Crane 1 2 HH400-1518-4

Dept.
C7250
INSTRUCTION MANUAL
Project No.
Date: 2008-11-27
2/08006.01DAL-1
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-1
Mfg. No.
62509354 - Right crane; 62509355 - Left crane
Type of crane
HH 400-1518-4
Order specification
490 6594-801, -802 /A
Mechanical spec.
490 5946-801, -802 /-
Hydraulic spec.
490 6619-801, -802 /B
Electrical spec.
490 6620-801, -802 /-
Slewing spec.
SAFETY DOCUMENTS
Document names written with bold letters are documents with safety aspects.
INSTRUCTION NO.
GENERAL
TECHN. DESCRIP.
FUNCTION
OPERATION
MAINTENANCE
SERVICE
REV
NAME OF INSTRUCTION
1.005 E
PREFACE
1.009 E
GENERAL INSTRUCTIONS, CLEANLINESS IN HYDRAULIC SYSTEMS
1.102 E
CONVERSION FACTORS
1.518.3 ED
HYDRAULIC AND ELECTRIC SYMBOLS
2/08006.01DAL-1
TECHNICAL DATA
2.007.56 E
TECHNICAL DESCRIPTION
3.110.118 E
HYDRAULIC FUNCTION
3.142.10 E
CRANE CONTROL SYSTEM
PM40 0815-E00
OPERATING INSTRUCTION
PM40 1822-E00
CREW CHECKLIST BEFORE TAKING CRANE INTO OPERATION
4.620.13 E
PARKING THE CRANE, SEA STOWING
5.005.25 E
MAINTENANCE CHART
5.019 E
INSPECTION OF STRESSED COMPONENTS AND STRUCTURES
PM51 1217-E00
LUBRICATING CHART, GP AND HH CRANES
5.302.15 E
CRANE HOUSING / HYDRAULIC OIL TANK
5.421.16 E
LUBRICANTS FOR DECK MACHINERY
6.000 E
HOW TO ORDER SPARE PARTS
6.000.1 E
STATEMENT REGARDING DELIVERY OF SPARE PARTS TO SWIVELS, LIFTING B
6.000.2 E
RETURN FORM
6
6.0
The Original Manufacturer of HGGLUNDS Cranes
Dept. C7250
INSTRUCTION MANUAL
Project No.
Date: 2008-11-27
2/08006.01DAL-1
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
INTRODUCTION
6.100 E
MEASURES BEFORE STARTING, DURING AND AFTER COMPLETED SERVICE/M
6.120.15 E
SLEWING GEARSET
6.120.62 E
HYDRAULIC MOTORS, HOISTING AND SLEWING
6.120.96 E
WINCH
6.142.5 E
RECOMMENDATION FOR INSPECTION AND REPLACEMENT OF HYDRAULIC HO
6.214 E
TIGHTENING TORQUES STUDS/SCREWS AND BOLTS
6.216.69 E
ROPE REEVING DIAGRAM FOR CRANES TYPE GP AND HH
6.222.1 E
HANDLING, INSTALLATION AND MAINTENANCE OF STEEL WIRE ROPES
625/1473 E
INDENTATION AND WEAR ON WIRE SHEAVES
625/1560 E
LIFTING BLOCK/BEAM
625/1618 E
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 OPERAT
EXTRA EQUIPMENT 7
APPENDICES
SPARE PARTS
SEE SEPARATE TABLE OF CONTENTS
Dept. C7250
PARTS MANUAL
Project No.
Date: 2008-11-27
2/08006.01DAL-1
Page
3(3)
TABLE OF CONTENTS
GROUP DESCRIPTION
PART NUMBER
FIG
9
9.0
HOW TO ORDER SPARE PARTS
9.1
WINCH ASSEMBLY
WINCH
9.2
9.3
9.4
6.000 E
289 3955-801
A/
625-1260.156
289 3818-801
B/
625-1450.095A
WINCH ASSEMBLY
289 3955-802
A/
625-1260.157
WINCH
289 3818-802
B/
625-1450.096A
GEAR, COMPLETE
875 13019-103
-/
625-1451.096
FLANGE, COMPLETE
875 13021-034
-/
625-1451.097
DRIVE IN, COMPLETE
875 13004-105
-/
625-1451.098A
OIL PIPE, COMPLETE
875 13009-078
-/
625-1451.099
CAM LIMIT SWITCH, COMPLETE
875 13035-003
-/
625-1451.091
HYDRAULIC MOTOR
288 0303-801
E/
625-2205.003A
SLEWING GEAR
288 0867-801
E/
625-3255.002C
HYDRAULIC MOTOR
188 1223-801
B/
625-2205.010
PUMP DRIVE
289 3511-801
-/
625-4935.141
PUMP
188 1108-801
A/
625-4945.013A
JIB BEARING
288 0348-801
A/
625-6170.004A
JIB TOP
288 0094-801
A/
625-6239B
CYLINDER ASSEMBLY
289 3675-801
-/
625-5882.032
LOAD WIRE ROPE W. THIMBLE; SEE
390 9790-807
N/
HOOK BLOCK
388 7571-801
G/
625-7010C
PENNANT
389 1689-803
F/
625-6915.007A
GENERAL ARRENGEMENT
189 7278-801
A/
189 7278
CRANE ASSEMBLY, RIGHT
189 7313-801
-/
189 7313
CRANE ASSEMBLY, LEFT
189 7314-801
-/
189 7314
SLEWING ASSEMBLY
289 0842-801
A/
289 0842
SLEWING BEARING
388 7343-801
B/
388 7343
DIRECTIONAL VALVE
189 0523-801
C/
625-7322.017A
MOTOR VALVE
287 9489-802
B/
625-7327A
BALANCE VALVE
289 0687-801
-/
625-7330.004A
BALANCE VALVE
289 0840-801
A/
625-7330.005
FILTER
287 9463-801
B/
625-7335
HYDRAULIC CYLINDER
289 3195-801
B/
625-7990.052
HYDR.INST.HOUSE JIB R
189 5796-801
B/
189 5796
HYDR.INST.HOUSE JIB L
189 5797-801
B/
189 5797
HYDRAULIC CIRCUIT DIAGRAM
289 5231
-/
289 5231
EL. CENTRAL/STARTER
324 1660-801
A/
625-8630.067
ELECTRICAL SYSTEM
324 1623
-/
324 1623
HAND PUMP
189 3090-801
D/
624-2494B
HYDRAULIC HOSES
9.5
9.7
625-7970G
GENERAL
1.005 E rev.: e 2003-09-09
Preface
This instruction manual covers the MacGREGOR
hydraulic deck crane. We hope that it will prove a
valuable companion to everyone concerned with the
operation of the crane or otherwise in a responsible
position.
Spare parts
General advice how to order spare parts; spare parts
lists and illustrations.
Every manual belongs to a specific crane or piece of

