRV) d.o.o.

961A West 1st Street NORTH VANCOUVER, B.C., V7P 1A5 Phone: (+1) 604-985 61 73 Telefax: (+1) 604-980 44 76

Vrh Martinscice 93B HR-51221 KOSTRENA-RIJEKA Phone: (+385) 51-289 717 / 718 Telefax: (+385) 51-287 154

CHILE

CYPRUS

Santiago (Valparaiso), (S) EXIMTEC Ltda. Neveria 4444 - Piso 9 Las Condes SANTIAGO Phone: (+56) 2-207 65 90 Telefax (+56) 2-207 65 91

Limassol , (P) MacGREGOR (CYPRUS) Ltd. Titos Building, Office 201 58 Gladstone Street CY 3041 LIMASSOL Phone: (+357) 25 763 670 Telefax (+357) 25 763 671

DENMARK Copenhagen, (S) (P) MacGREGOR (DNK) A/S Smedeholm 11, DK-2730 HERLEV Phone: (+45) 44-53 84 84 Telefax: (+45) 44-53 84 10

FINLAND Turku, (P) MacGREGOR (FIN) OY Hallimestarinkatu 6 FI-20780 KAARINA Phone: (+358) 2-412 11 Telefax: (+358) 2-4121 517

FRANCE Marseille, (P) MacGREGOR (FRA) S.A. Porte 4, Cap Janet 13314 MARSEILLE Cedex 15 Phone: (+33) 491-09 52 52 Telefax: (+33) 491-095 240

GERMANY Hamburg, (S) (P) (LCE) MacGREGOR (DEU) GmbH Normannenweg 24 D-20537 HAMBURG Phone: (+49) 40-25 44 40 Telefax: (+49) 40-25 44 44 44

Hamburg LCE MacGREGOR Logistic Centre c/o Kühne & Nagel (AG & Co.) KG Altenwerder Hauptstraße 1 D-21129 HAMBURG Phone: (+49) 40-30 333 6290 Telefax: (+49) 40-30 333 6210

Codes for available services from branches (S) = Branch with specially trained crane service engineers (LCE) = Central spare parts stock (LC) = Regional parts stock, servicing many countries in the same region (P) = Branch with spare parts sales resources (S) (P)

MacGREGOR (SWE) AB Service Division www.macgregor-group.com/cranes

Address SE-891 85 ÖRNSKÖLDSVIK Sweden

Telephone (+46) 660-29 40 00


Telefax (+46) 660-139 77

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SERVICE & PARTS

6.004.1 E rev.: ba 2008-05-08

GREECE

KOREA

Piraeus, (S) (P) MacGREGOR (GRC) Ltd.

Busan, (S) (P) MacGREGOR (KOR) Ltd.

4-6 Efplias Street GR-185 37 PIRAEUS Phone: (+30) 210-42 83 838 Telefax: (+30) 210-42 83 839

173-5, Songjeong-dong Haeundae-gu 612-040 BUSAN Phone: (+82) 51-704 0844 Telefax: (+82) 51-704 0414

INDIA Flat 8, Building D/6-9 Radha Nagar, Barave Road KALYAN (WEST), Pin - 421 301 Phone: (+91) 251 232 30 65 Telefax: (+91) 251 232 06 43

Singapore, (S) (P) (LC) MacGREGOR (SGP) Pte. Ltd. 9 Kian Teck Drive 628826 SINGAPORE Phone: (+65) 626 52 322 Telefax: (+65) 626 41 261

SPAIN

NETHERLANDS

Bombay, (S) Renascent Enterprises

SINGAPORE

Rotterdam, (S) (P) MacGREGOR (NLD) B.V.

Bilbao, (P) MacGREGOR (ESP) S.A.

Albert Plesmanweg 95-97 3088 GC ROTTERDAM Phone: (+31) 10-283 2121 Telefax: (+31) 10-42 93 219

Edificio Inbisa Amaya, 2 - 1o, Leioa ES-48940 VIZCAYA Phone: (+34) 94-480 7339 Telefax: (+34) 94-431 6945

Bombay, (S) Kalmar India Private Limited

NORWAY

Alicante, (S)

903-905, Plot No. 66, Greate Eastern Summit Building "B" Wing 9th Floor, sector-a5, CBD Belapur 400 614 NAVI MUMBAI Phone: (+91) 22 2758 2222 Telefax: (+91) 22 2758 2227

Skur 39, Vippetangen NOR-0150 OSLO Phone: (+47) 23-10 34 00 Telefax: (+47) 23-10 34 01

ITALY

Bergen, (S) MacGREGOR (NOR) A/S

Genoa, (S) (P) MacGREGOR (ITA) S.p.A.

Oslo, (P) MacGREGOR (NOR) A/S

Bleivassvegen 105 N-5363 ÅGOTNES Phone: (+47) 55-56-31 33 00 Telefax: (+47) 55-56-31 33 23

Via Al Molo Giano I-16128 GENOA/PORTO Phone: (+39) 010-254 631 Telefax: (+39) 010-2461 194

POLAND

JAPAN Tokyo, (S) (P) MacGREGOR-Kayaba Ltd. Head Office 9/F, Suzue Baydium Bldg. 1-15-1, Kaigan, Minato-Ku 105 - 0022 TOKYO Phone: (+81) 3-5403 1966 Telefax: (+81) 3-5403 1953

Gdynia, (P) MacGREGOR (POL) Sp. z. o.o. ul. Luzycka 8 PL-81-537 GDYNIA Phone: (+48) 58-7855 110 Telefax: (+48) 58-7855 111

Stanley van der Pers c/o Vanpershydro S.L. Apartado de Correos No. 7 ES-03170 ROJALES - ALICANTE Phone/telefax: (+34) 9667 13665 Mobile: (+34) 620 953 722

SWEDEN Örnsköldsvik, (S) (P) MacGREGOR (SWE) AB Service Division Sjögatan 4 G SE-891 85 ÖRNSKÖLDSVIK Phone: (+46) 660-29 40 00 Telefax: (+46) 660-139 77 www.macgregor-group.com/cranes

Gothenburg, (S) (P) MacGREGOR (SWE) AB Warehouse, Atlashuset, Banehagsliden 2 SE-414 58 GOTHENBURG Phone: (+46) 31 850 700 Telefax: (+46) 31 424 946



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Telephone (+46) 660-29 40 00


Telefax (+46) 660-139 77

SERVICE & PARTS

6.004.1 E rev.: ba 2008-05-08

U. A. E. Dubai, (S) (P) Cargotec (ARE) LLC. P.O. Box 30029 Al Quoz Industrial Area 4 Street 14B Between Interchanges 3 and 4 DUBAI Phone: +971-4-34 13 933 Telefax: +971-4-34 13 110 24h phone: +971-50-65 10 371

UNITED KINGDOM Newcastle, (P) MacGREGOR (GBR) Ltd. 1st Floor, Power House Silverlink Business Park Wallsend NE28 9ND TYNE & WEAR Phone: (+44) 191-295 2180 Telefax: (+44) 191-295 2188

USA Norfolk, (S) (P) (LCE) MacGREGOR (USA) Inc. 1220-E Fleetway Drive VA 23323 CHESAPEAKE Phone: (+1) 757-558-4580 Telefax: (+1) 757-558-4581

New Orleans, (S) MacGREGOR (USA) Inc. 4757 River Road Jefferson 70121 LOUISIANA Phone: (+1) 504-733-3321 Telefax: (+1) 504-733-3360




Telephone (+46) 660-29 40 00


Telefax (+46) 660-139 77

3 (4)

SERVICE & PARTS

6.004.1 E rev.: ba 2008-05-08




4 (4)


Telephone (+46) 660-29 40 00


Telefax (+46) 660-139 77

6.008.2 E rev.: a 2007-01-12

SERVICE

Introduction

Before proceeding to trouble-shooting, the crane operator and the service staff should familiarize themselves with the construction and functions of the crane. It is a bit late in the day to learn how to operate the crane when it has already broken down. Begin by learning the hydraulic and electric symbols used in the circuit diagrams to facilitate tracing the probable fault in the circuit diagrams, checking the findings afterwards in the crane proper. Take care always to have correct circuit diagrams available on board. If a diagram has gone astray, a new one can be had from MacGREGOR (SWE) AB, Service Division. Proper measuring instruments must always be available, e.g. pressure gauges and voltmeters. The trouble-shooting method described here is only intended as a general guide. Methods and practices may vary, but the purpose is always the same: to find the fault quickly and methodically in order to put it right.

Hydraulic circuit diagram

When a crane function ceases to operate properly, it generally does so in actual operation. This means that the crane operator will often be able to give valuable suggestions, e.g.: - Did the crane function fail without warning? - Was the operating speed first reduced, or did the movement run irregularly? - What manoeuvre immediately preceded the failure?

Electric circuit diagram Electric circuit diagram Electric circuit diagram

Begin checking if there are any visible defects.


1 (2)

6.008.2 E rev.: a 2007-01-12

SERVICE

When consulting MacGREGOR (SWE) AB, Service Division for service or advice, always give the following information at once:

Analysis of information collected

By methodical trouble-shooting, it is often possible to find, at an early stage, the defect producing the faulty operation, thereby avoiding unnecessary waste of time.

1. Which crane function has ceased to function? 2. Has it failed completely, or in part? A first check of the crane may be made thus: - Are there any leakages (jog crane) - Does the pump follow the control lever movements? To summarise, trouble-shooting operations should prefarably be carried out in the following manner: By studing the symptoms of the crane and its equipment, it is possible to deduce: 1. Is the fault electrical, hydraulic, or mechanical in nature? 2. In which function does the fault appear: - Hoisting circuit - Luffing circuit - Slewing circuit 3. Is the trouble limited to: - Raising or lowering of the load - Raising or lowering of the jib - Slewing right or left 4. Special observations: - Is the hoisting, luffing, or slewing capacity restricted? - Do disturbances occur only at certain speeds? - In the event of abnormal noise: - To which of the main functions does the noise pertain? - Is the frequency of the noise high or low? - Try to describe the noise (hissing, blowing, humming, rasping etc.) These questions are always to be answered when consulting MacGREGOR (SWE) AB, Service Division.

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SERVICE

6.100 E rev.: b 1998-10-22

Measures Before Starting, During and After Completed Service/Maintenance Work WARNING !

When it is necessary to search for/or correct faults in the crane's electrical, hydraulic or mechanical systems with the crane powered up, only authorized personnel may carry out such work. The following measures must be taken before any service or maintenance work is started. 1. The jib must be secured preferably in the parking support, (see separate instruction). 2. All lifting equipment must be parked/secured. 3. All power supplies to the crane must be cut. A. Cut the main power supply to the crane and all separate supplies such as heating, lighting etc., with the power switch(es) in the ship’s engine room. B. Warning signs must be hung on the switches involved. 4. Make sure that the crane is completely without power. If necessary, lock switches, take out fuses etc. so nobody by mistake can start the crane. 5. When special work has to be done see separate instruction or contact our service department. 6. If some special arrangements are done for testing during the service, these arrangements have to be removed after completed service. 7. Function test safety items i.e. limits, brakes etc. after completed work. 8. Protections i.e. covers, rails etc. to be reinstalled after completed work.


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SERVICE

6.100 E rev.: b 1998-10-22



2 (2)

SERVICE

6.120.15 E rev.: d 2005-10-04

Slewing Gearset

Oil filling Plug

Air filter Expansion tank a Expansion pipe Disc brake

Oil level sight glass

Screws holding gearset to crane house floor

Oil outlet

- Fill gear oil as required (see lubricating instructions for appropriate type; the approximate quantity needed is given on the nameplate). - Fill brake disc chamber with hydraulic oil; e.g. 0,1 litre ATF-oil, type A. Brake surface sealed with Loctite type 573. - Before assembling the drive motor, grease shaft and gear teeth with a suitable grease for protection against corrosion; we suggest OPTIMOLY PASTE White T. - Check function of slewing gearset with the drive motor running, paying particular attention to the function of the brake and the correct control of the motor.

Maintenance Lubrication

Fig. 1. Slewing gearset. Assembly of slewing gearset

- Install slewing gearset in crane without using force. - Use hand pump to release disc brake hydraulically. Input drive sleeve must turn easily. - Check slewing gear backlash (pinion-to-rim gear). See description under Checking and adjusting slewing rim backlash. - The gear backlash may be adjusted by rotating the gearset one or more screw hole divisions. - Tighten the screws to torque recommended, secure with Loctite 242 (or a similar compound). Applying a suitable sealing compound, such as Loctite 640, on the mating surfaces of the flanged connection, is recommended. - Remove threaded plug from top of expansion pipe (for transport sealing only). - After installation of gear unit fit supplied air filter with oil expansion tank, at marked position a (optional to fit with a tube turn). See Fig. 1.

The slewing gearset is splash lubricated. The output shaft roller bearing is ”for-life” lubricated with ball bearing grease. Oil level check

Inspect oil level when the gear is at rest with the brake engaged. Oil changes

Whenever practicable, let the oil drain off while still hot; remove also the filler plug(s). For oil change open both pipes. Remove air filter with oil expansion tank at marked pos. a, see Fig 1. At low ambient temperatures, flush out the gearcase with a quantity of fresh oil to remove abraded matter and contamination products.


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SERVICE

6.120.15 E rev.: d 2005-10-04

Gearcase and oil inspection Sampling oil

Withdraw a sample of gearcase oil for inspection from the filling drained off at intervals as described in the Maintenance Chart. To obtain a representative sample, drain the gearcase during operation and with the oil at operating temperature. Oil discoloration

A darkish or black colour of the used oil suggests that temperatures in excess of 100o C did occur in operation, causing accelerated aging of the oil and impaired lubricating properties. In this case the oil should be changed at shorter intervals. If the oil sample displays a cloudy aspect, it may be that water has managed to seep into the oil. The oil must then be changed a t o n c e, and the gearcase flushed out very thoroughly several times with fresh oil. The gearcase should preferably be dismantled for inspection beginning at the input side, and the components examined for signs of corrosion.

If coarser abraded matter (above 25 µ) or flake off material from the gear teeth is found, the gearset must be dismantled, irrespective of the actual amount of foreign matter present, beginning at the input end of the gearset.

Hydraulic-Release Multiple-Disc Brake Technical description

The brake comprises the following major components: - Brake piston - Brake cylinder - Disc carrier - Internal discs - External discs - Sealings - Thrust spring The brake housing is mounted on top of the gearcase, with long assembly screws through the motor adapter housing and both parts of the brake housing. The sleeve disc carrier, with the internal discs, is fixed on the driven shaft with a shaft key or by splines.

Foreign solid matter

- As a first simple test, drop some of the used oil onto the filter fleece specified. Coarse foreign matter, if present, will then show up on inspection, preferablythrough a magnifying glass. - A better test may be made by diluting an oil sample with n-heptane, passing it through a diaphragm filter, washing and drying it, and weighing it to determine the mass difference.

The disc assemblies are pressed together by a set of thrust springs and the brake is disengaged by hydraulic power. Maintenance

The brake is self-adjusting. Trouble-shooting

Overall assessment

a. Braking torque insufficient

The maximum permissible amount of foreign matter carried by the oil is some 0.15 per cent of the total mass of the oil in the gearcase. These impurities must be, exclusively, very fine abraded matter (max 25 µ). If the contamination keeps within these limits, continued operation of the gearset is permitted after the oil has been changed.

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Test of brake torque may be performed according to following: - Drive hydraulic motors against closed brakes. Brakes shall be able to withstand motor torque without slipping. Note! Test procedure shall be performed only for a short period, a few seconds.


SERVICE

6.120.15 E rev.: d 2005-10-04

Motor side Thrust spring

Brake piston

Brake cylinder

Pressure oil connection

Sealing Sealing Total thickness of discs Internal discs

Leakage oil Disc carrier External discs

Gear side

Fig. 2. Disc brake. Attention: Please select the requisite number of thrust springs from parts list "gear". - Inspect brake discs and replace if excessively worn. - If discs are coloured dark yellow to blue, the discs have been overheated. Replace discs and springs. - Inspect sealings for wear. If sealings are defect replace brake cylinder and piston with sealings to new ones. b. Brake heats Check the hydraulic pressure to make sure that it is sufficient in order to disengage the brake completely.

Checking backlash

and

setting

slewing

rim

An oversize backlash between the pinion and the slewing rim will cause irregularities in the slewing movement of the crane. Read this instruction carefully prior to checking or resetting!

- Slew the crane 90 degrees and check. - Proceed to check the backlash at four 90-degree position in the rim. - Put the dial gauge on the tooth of the pinion. By manual turning at the input, the pinion can be moved in both directions up to contact with the teeth. Now, the tooth flank clearance can be exactly measured on the dial gauge. - Check the backlash at one spot - Slew the crane 90°. Check again - Proceed to check the backlash at four 90-degree positions in the rim - Compare the four backlash values. Backlash values: See drawing "Slewing assembly". The backlash shall be set at the position of the slewing rim with the lowest backlash value. Setting backlash

The backlash may be set by turning the entire gearset one or more screw hole divisions.

Checking backlash

The backlash should be checked by a dial gauge or a feeler. When slewing the crane, the backlash may vary from one position to another due to some slight excentricity of the slewing rim. It is therefore recommended to check the backlash at four positions of the slewing rim. Proceed as follows: - Check the backlash at one spot.

Proceed as follows: - Slew the crane into the position with the lowest backlash value. - Remove all screws holding the gearset to crane house floor. - Release the disc brake hydraulically by means of a manual pump.


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SERVICE

6.120.15 E rev.: d 2005-10-04

- Turn the entire gearset one or more screw hole to achieve the desired setting. To turn the gearset, remove the hydraulic motor andturn the spline sleeve on top of the gear. Note!

The turning of the entire gearset may be restricted by the hoses connected or by space limitations. To overcome this problem, release the upper part of the gearset by just removing the holding screws, see Fig. 3 ”Slewing gearset”.

Upper part Screws

Screws holding gearset to crane house floor

Make sure that the upper part can be turned freely. Turn the entire gearset (except the upper part), until the desired setting is achieved. Watch the hoses! - Replace and tighten the screws holding the gearset to the crane house floor using ”Loctite 242” or a similar compound. If the upper part has been removed

If the upper part has been removed, clean its contact surfaces and apply Loctite 640 Sealant or a similar compound. Make sure not to strain the hoses. Apply Loctite 242 on the screws holding the upper part, reinstall and tighten.

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Fig. 3. Slewing gearset.


SERVICE

6.120.62 E rev.: f 2003-03-19

Hydraulic Motors, Hoisting and Slewing Cranes type GP and HH

Hydraulic Motor 187 8383-801

Oil filling/Drain connection

Before the first operation the hydraulic motor housing should be pre-filled with hydraulic oil. The type of hydraulic oil must agree with the "Lubricating Chart", Section 5. Displacement: 30.0 cm3/rev. Pre-filling volume: 1.0 litre (Approx.) T1 alternatively T2 can be used as oil filling and drain connections. Oil filling/Drain connection



Before the first operation the hydraulic motor housing should be pre-filled with hydraulic oil. The type of hydraulic oil must agree with the "Lubricating Chart", Section 5. Displacement: 56.1 cm3/rev. Pre-filling volume: 1.0 litre (Approx.) T1 alternatively T2 can be used as oil filling and drain connections.



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SERVICE

6.120.62 E rev.: f 2003-02-19



Before the first operation the hydraulic motor housing should be pre-filled with hydraulic oil. The type of hydraulic oil must agree with the "Lubricating Chart", Section 5. Displacement: 28.1 cm3/rev. Pre-filling volume: 1.0 litre (Approx.)



Oil filling/ Drain connection

Before the first operation the hydraulic motor housing should be pre-filled with hydraulic oil. The type of hydraulic oil must agree with the "Lubricating Chart", Section 5. Oil filling/ Drain connection

Displacement: 63.0 cm3/rev. Pre-filling volume: 1.0 litre. (Approx.)



Before the first operation the hydraulic motor housing should be pre-filled with hydraulic oil. The type of hydraulic oil must agree with the "Lubricating Chart", Section 5. Displacement: 56.1 cm3/rev. Pre-filling volume: 1.0 litre. (Approx.)


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SERVICE

6.120.62 E rev.: f 2003-03-19




Hydraulic Motor

288 0303-801 288 2158-801



Before the first operation the hydraulic motor housing should be pre-filled with hydraulic oil. The type of hydraulic oil must agree with the "Lubricating Chart", Section 5. Displacement Vg: 54.8 - 0 cm3/rev. Pre-filling volume: 1.0 litre. (Approx.) Oil filling/ Drain connection






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SERVICE

6.120.62 E rev.: f 2003-02-19


4 (4)


SERVICE

6.120.96 E rev.: a 2007-01-12

Winch Winch and gearbox General The hoisting winch is driven by a high speed hydraulic motor via a planetary gearbox. The planetary gearbox has splash lubrication and is normally filled with gear oil. If the winch is supplied without oil, this is indicated on a corresponding label. A brake is integrated in each winch gear set. When the winch is running, the brake is automatically released by hydraulic pressure. Assembly of winches - Mount the winch together with winch support. The clamping screws of the winch support must be easily connectable. - Tighten the screws according to torque recommended. Secure with Loctite 242 or a similar compound. - Remove the motor flange transport cover.

Journal bearing Oil filler inlet Oil dipstick

- Connect brake line and release the disc brake hydraulically. The drive sleeve in the drive unit must turn easy. - Remove plug from the drive sleeve of the drive unit. For protection against corrosion, the drive sleeve is provided with gear oil from the gear. The plug prevents the motor flange filling with oil before mounting the motor. - Centre motor on the motor flange. Seal connection surface with Loctite 572 or similar. Fix motor with screws. Motor shaft must be grease-free. - Before test-running, fill the motor flange completely with gear oil. - Check oil level with oil dipstick. Refill oil if necessary. - Be sure that jib is in horizontal position, see Fig. 2, when checking oil level. - Oil volume: See nameplate on winch or instruction "Technical Data", section 2. - Oil type: See instruction "Lubricants for Deck Machinery", section 5. - Check rope winch with running motor as to function. Check above all the control and function of the holding brake and the drive motor. - After test-running, check oil level once more with oil dipstick. During the test-running, the oil level in the gear and motor flange adjusts itself and fills the space around the motor shaft slowly with gear oil. The oil level may therefore be reduced. - If necessary, refill oil. - The journal bearing is filled with grease. Before bringing into operation, grease again until grease emerges at the sealing profile. - Insert rope and fix it. Secure screws accordingly.

Oil filler inlet for wet running motor and shaft. Oil outlet

Fig. 1. Winch with oil filler inlet, dipstick and outlet.

Fig. 2. Jib in horizontal position.


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SERVICE

6.120.96 E rev.: a 2007-01-12

Oil changes

Oil discoloration

Whenever practicable, let the oil drain off while still hot. Remove the inlet plug (air filter). At low ambient temperature, flush out the gearbox with a quantity of fresh pre-heated oil to remove particles and sediment.

A darkish or black colour of the used oil suggests that temperatures in excess of 100°C have occurred in operation, causing accelerated ageing of the oil and impaired lubricating properties. In this case the oil should be changed at shorter intervals.

Maintenance - Change gearbox oil, see Fig 1. - Grease journal bearing, see Fig 1. - Check oil level, see Fig 1. Note! Oil level can only be inspected with non-running gears and with jib in horizontal position, see Fig. 2. Maintenace interval and number of grease nipples: See "Lubricating Chart", section 5.

If the oil sample displays a cloudy aspect, it may be that water has managed to seep into the oil. The oil must then be changed at once, and the gearbox flushed out very thoroughly several times with fresh oil. The gearbox should preferably be dismantled for inspection beginning at the input side, and the components examined for signs of corrosion.

Foreign solid matter

Sampling oil

As a first simple test, drop some of the used oil onto the filter fleece specified. Coarse foreign matter, if present, will then show up on inspection through (preferably) a magnifying glass. A better test can be made by diluting an oil sample with n-heptane, passing it through a diaphragm filter, washing and drying it, and weighing it to determine the mass difference.

Take a sample of gearbox oil for analysis at intervals as described in the "Maintenance Chart".

Overall assessment

Types of oil and grease: See "Lubricants for Deck Machinery", section 5. Oil volume: See "Technical Data", section 2.

Procedure for oil sampling: - The oil temperature in the gearbox should be above +40 0C. - Special oil sampling bottles should be used that can be obtained from oil companies. - The oil sample should be taken from the oil drain on the winch, see Fig. 1. - Drain 1-2 litres of oil into a bucket. This oil should be disposed of. - Fill the oil sample bottle. - Send the oil sample to an oil company for analysis. The oil company will be able to recommend if the oil can be further used. Feedback on the oil analysis can also be obtained from MacGREGOR (SWE) AB, Service Division.

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The maximum permissible amount of foreign matter carried by the oil is some 0.15 per cent of the total mass of the oil in the gearbox. These impurities may only consist of very finely abraded matter (max. 25 µm). If the contamination keeps within these limits, continued operation of the gear set is permitted after the oil has been changed. If coarser abraded matter (above 25 µm) or flake-off material from the gear teeth is found, the gear set must be dismantled, irrespective of the actual amount of foreign matter present, beginning at the input end of the gear set.


SERVICE

6.120.96 E rev.: a 2007-01-12

Hydraulic-Release Multiple-Disc Brake Technical description

Trouble-shooting

The brake comprises the components. See also Fig. 3. -

following

major

Brake piston Brake cylinder Disc carrier Inner discs Outer discs Hydr. part for disc brake Compression spring

The brake housing is mounted on the input side of the gearbox, with long assembly screws through the motor adapter housing and both parts of the brake housing. The disc assemblies are pressed together by a set of compression springs and the brake is disengaged by hydraulic power.

Braking torque insufficient Test of brake may be performed as follows: - Drive winch hydraulic motors against closed brake. The motor shall not be able to rotate. Note! Test procedure shall be performed only for a short period; a few seconds. - Inspect brake discs and replace if excessively worn. If brake discs are coloured dark yellow to blue, the discs have been overheated. Replace discs and springs. - Inspect brake for leakage. If leakage appears in oil pressure unit, the complete unit must be replaced. Note! Sealings are not available as spare parts. Brake heats Check the hydraulic pressure to make sure that it is sufficient in order to disengage the brake completely.

Maintenance The brake is self-adjusting.

Motor side Hydr. part for disc brake

Compression spring Connect pressure oil

Leakage oil

Outer disc

Arrangement of the brake discs

Inner discs

Disc carrier

Gear side

Fig. 3. Disc brake.


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SERVICE

6.120.96 E rev.: a 2007-01-12


4 (4)


SERVICE

6.142.5 E rev.: a 2002-01-09

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

Hydraulic hoses and couplings assembled on outside of crane house Hydraulic hoses assembled on outside of crane house should be inspected for damage every two (2) years, see Maintenance Chart in section 5.

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

Replacement of hydraulic hoses All hydraulic hoses assembled inside crane house should be replaced after ten (10) years due to safety reasons. All hydraulic hoses assembled on outside of crane house should be replaced after five (5) years due to safety reasons.

Hose coupling

Mating coupling

O-ring

Screw

Fig. 1. Hose coupling with O-ring.

Fig. 2. Flange coupling with O-ring.


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SERVICE

6.142.5 E rev.: a 2002-01-09


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SERVICE

6.214 E rev.: i 2007-03-02

Tightening Torques Studs/Screws and Bolts Introduction This instruction applies to studs, screws and bolts generally, if separate recommendations are not given. Apply Molykote R 1000 lubrication on the threads and under the bolt head. For stainless elements and hydraulic pipe couplings apply Gleitmo paste. Slewing bearing, studs/screws

Note! Threads that have been rolled after hardening have a lower surface notch indicating that the permitted tension amplitude at fatigue can be about doubled compared to threads that have been rolled before hardening. If the screw has been loaded beyond the yield limit, this feature will disappear.

See drawings "Slewing bearing mounting" and "Slewing bearing yard mounting" in Section 9.3.

Phosphatized bolts greased with Molykote R 1000

Untreated bolts greased with Molykote R 1000

(Also valid for bolts greased with Loctite 243 or oil.)

(Also valid for bolts greased with Loctite 243 or oil.)

Thread

Tightening torque in Nm 10 Nm 1 kpm 8.8 10.9 12.9

Thread

Tightening torque in Nm 10 Nm 1 kpm 8.8 10.9 12.9

≈

M

UNC

4 5 6 7 8 10 12 1/2" 14 5/8" 16 3/4" 18 20 22 24 1" 27 30 1 1/4" 33 36 39 42

2.5 4.9 8.4 13.8 20.6 40.4 69.7 80.8 110 159 169 280 237 331 445 572 670 826 1127 1308 1522 1961 2520 3130

3.4 7.0 12.0 19.8 28.4 55.9 98 114 156 224 238 393 332 465 626 804 942 1161 1582 1840 2133 2761 3543 4395

4.2 8.3 14.6 23.2 34.4 67.9 117 136 187 269 286 471 398 558 752 963 1131 1393 1901 2208 2563 3311 4248 5280

≈

M

UNC

4 5 6 7 8 10 12 1/2" 14 5/8" 16 3/4" 18 20 22 24 1" 27 30 1 1/4" 33 36 39 42

2.9 5.7 9.8 16.1 24.0 47.0 81.0 94.0 128 185 197 325 275 385 518 665 779 961 1310 1521 1770 2280 2930 3640


4.0 8.1 14.0 23.0 33.0 65.0 114 132 181 260 277 457 386 541 728 935 1095 1350 1840 2140 2480 3210 4120 5110

4.9 9.7 17.0 27.0 40.0 79.0 136 158 217 312 333 548 463 649 874 1120 1315 1620 2210 2567 2980 3850 4940 6140

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SERVICE

6.214 E rev.: i 2007-03-02

As a rule, always change screws with specified tightening torque on cranes in operation if the joint has to be opened for some reasons. If any joint has been opened apply Intertuf after tightening the joint to avoid rust damage.

SAE flange for high pressure hose couplings Flange 6000 psi 3/4" 1" 1 1/4" 1 1/2" 2"

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Screw

M10 M12 M14 M16 UNC 3/4

Tightening torque in Nm 10 Nm 1 kpm Class H 10.9 and 12.9 ≈

54 94 150 230 377

Stainless bolts and hydraulic pipe couplings greased with Gleitmo paste Thread d

6 8 10 12 14 16 18 20 22 24 27 30 33 36 39

Tightening torque in Nm 10 Nm 1 kpm Austenite (A) 50 70 80 3.3 7 9.3 7.8 17 22 15 33 44 27 57 76 43 91 121 65 140 187 91 195 260 127 273 364 171 367 490 220 472 629 318 682 909 434 930 1240 585 1250 1670 755 1620 2160 969 2080 2770


≈

SERVICE

6.214 E rev.: i 2007-03-02

Strength of screws and bolts Strength class 4.6 5.8 6.6 8.8 10.9 12.9

Min. ultimate strength (kp/mm2) N/mm2 400 500 600 800 1000 1200

(40) (50) (60) (80) (100) (120)

Min. tensile strength N/mm

(kp/mm )

Corresponding strength class of nuts

240 400 360 640 900 1080

(24) (40) (36) (64) (90) (108)

4 5 6 8 10 12

2

2

Examples of markings: Hexagonal screw

Allen screw

Strength class 4.6:

Strength class 12.9:

BH 12 9 M

Strength class 8.8:

Hexagonal nut Strength class 8:

Strength class 10.9:

M-thread

UNC- and UNF-thread Cold forged

UNC- and UNF-thread Forged

Strength class 10:

M-thread

UNC- and UNF-thread Forged


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SERVICE

6.214 E rev.: i 2007-03-02

Tightening Torques Hydraulic Couplings The values below presume greasing of threads when assembling.

Type of coupling GE 10-LM GE 10-LR GE 12-LM GE 12-LR GE 15-LM GE 15-LR GE 18-LM GE 18-LR GE 22-LM GE 22-LR GE 28-LM GE 28-LR GE 35-LM GE 35-LR GE 42-LM GE 42-LR

Thread M and R

Tightening torque in Nm

M 14x1,5 R 1/4 M 16x1,5 R 3/8 M 18x1,5 R 1/2 M 22x1,5 R 1/2 M 26x1,5 R 3/4 M 33x2 R1 R 42x2 R 1 1/4 M 48x2 R 1 1/2

ca 39 ca 39 ca 59 ca 59 ca 69 ca 108 ca 108 ca 108 ca 128 ca 157 ca 216 ca 265 ca 353 ca 392 ca 491 ca 491

Type of coupling GE 10-SM GE 10-SR GE 12-SM GE 12-SR GE 14-SM GE 14-SR GE 16-SM GE 16-SR GE 20-SM GE 20-SR GE 25-SM GE 25-SR GE 30-SM GE 30-SR

Thread M and R M 16x1,5 R 3/8 M 18x1,5 R 3/8 M 20x1,5 R 1/2 M 22x1,5 R 1/2 M 27x2 R 3/4 M 33x2 R1 M 42x2 R 1 1/4

Sealing

d = 10

Fitting Sealing cone Insert the sealing cone into the 24-degree coupling fitting, firmly tighten the coupling by hand. Using a wrench, tighten the coupling nut another 1/4 to 1/2 turn. The O-ring should preferably be oiled. Hose

Coupling

Tables 1 and 2 Grease

O-ring sealed

4 (4)

ca 59 ca 69 ca 78 ca 69 ca 108 ca 128 ca 128 ca 128 ca 196 ca 206 ca 294 ca 314 ca 491 ca 491

Table 2. Example: GE 10 - LM

Table 1.

Tiightening torque in Nm

Sealing


SERVICE

6.216.69 E rev.: d 2005-06-23

Rope Reeving Diagram for Cranes Type GP and HH 1-Part Rigging

Hoisting wire rope


1 (4)

SERVICE

6.216.69 E rev.: d 2005-06-23

Rope Reeving Diagram for Cranes Type GP and HH 2-Parts Rigging

Hoisting wire rope

Locking plate Lock washer Screw

Spacer Wire thimble

Note! The wire rope thimble should be safely secured.

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SERVICE

6.216.69 E rev.: d 2005-06-23


Hoisting wire rope

Spacer

Bolt

Nut

Split pin



3 (4)

SERVICE

6.216.69 E rev.: d 2005-06-23


Hoisting wire rope

Locking plate Lock washer Screw

Spacer Wire thimble


4 (4)


SERVICE

6.222.1 E rev.: a 1998-04-17

Handling, Installation and Maintenance of Steel Wire Ropes


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SERVICE

6.222.1 E rev.: a 1998-04-17

Unloading steel wire ropes

It is advisable to lift a reel by means of a shaft which is put through its axis bore.

When handling a steel wire rope, the first trouble often occurs immediately upon receiving it: the fork of the fork lift truck is either placed under the reel or inside the coil.

If the fork of the fork lift truck is longer than the width of the reel, the reel can also be lifted at the flanges.

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

Storing steel wire ropes

Steel wire ropes should be stored in a clean, cool, dry place indoors. The ropes must not be allowed to rest on the floor. They can be placed on pallets.

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SERVICE

6.222.1 E rev.: a 1998-04-17

If outdoor storage cannot be avoided the ropes must be covered in a way that moisture cannot create corrosion problems. Although plastic foil protects the ropes from rain, condensation from beneath might not be able to escape and could damage the ropes permanently. To avoid condensation problems, it is advisable to use breathable water-proof fabric covers readily available from tarpaulin manufactures.

Unwinding steel wire ropes from the reel

An unreeling stand (turnable) should be used to unwind a wire rope from its reel. Another accepted unreeling method is to mount the reel on a shaft supported by two jacks or a stand.

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

Installing steel wire ropes

When installing steel wire ropes, extra care must be taken that the ropes are unwound from the ring or reel without torsions and without any outer damage. The same applies to reeving the ropes into the system.

Rolling the wire rope along the floor, as is sometimes recommended in the relevant literature, does not work very well in practice because the reel always unwinds less wire than the distance the reel travels, so that with this method the rope has to be dragged along the worker.

Unwinding steel wire ropes from the coil

If a rope is delivered on a coil, it is either unwound on a turntable or the coil is rolled along the ground like a hoop. In the latter case ensure that the surface is clean; sand or grit that sticks to the lubricant might damage the wires when the rope travels or sheaves.


3 (12)

SERVICE

6.222.1 E rev.: a 1998-04-17

Under no circumstances must the rope be pulled off a coil while it is lying on the ground or looped over the head of the reel, because this will inevitably induce one torsion per wrap into the rope.

If one end of the ropes has a fitting attached, as it is mostly the case with deck cranes, there is no other possibility than pulling the loose rope end through the whole reeving system. The most common rope fittings for deck cranes are shown below.

Every torsion will change the lay lengths of the stands and of the wire rope; at the same time the proportions of lengths of the rope elements and finally the distribution of load within the rope are changed. A rope that is unwound at the sides of a coil or reel will try to resist the enforced torsions and form loops. When pulled taut these loops will result in irreparable kinks.

The aluminum ferrule with mechanical splice.

The cast steel ferrule with mechanical splice.

Steel wire ropes with kinks are not safe to operate and must be discarded. The spelter socket. The installation procedure

Typical deck crane example

The most advantageous way of installing a steel wire rope varies from crane to crane. In any case a procedure should be chosen that (under justifiable expenditure) guarentees the least risk of torsions and avoids damage to the rope by contact with parts of the construction.

Below is shown an example of a typical deck cran e, where the rope must be spooled from the reel via sheaves S1 through S9 onto the drum.

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

4 (12)


SERVICE

6.222.1 E rev.: a 1998-04-17

Here, special attention must be paid to the hook block. It must be secured in an upright position so that the rope can be spooled without any fleet angles occuring between the rope and the block´s sheaves.

Winding the steel wire rope from the reel onto the drum

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

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

Installing the rope with the help of the old one or by a thinner rope

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

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

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


5 (12)

SERVICE

6.222.1 E rev.: a 1998-04-17

When installing a lang lay rope one must take care that the Chinese finger cannot unwind from the rope like the nut from a screw. It is recommended to wrap a tape around the whole rope length to be held by the Chinese finger to increase the friction.

Under no circumstances should one attempt to generate the tensioning load by jamming the rope, for instance between two boards. Structural changes would deform the rope beyond repair.

Installing under load

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

Attaching the rope termination to the fix point

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

Ample rope tension can be provided by a simple plank bearing against the reel flanges or by a braking disk attached to the reel.

6 (12)


SERVICE

6.222.1 E rev.: a 1998-04-17

"Breaking-in" the steel wire rope

After the rope has been installed and before it is going to do its proper job, several run-throughs of the normal operational circle should be carried out under light load. The new rope should be "broken-in", so that the component parts can settle and adjust themselves to the actual operating conditions. It is most unfortunate that in practice only too often the exact opposite of this recommendation is performed: quite frequently after installing the rope overload tests are carried out with loads beyond the safe working load of the system.

The rope and this wire end are now wrapped moving away from the location of the intended cut.

The rope is tightly wrapped for a distance of approx. three rope diameters.

Both ends of the seizing wire are then pulled tight and twisted together for a length of one rope diameter.

Cutting steel wire ropes

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

The twisted connection is then hammered into a gusset between the strands. After preparing the other side of the intended cut accordingly the rope can now be cut.

Instead of using one long seizing it is also possible to apply at least three seizing the size of one rope diameter each on both sides of the intended cut.

The maintenance of steel wire ropes

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


7 (12)

SERVICE

6.222.1 E rev.: a 1998-04-17

Relubricating steel wire ropes

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

It is important with all different methods of relubrication of steel wire ropes that they are carried out regularly right from the beginning of the service life of the rope and not only after the first damage has been ascertained.

Cleaning steel wire ropes

DIN 15 020 recommends: "From time to time very dirty steel wire ropes should be cleaned externally". This applies particularly to ropes operating in extremely abrasive conditions and to those that take up chemicals. Effective cleaning without proper tools is quite a laborious job. For cleaning steel wire ropes the Canadian Rigging Manual recommends an appliance with three rotating wire brushes and an air blast drying system to follow. An American manufacturer offers a "rope porcupine", a sleeve equipped with brushes, which is drawn along the steel wire rope.

There are several techniques of lubricant application: The most common ones at present are painting or swabbing.

Removing broken wires

Quite often the lubricant is applied at a sheave, sometimes a continuous drip method is used. If only a little lubricant is required, pressure spray nozzles can be applied.

If during an inspection ends of broken wires are detected which might cross adjacent wires and destroy them when running over sheaves, these broken wire ends must be removed.

Maximum penetration of the lubricant into the gaps of the rope, can only be quaranteed if high pressure lubrication is applied with the help of a pressure lubricator.

Under no circumstances should the broken wire ends be pinched off with a pair of nippers. The best method is to move the wire ends backwards and forwards until they break deep in the valley between two outer strands. With thicker wires a tool should be moved backwards and forwards on the surface of the rope, thus bending the wires until they break.

With this method the two halfs of a sleeve, which is equipped with rubber sealings, are clamped round the rope and screwed together. While the rope runs through the lubricator the lubricant is pressed into the sleeve at a pressure upto about 30 bars.

8 (12)


SERVICE

6.222.1 E rev.: a 1998-04-17

Cutting or shifting steel wire ropes

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


9 (12)

SERVI CE

6 . 2 2 2 . 1 E r e v. : a 19 9 8 - 0 4 - 1 7

Examples of damage to steel wire ropes

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

Localized wear caused by chafing against adjacent steel structures possibly because of vibrations of the length of wire rope laying between drum and sheave.

Heavy wear caused by high contact pressure in sheave groove.

Severe corrosion.

Typical wire rupture caused by bending fatigue.

Typical example of localized wear and indentation caused by a kink in the rope.

Nonrotating multi-strand wire rope with outer strand partially disengaged because of nonuniform torsional stress.

High shock loads have caused outer layer to split open exposing steel wire rope core between strands that have come apart.

10 (12)


SERVI CE

6 . 2 2 2 . 1 E r e v. : a 1 9 9 8 - 0 4 - 1 7

Some examples of wire rupture

Contraction rupture caused by excessive stress, (e.g., if a slack line suddenly snaps taut under full load).

Wear and identations of surface wires also promote fatigue and lead to premature wire rupture.

Crown wires of outer strands may wear so thin that the residual cross sectional area of steel in the rope will not support the normal design load and contraction rupture may ensue.

Corrosion may cause wire ropes to break. As a safety measure, inspect ropes regularly and carefully to prevent catastrophes; observe manufacturer's instructions

Rupture from fatigue will often occur when undersize sheaves are used. Vibrations and torsional stress loads in the rope accelerate fatigue rupture.


11 (12)

SERVI CE

6 . 2 2 2 . 1 E r e v. : a 19 9 8 - 0 4 - 1 7


12 (12)


S E RV I C E I N F O R M AT I O N 625/1473 E rev.: b 2008-04-18

Indentation and Wear Wear on Wire Sheaves General To ensure safe working conditions and long lifetime of the wire rope it is important to inspect the condition of the wire sheaves.

The wear, see Table 1, can certainly occur on every spot where the wire rope is in contact with the wire sheave, not only on places shown in Fig. 1.

Wear criterias

Indentation

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

A new wire rope and wire sheave are in contact on certain spots, see Fig. 2. After some time the indentation will have the shape shown in Fig. 3. This is considered as normal wear.

Fig. 1. Wear on wire sheave.

Fig. 2. Contact spots.

a max 4 3 2.5 2 1.5

t 16 12 10 8 6

Table 1.

Fig. 3. Good contact between an old wire rope and the wire sheave.


1 (2)

S E RV I C E I N F O R M AT I O N 625/1473 E rev.: b 2008-04-18

An old wire rope and a worn wire sheave might have good contact condition, see Fig. 3, but when a new wire rope is installed the contact condition might be very bad, see Fig. 4. This will decrease the lifetime of the wire rope and wire sheave. It is therefore important to inspect the wire ropes according to paragraph "Wear criterias".

Fig. 4. Bad contact between a new wire rope and the wire sheave.

2 (2)


SERVICE INFORMATION 625/1560 E rev.: e 2007-01-02

Lifting Block/Beam Warning! Where equipment has swivelling and moving parts there are potential safety hazards. Care should be taken when working with or repairing equipment. If used incorrectly, breakage could occur injury or death.

General Safety

Eyes for stabilizing wires (extra equipment)

When equipment is in use, do not put hands: 1. Between sheaves, sideplates and guards. 2. In area of hook, hook nut and swivel.

Fig. 1. Lifting block for crane with two sheaves.

Take great care to avoid clothing becoming trapped. Repair and reeving should be carried out by trained personnel only. Power should be switched off before operations are carried out. Work should only take place when equipment is supported on a firm surface.

Maintenance and Service Inspection should be carried out on every possible occasion before taking into operation.

Fig. 2. Lifting block for crane with one sheave.

Particular attention should be paid to the following: 1. Wear in hook, centre pin, steel structure and threads. 2. Play in sheave bushes or bearings. 3. Spacer bolts and nuts. 4. Check for cracks in welds in steel structure. 5. Condition of safety latch and grease nipples. 6. Wear in holes in sideplates and links. If cracks or heavy gouges appear, the equipment should not be used until a qualified person examens the equipment. Contact MacGREGOR (SWE) AB, Service Division.

Fig. 3. Lifting beam for 4-rope crane.


1 (2)

SERVICE INFORMATION 625/1560 E rev.: e 2007-01-02

NO welding should be carried out unless prior authority is obtained.

working hours, see also separate lubrication chart.

If the holes in the sideplates, eyes and swivels are enlarged by more than 5%, the part should be

Limitation of use 1. Safe working load should never be exceeded. 2. Crane blocks should be used in vertical lift only. 3. Shock or side loading should not be applied, unless equipment is desigend for that purpose. 4. Load should always be in seat of hook or eye.

Fig. 4. Lifting eye.

replaced or maybe repaired. Contact MacGREGOR (SWE) AB, Service Division, for instructions. All repairs should be carried out by responsible personnel, and great care should be taken in the re-assembly of the equipment and retaining parts, i. e., grub screws, pins, etc. Check and refit only correct sizes and threads. Important:

When replacing genuine parts an overload test of the complete unit must be performed and new certificate must be issued.

Lubrication As a general rule sheaves, shafts and swivels should be greased through nipples every 100

2 (2)


S E RV I CE I N FO R MAT I ON 625/1618 E rev.: b 2007-01-02

Measuring Procedure for Wear in Slewing Bearings for Crane Types GP and HH General The slewing bearing is an essential part of the crane and must be well maintained. Over the years the slewing bearing will have some wear, and to be able to know if there is a need for changing the slewing bearing it is needed to keep a record of the wear. The initial measurements should be taken when the crane is installed at yard or within 2 months from crane installation. If the wear measurement shows wear, grease samples can be taken for analyze. See procedure on page 3.

Measuring Measurements should be taken regularly, every 6 months. When measurements are to be taken the ship shall have as little list/trim as possible. Reference points On some cranes there are two machined surfaces in the front and rear of the crane bottom plate, see Fig.1. These surfaces should be used when measuring the wear of the slewing bearing. If no such surfaces are provided two reference points must be marked on the crane bottom plate, see Fig. 2, to be used as reference point in future measuring. The first time a measurement is to be taken four reference points must be marked on the foundation Machined surface/ reference point

or lower face of slewing bearing (non rotating part). The reference points should be made on fore, starboard, aft and port side of the foundation/slewing bearing. These reference points must be made in a way that ensures that they will last the lifetime of the bearing. The reference points shall always be used at any future measuring. Procedure Two measurements shall be taken on four positions of the slewing bearing, if possible, with the jib pointing: - forward to the ship - starboard - aft - port side See Fig. 3 or 4, depending on crane design. It is important that the same position are used for all further measurements to be able to compare the measurements. For maximum allowed wear, see table on page 4. Enclosed table, on page 5, can be used to record the measurements. WARNING! Do not enter the crane foundation during crane operation. Moving crane house and machine parts may suddenly cause bodily injury or death.

Machined surface/ reference point Jib

Fig. 1. Machined surface on crane bottom plate.

Fig. 2. Marking of reference points.


1 (6)

S ER VI CE I NF OR MAT IO N 625/1618 E rev.: b 2007-01-02

Jib direction

Measurement B (back of crane)

Jib at maximum outreach

Jib direction Measurement A (front of crane)

Machined surface/ reference point on crane bottom plate

Reference point on slewing bearing

Sliding caliper

Fig. 3. Measuring wear on slewing bearing.

2 (6)


Empty hook


Jib direction

Measurement B (back of crane)

Jib at maximum outreach

Empty hook

Measurement A (front of crane)

Machined surface/ reference point on crane bottom plate

Micrometer screw

Reference point on foundation

Fig. 4. Measuring wear on slewing bearing.


3 (6)


Maximum allowed wear on slewing bearing Crane size

Allowed wear (mm)*

63

1.4

100

1.5

160

1.6

250

2.0

320

1.8

400

2.1

500

2.2

630

2.8

800

2.9

- One sample should be taken in the area under jib and one sample 180° in opposite direction. - Clean the outer or inner seal close to the next grease nipple. When cleaning the area of the seal, prevent the cleaner from contacting the seals or from entering the raceway's system. - Push new grease into the grease nipples / bearing without rotation and collect the first used grease which will come out at the seal. Attention: Do not take fresh grease for analyzing! The required quantity of grease for analyzing is approx. 2 cm3.

* Allowed wear is the maximum difference between initial measurement and actual measurement, see table on page 5. For crane size, see Technical Data in section 2 of the instruction manual: Type of crane : GP 100-xxxx HH 400-xxxx If the measured wear is bigger than the allowed wear contact MacGREGOR (SWE) AB, Service Division.

Procedure for grease sampling Following information is necessary in order to give a correct statement and allow further advice: 1. Used grease (manufacturer and type). 2. Lubrication intervals. 3. Running hours. 4. Information where the samples are taken. The correct procedure for grease sampling is very important. Procedure Proceed as follows: - The grease sample can be taken either at the inner or outer seal of the bearing.

4 (6)



Measuring of wear on slewing bearing

Fore

Vessel name:

Ps

Crane No./Mfg. No.:

Stb

Aft Initial Measurement (accuracy 0.1 mm)

Date

Jib direction

A1 (front of crane)

Allowed wear (see B1 (back of crane) table on page 4)

Fore

mm

mm

mm

Stb

mm

mm

mm

Aft

mm

mm

mm

Ps

mm

mm

mm

Measured wear

Actual measurement (accuracy 0.1 mm) Date

Jib direction

A (front of crane)

B (back of crane)

A - A1

Fore

mm

mm

mm

mm

Stb

mm

mm

mm

mm

Aft

mm

mm

mm

mm

Ps

mm

mm

mm

mm

Measured wear


Jib direction

A (front of crane)

B (back of crane)

A - A1

B1 - B

Fore

mm

mm

mm

mm

Stb

mm

mm

mm

mm

Aft

mm

mm

mm

mm

Ps

mm

mm

mm

mm

Measured wear


B1 - B

Jib direction

A (front of crane)

B (back of crane)

A - A1

B1 - B

Fore

mm

mm

mm

mm

Stb

mm

mm

mm

mm

Aft

mm

mm

mm

mm

Ps

mm

mm

mm

mm


5 (6)



6 (6)


SERVICE

6.305.11 E rev.: -

1999-06-08

Electrical Equipment, General Maintenance Introduction

Portable control boxes

General maintenance of the electric equipment of the crane is important in order to prevent unexpected breakdowns. The following general advice may be useful. Relevant block diagrams and detailed circuit diagrams are placed in section 9, SPARE PARTS.

Control panels and remote control boxes may be subjected to abuse an abnormal wear, and should be inspected after every use. The control boxes must be stored in a compartment that is well protected against moisture. Remove moisture that may have collected in the boxes, and find out how it entered.

Start the crane and try out all combinations of movements that are practicable. This will show if the electric functions are satisfactory. Inspect all electrical equipment cabinets, and components. Any defective component must be repaired or replaced without delay. A detailed inspection and overhaul at two-year intervals is recommended. Check that all screws and nuts are securely tightened in the contactor cabinets, that all switches and pushbuttons operate correctly, and that cable connections are perfectly tight and all insulating parts intact. Make sure that inspection door gaskets seal perfectly.

- Clean contacts, insulating parts, cams, contact rolls, and rotary potentiometers. - Make sure that all cable connnections are clean and securely tightened. - Clean the control levers, and grease their sliding surfaces. - Check on the return springs and grease lightly so that no grease transfers to the contacts.

Earth connection, hull Verify that the protective earth connection of the crane is made to the ship’s hull. Clean contact surfaces, when required. Earth connection, crane Check crane system earth connections, and clean contact surfaces as required.


1 (2)

SERVICE

6.305.11 E rev.: -


2 (2)


1999-06-08

SERVICE

6.990.54 E rev.: - 2008-04-02

Emergency Lowering in Case of Complete Power Failure Operation of Crane Using a Hand Pump (Optional) Introduction In the case of a power failure the hoisting, luffing and slewing circuits of a deck crane may still be operated to a limited extent by releasing their respective brakes, while observing the greatest care. The release of the brakes must be done by means of a separate hydraulic pressure source with variable pressure. This instruction describes an emergency brake release of crane by using a hand pump.

CAUTION!

- This work has to be done by skilled persons with great caution. - Only one function to be activated at the time. - Verify that no persons are within the working area of the crane. - Pump with the handle until the pressure reaches 30-33 bar (3,0-3,3 MPa) on the pressure gauge. - Release the safety valve button. Now the pressure should decrease rapidly. 14

Before taking pump into operation

5

9

2 1

Before using the pump for the first time the plug must be removed and the air filter put in place, see Fig. 2. During transportation the air filter must be replaced with the plug to avoid oil leakage and filter contamination. Check function of pump

- Press down the safety valve button and pump with the handle until pressure reaches 30-33 bar (3,0-3,3 MPa) on the pressure gauge. - Stop pumping. Now the pressure should decrease slowly.

3 16

33 bar

15

17

1. 2. 3. 5. 9.

Pump Pressure relief valve Safety valve Hydraulic hose Quick connection

14. Pressure gauge 15. Oil filling and air filter 16. Valve block 17. Tank

Fig. 1. Hand pump. Oil cap/filling, with air filter

Pressure relief valve Handle

Safety valve button Pressure gauge

Plug, used for transport Quick connection

Fig. 2. Hand pump.


1 (6)

SERVICE

6.990.54 E rev.: - 2008-04-02

Hoisting circuit, Figs. 5, 6 and 7 Hoisting machinery with fixed or variable high speed motor and multiple disc brake. Preparation

- Open ball valve 105 on the winch, see Figs. 3 and 4. - Connect hand pump to quick coupling 108, see Fig. 5. - Set handle 1A, on main valve 002, in lowering position, 19.5°, see Figs. 5, 6 and 7.

10 5

Fig. 4. Winch with variable motor. Operation

- To release the brake, press and hold the safety valve button on the hand pump unit, see Figs. 1 and 2, and start pumping oil into the multiple disc brake until it begins to open. - When the winch starts to move the greatest care must be observed so that the speed is not too high. If the speed increases too much the emergency stop should be released immediately so that the brake is closed.

19.5°

After operation

- When the operation has been completed, close the ball valve 105. - Remove hand pump.

1A

Quick coupling 108

105 002

Hand pump

Fig. 3. Winch with fixed motor.

2 (6)

Fig. 5. Hand pump connected to main control valve.


SERVICE

6.990.54 E rev.: - 2008-04-02

Example:

A complete hydraulic circuit diagram relating specifically to your crane will be found in section 9.4 in the parts manual.

Fig. 6. Part of hoisting circuit with fixed hydraulic motor.


3 (6)

SERVICE

6.990.54 E rev.: - 2008-04-02

Example:


Fig. 7. Part of hoisting circuit with variable hydraulic motor.

4 (6)


SERVICE

6.990.54 E rev.: - 2008-04-02

Luffing circuit, Fig. 10 Slew the crane to a suitable position. Lowering of the jib can be done as follows: - Remove Remove pro protec tectiv tive e cap cap.. - Not Note e me measu asure re A, A, see see Fig. Fig. 9. - Loos Loosen en the locki locking ng nut, nut, then care carefull fully y loosen loosen the the set screw on valve 204, see Figs. 9 and 10, until the jib begins to lower slowly. Note! After lowering of the jib tighten the set screw to its position, measure A, and lock with th e locking nut.

Fig. 10. Part of luffing circuit. Example:


Cap Locking Set screw nut

Fig. 9. Valve 204.

The Original Manufacturer of HÄGGLUN HÄGGLUNDS DS Cranes

5 (6)

SERVICE

6.990.54 E rev.: - 2008- 04-02

Slewing circuit, Fig. 12 12 307

Slewing machinery with high speed motor and multiple disc brake. Preparation

- Close Close the brake brake line line to tank tank by clos closing ing the the shut-off shut-off valve 307, Figs. 11 and 12. - Op Open en va valv lve e 309 309.. - Con Connec nectt the hand hand pump pump to the quic quick k coupli coupling ng 308, 308, Figs. 11 and 12.

30 9

Quick coupling 308

Operation

- Release Release the the brake brake by by pumping pumping oil from from the the hand hand pump into the disc brake so that slewing machinery machin ery is released. - The crane may now now be slew slewed ed to the desire desired d position by means of another crane.

Hand pump

After operation

- Cl Clos ose e val valve ve 30 309. 9. Fig. 11. Hand pump connected to the slewing machinery.

Example:


Fig. 12. Part of slewing circuit.

6 (6)

The Original Manufacturer of HÄGGLUN HÄGGLUNDS DS Cranes

Spare Parts Manual

9.0

How t o o rder spare parts

9.1

Mach iner y

9.2

Pu mp unit Oil cooler

9 .3

Mech anic al equipment

9. 4

Hydrau lic components

9.5

Elect ric components

9.6

4 1 9 0 7 0 0 2

Address: MacGREGOR (SWE) AB SE-891 85 ÖRNSKÖLDSVIK, Sweden Teleph Tel ephone: one: 46 - 660 - 29 29 40 00 Telefax: 46 - 660 - 13 139 77 77 (Spare Parts, Technical Services & (Technical Documentation Services) www.macgregor-group.com/cranes


9.7 9. 7

Extr tra a equ quiipme men nt

PARTS MANUAL

WINCH MOUNTING

Date

Group

Fig.

Page

2006-01-23

9.1

625-1440.102

1 (2)

PARTS MANUAL

Date

Group

Fig.

2006-01-23

9.1

625-1440.102

WINCH MOUNTING Item

Qty

Article no

Description

Supplementary data

000

1

289 3951-801

WINCH MOUNTING

001

1

289 3815-801

. WINCH

SEE FIG. 625-1450.091

002

1

188 1769-801

. HYDRAULIC MOTOR

see fig. 625-2205.016

003

8

489 4472-001

. WASHER

004

4

2151 2052-178

. WASHER

TBRB 13 x 24 FZB

005

4

2121 2030-789

. SCREW

M6S 30 x 160 -10.9

006

4

2121 2034-540

. SCREW

M6S 12 x 40 -A4-70

007

4

2126 2038-130

. NUT

M6M 30 -10

Page 2 (2)

PARTS MANUAL

WINCH

Date

Group

Fig.

Page

2006-01-23

9.1

625-1450.091

1 (2)

PARTS MANUAL

Date

Group

Fig.

2006-01-23

9.1

625-1450.091

WINCH Item

000

Qty

1

Article no

289 3815-801

Description

Supplementary data

WI NCH

5 tonnes

Page 2 (2)

PARTS MANUAL

HYDRAULIC MOTOR

Date

Group

Fig.

Page

1999-06-28

9.1

625-2205.016

1 (2)

PARTS MANUAL

Date

Group

Fig.

Page

1999-06-28

9.1

625-2205.016

2 (2)

HYDRAULIC MOTOR Item

Qty

Article no

Description

001

1

188 1769-801

HYDRAULIC MOTOR

002

1

489 6118-801

. GASKET SET

Supplementary data

PARTS MANUAL

SLEWING GEAR

Date

Group

Fig.

Page

2005-11-14

9.1

625-3255.022

1 (2)

PARTS MANUAL

Date

Group

Fig.

2005-11-14

9.1

625-3255.022

SLEWING GEAR Item

001

Qty

1

Article no

289 3822-801

Description

SLEWING GEAR

Supplementary data

Page 2 (2)

PARTS MANUAL

HYDRAULIC MOTOR

Date

Group

Fig.

Page

2000-03-07

9.1

625-2205.017

1 (2)

PARTS MANUAL

Date

Group

Fig.

Page

2000-03-07

9.1

625-2205.017

2 (2)

HYDRAULIC MOTOR Item

Qty

Article no

Description

001

1

188 1227-801

HYDRAULIC MOTOR

002

1

489 6120-801

. GASKET SET

Supplementary data

PARTS MANUAL

PUMP DRIVE

Date

Group

Fig.

Page

2005-12-19

9.2

625-4935.067A

1 (2)

PARTS MANUAL

Date

Group

Fig.

Page

2005-12-19

9.2

625-4935.067A

2 (2)

PUMP DRIVE Item

Qty

Article no

Description

Supplementary data

000

1

289 0543-801

PUMP DRIVE

001

1

188 1097-801

. PUMP

002

1

288 1629-801

. ELECTRIC MOTOR

003

1

388 6362-801

. CARDAN SHAFT

004

1

388 7217-001

. PUMP BRACKET

005

1

489 4369-801

. FLANGE BOLT FITTINGS

006

1

2152 2115-555

. O-RING

007

1

2152 2115-526

. O-RING

008

2

2183 2022-126

. LIFTING EYE BOLT

M20; DIN 580

010

12

2121 2032-540

. SCREW

M6S 12 x 40 -8.8 FZB; DIN 933

011

12

2151 2022-178

. WASHER

BRB 13 x 24 FZB

012

4

2121 2032-544

. SCREW

M6S 12 x 60 -8.8 FZB

013

4

2126 2636-122

. NUT

NYLOC -M6M 12 -8 FZB

014

8

2151 2022-178

. WASHER

BRB 13 x 24 FZB

PARTS MANUAL

PUMP

Date

Group

Fig.

Page

1999-06-09

9.2

625-4945.012

1 (2)

PARTS MANUAL

Date

Group

Fig.

Page

1999-06-09

9.2

625-4945.012

2 (2)

PUMP Item

Qty

Article no

Description

001

1

188 1097-801

PUMP

002

1

489 6144-801

. GASKET SET

Supplementary data

PARTS MANUAL

CYLINDER ASSEMBLY

Date

Group

Fig.

Page

2004-11-17

9.3

625-5882.037

1 (2)

PARTS MANUAL

Date

Group

Fig.

2004-11-17

9.3

625-5882.037

CYLINDER ASSEMBLY Item

Qty

Article no

Description

Supplementary data

000

1

289 4027-801

CYLINDER ASSEMBLY

002

2

388 7100-001

. SHAFT

003

2

489 4345-003

. LOCKING PLATE

004

2

489 4346-003

. LOCKING PLATE

WELDED

005

4

2121 2034-624

. SCREW

M6S 16 x 30 -A4-80

006

4

2151 2027-185

. WASHER

RB 17 x 30 -A4-80

007

2

2545 2110-001

. GREASE NIPPLE

G 1/4 A2-50

Page 2 (2)

PARTS MANUAL

JIB TOP

Date

Group

Fig.

Page

2004-08-03

9.3

625-6244.001B

1 (2)

PARTS MANUAL

Date

Group

Fig.

Page

2004-08-03

9.3

625-6244.001B

2 (2)

JIB TOP Item

Qty

Article no

Description

Supplementary data

000

1

288 0136-801

JIB TOP

001

2

388 7440-001

. SHAFT

002

1

388 7441-001

. SHAFT

003

3

388 7278-001

. CLIMB PROTECTION

004

2

489 4488-801

. WIRE SHEAVE

005

2

489 4345-002

. LOCKING PLATE

006

1

489 4345-001

. LOCKING PLATE

007

2

489 4465-008

. SPACER

008

3

2545 2110-001

. GREASE NIPPLE

G 1/4 A2-50

010

6

2114 2014-201

. SPLIT PIN

SP 4 x 40 A4

011

2

2121 2034-491

. SCREW

M6S 10 x 20 -A4-80

012

4

2121 2034-532

. SCREW

M6S 12 x 20 -A2 -70

013

4

2154 2233-178

. LOCK WASHER

13 RF

014

2

2154 2233-173

. LOCK WASHER

10.5 BR = 20 RF

015

15

489 4473-002

. WASHER

PARTS MANUAL


Date

Group

Fig.

Page

2004-06-04

9.3

625-6253A

1 (2)

PARTS MANUAL

Date

Group

Fig.

Page

2004-06-04

9.3

625-6253A

2 (2)

JIB BEARING ASSEMBLY Item

Qty

Article no

Description

Supplementary data

000

1

287 9974-801


001

1

388 7099-001

. SHAFT JIB BEARING

002

2

489 4371-001

. FLANGE, BEARING

003

1

489 4345-004

. LOCKING PLATE

004

2

2151 2027-192

. WASHER

RB 21 x 37 -A4

005

2

2121 2034-672

. SCREW

M6S 20 x 40 -A4-80

006

2

489 4453-001

. BOLT

007

2

2545 2110-001

. GREASE NIPPLE

G 1/4 A2-50

PARTS MANUAL

HOOK BLOCK

Date

Group

Fig.

Page

1999-05-27

9.3

625-7013.005D

1 (2)

PARTS MANUAL

Date

Group

Fig.

Page

1999-05-27

9.3

625-7013.005D

2 (2)

HOOK BLOCK Item

Qty

000

1

001

Article no

Description

Supplementary data

388 7531-801

HOOK BLOCK

SWL 5 tonnes

1

875 12401-005

. SHEAVE, COMPLETE

Incl. bearing and lock rings.

002

1

875 12054-006

.. BEARING

003

2

875 12062-004

.. LOCK RING

004

2

875 12009-001

.. SPACER

005

1

875 12404-003

. SHAFT, COMPLETE

Incl. retainer, screw, nipple.

006

1

2545 2011-025

.. GREASE NIPPLE

M10 x 1; DIN 71412

007

4

875 12406-004

. SPACER, COMPLETE

Incl. spacer tube, screw, nut.

008

1

875 12409-004

. CABLE LEADER, COMPLETE

Incl. screws, nuts.

009

1

875 12073-002

. SHACKLE

010

1

875 12001-004

. HOOK, COMPLETE

PARTS MANUAL

DIRECTION VALVE

Date

Group

Fig.

Page

1998-09-29

9.4

625-7322.011

1 (2)

PARTS MANUAL

Date

Group

Fig.

1998-09-29

9.4

625-7322.011

DIRECTION VALVE Item

Qty

Article no

Description

Supplementary data

000

1

188 1338-801

DIRECTION VALVE

001

1

489 4422-801

. GASKET SET

002

3

. MECHANICAL ACTIVATION PVM

003

1

. END PLATE PVSI

004

3

. COVER FOR HYDR. ACTIVATION PVH

005

1

. BASIC MODULE PVB

SLEWING

006

1

. BASIC MODULE PVB

LUFFING

007

1

. BASIC MODULE PVB

HOISTING

008

1

. PUMP SIDE MODULE PVP

Page 2 (2)

PARTS MANUAL

BALANCE VALVE

Date

Group

Fig.

Page

1997-12-04

9.4

625-7330.001

1 (2)

PARTS MANUAL

Date

Group

Fig.

Page

1997-12-04

9.4

625-7330.001

2 (2)

BALANCE VALVE Item

Qty

Article no

Description

001

1

388 6376-801

BALANCE VALVE

002

1

489 4539-801

. GASKET SET

Supplementary data

PARTS MANUAL

BALANCE VALVE

Date

Group

Fig.

Page

2004-03-03

9.4

625-7330.006A

1 (2)

PARTS MANUAL

Date

Group

Fig.

2004-03-03

9.4

625-7330.006A

BALANCE VALVE Item

Qty

Article no

Description

001

1

289 0839-801

BALANCE VALVE

002

1

489 5703-801

. GASKET SET

Supplementary data

Page 2 (2)

PARTS MANUAL

MOTOR VALVE

Date

Group

Fig.

Page

1995-07-06

9.4

625-7331

1 (2)

PARTS MANUAL

Date

Group

Fig.

Page

1995-07-06

9.4

625-7331

2 (2)

MOTOR VALVE Item

Qty

Article no

Description

000

1

388 6358-801

MOTOR VALVE

001

1

489 4437-801

. GASKET SET

Supplementary data

PARTS MANUAL

LIMIT VALVE

Date

Group

Fig.

Page

1995-07-06

9.4

625-7334

1 (2)

PARTS MANUAL

Date

Group

Fig.

Page

1995-07-06

9.4

625-7334

2 (2)

LIMIT VALVE Item

Qty

Article no

Description

000

1

388 6361-801

LIMIT VALVE

001

1

489 4439-801

. GASKET SET

Supplementary data

PAR TS MANU AL ARTS MANUAL

FILTER

Date

Group

Fig.

Page

1995-07-06

9.4

625-7335

1 (2)

PAR TS MANU AL AL ARTS MANUAL

Date

Group

Fig.

Page

1995-07-06

9.4

625-7335

2 (2)

FILTER Item

Qty

Article no

Description

000

1

287 9463-801

FILTER

001

1

489 4436-801

. FILTER ELEMENT

Supplementary data

PARTS MANUAL

BALL VALVE

Date

Group

Fig.

Page

1999-09-08

9.4

625-7620.004

1 (2)

PARTS MANUAL

Date

Group

Fig.

1999-09-08

9.4

625-7620.004

BALL VALVE Item

Qty

Article no

Description

Supplementary data

000

1

389 4128-801

BALL VALVE

001

1

389 3199-001

. BRACKET

002

1

389 3201-801

. HANDLE

003

2

389 3352-801

. BALL VALVE

004

1

389 3369-801

. BALL VALVE BRACKET

005

1

489 6086-801

. BRACKET

006

1

489 6127-001

. TENSION SPRING

007

4

2121 2550-325

. SCREW

MC6S 5 x 10 A4-80

008

4

2121 2550-341

. SCREW

MC6S 5 x 50 A4-80

009

4

2126 2634-114

. NUT

M6M 5 -A4 -80

010

8

2151 2027-146

. WASHER

RB 5.3 x 10 -A4

Page 2 (2)

PARTS MANUAL

Date

Group

Fig.

Page

2003-06-10

9.4

625-7970G

1 (2)

HYDRAULIC HOSES

When ordering hydraulic hoses, see marking on each hose

Article number for hydraulic hoses

Quality demands hydraulic hoses, see page 2

PARTS MANUAL

Date

Group

Fig.

Page

2003-06-10

9.4

625-7970G

2 (2)

HYDRAULIC HOSES

MacGREGOR Cranes Quality and Manufacturing Demands - Hydraulic Hoses

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

Factors Influencing the Lifetime of Hydraulic HOSES Pressure - temperature - bending radius - damage caused by outside factors. Sunlight and artificial light are also harmful to hydraulic hoses.

PARTS MANUAL

HYDRAULIC CYLINDER

Date

Group

Fig.

Page

2004-05-11

9.4

625-7990.044

1 (2)

PARTS MANUAL

Date

Group

Fig.

Page

2004-05-11

9.4

625-7990.044

2 (2)

HYDRAULIC CYLINDER Item

Qty

Article no

Description

Supplementary data

000

1

289 3178-801

HYDRAULIC CYLINDER

180 / 125

001

1

875 16403-002

. GASKET SET

Includes item 11-25.

011

1

.. PISTON SEAL

012

1

.. O-RING

013

5

.. BEARING RING

014

2

.. O-RING

015

1

.. SUPPORT RING

016

1

.. ROD SEAL

019

1

.. ROD WIPER

025

2

.. O-RING

108

2

875 16401-002

. BEARING

109

4

2545 2110-003

. GREASE NIPPLE

A-M 10 x 1 -A2-50; DIN 71412

110

1

2122 2519-445

. SCREW

MSK6SS 8 x 10 -A4; DIN 916

120

4

2121 2550-374

. SCREW

MC6S 6 x 30 -A4-80

121

2

2522 2105-014

. PLUG WITH SEAL

G 1/4; DIN 908

122

3

2545 2112-003

. GREASE NIPPLE

C-M 10 x 1 -A2-50; DIN 71412

(approx. Ø90)

(approx. Ø170)

(approx. Ø125)

PARTS MANUAL

EL. CENTRAL STARTER

Date

Group

Fig.

Page

2007-11-09

9.5

625-8630.050A

1 (2)

PARTS MANUAL

Date

Group

Fig.

Page

2007-11-09

9.5

625-8630.050A

2 (2)

EL. CENTRAL STARTER Item

Qty

Article no

Description

Supplementary data

000

1

324 1150-801

EL. CENTRAL STARTER

001

1

5829 4196-101

. EL. CABINET

002

1

324 1165-801

. TRANSFORMER

003

1

5354 4273-065

. CONTACTOR

004

1

5627 4216-054

. OVERLOAD RELAY

005

1

5381 4227-080

. LOAD SWITCH

006

1

4762 4105-075

. CURRENT TRANSFORMER

007

1

5347 4262-203

. CIRCUIT BREAKER

008

1

5692 4740-221

. HOUR METER

009

1

5697 4337-075

. AMMETER

010

1

5298 2071-221

. PILOT LIGHT

GREEN

011

1

5298 2071-220

. PILOT LIGHT

WHITE

012

1

5298 2071-222

. PILOT LIGHT

YELLOW

014

1

5347 4263-203

. CIRCUIT BREAKER

015

1

5372 2210-002

. PUSH BUTTON

RED

016

1

5372 2210-001

. PUSH BUTTON

GREEN

022

8

2647 4160-040

. EARTH CLAMP

023

4

2647 4160-350

. EARTH CLAMP

027

20

2663 4382-025

. TERMINAL BLOCK

029

2

2631 4123-252

. BRIDGE CONNECTOR

034

3

5354 4137-510

. AUXILIARY CONTACT BLOCK

035

3

5354 4137-501

. AUXILIARY CONTACT BLOCK

037

1

5381 4227-001

. HANDLE

038

1

5381 4227-002

. SHAFT

061

1

424 0494-801

. SIGN

064

1

2183 2022-122

. LIFTING EYE BOLT

PARTS MANUAL

Date

Group

Fig.

Page

2007-06-13

9.7

624-2494B

1 (2)

HAND PUMP

Oil

150

30

10

11

560

500

20

130

570

Separate part: For new motor valves

189 3090-801 624-2494 /B

90

140

Crane_3_GP160-0516-2

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