equipment. The identification can be found on the label
on the manuals back.
The manual contains nine sections. The various
sections cover the following subjects:
General
Contents list; Safety; Conversion tables; Hydraulic
and electric symbols.
Technical description
Technical data; description of crane design.
Function
Electric and hydraulic functions of the crane.
Operation
Operating instructions; crane operators checklist.
Maintenance
Lubricating chart and maintenance instructions.
Service
General service instructions for the hydraulic system,
mechanical, control system and electrical equipment.
Extra equipment
Extra equipment, if any; e.g. cargo handling equipment.
Appendices
Other information, which cannot be referred to any of
the above mentioned sections.
1 (2)
GENERAL
1.005 E rev.: e 2003-09-09
THIS PAGE IS INTENTIONALLY LEFT BLANK
2 (2)
GENERAL
1.009 E rev.: a 1996-05-20
General Instructions
Cleanliness in Hydraulic Systems
General
The fundamental and foremost rule in all work with
hydraulic systems and components is absolute
cleanliness.
Many components, e.g. valves and pumps, have
very narrow tolerances, therefore microscopic impurities, invisible to the human eye, may have disastrous effect on the function of a hydraulic system.
The hydraulic system installation contains a cleaner
with a cartridge designed to stop impurities produced within the hydraulic system during operation.
Every care must be taken to prevent external impurities from entering the system when servicing or
repairing it.
Use a brush for cleaning, wipe off with a nonlinting rag, repeat the cleaning if necessary. Finish by spraying the area of operations - hose connections etc. - with the solvent.
4. Mount protective covers immediately after removing a component, a pipe or a hose. Components,
shall also be fitted with covers and plugs in order
to prevent ingress of dirt.
These covers must be kept in clean and closed
packages. After use, covers are to be cleaned in
the workshop.
5. Observe minute cleanliness when handling all
types of quick-release connectors. Spray both
connectors with solvent before making up a connection. Clean all covers before reinstallation.
Storing and filling up of hydraulic oil
This also applies for components that have been

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

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

1,01325 bar
1,03323 at
0,986923 atm
14,2233 lbf/in2 (psi)
0,980665 bar
0,689476 bar
0,70307 at
1,01972 at
14,5038 lbf/in2 (psi)
14,2233 lbf/in2
100 kPa = 0,1 MPa
1 N/m2
10,2 10-6 kp/cm 2
0,145 10 -6 lbf/in2
7,5 10-3 mm Hg
98,07 103 Pa
Power
Force
1 kp
1 kp
1 lbf
1 lbf
1N
1N
=
=
=
=
=
=
1
1
1
1
1
1
2,20462 lbf
9,80665 N
4,44822 N
0,453592 kp
0,101972 kp
0,224809 lbf
kW = 1,35962 hk
kW = 1,34102 hp (UK, US)
hk = 0,986320 hp (UK, US)
hp (UK, US) = 1,01387 hk
hk
= 0,735499 kW
hp (UK, US) = 0,745700 kW
Temperature
Moment of force
1 kpm=
1 kpm=
1 Nm
1 lbf ft
1 lbf ft
1 lbf ft
1 daNm
1 daNm
0C
0C
0F
0F
0K
0K
9,80665 Nm
7,23301 lbf ft
= 0,737562 lbf ft
= 0,135582 daNm
= 1,35582 Nm
= 0,13825 kpm
= 1,01972 kpm
= 7,37562 lbf ft
C =
=
=
=
=
=
=
32F
273,15 K
-17,7778C
255,3722 K
-273,15C
-459,67F
1
(F - 32)
1,8
F = 1,8 (K - 273,15) + 32
F = C 1,8 + 32
Moment of inertia
K=
1
(F - 32) + 273,15
1,8
C = K - 273,15
1 kg m 2 = 3417,17 lb in2
1 lb in 2 = 0,00029264 kg m2
K = C + 273,15
1 (2)
1.102 E rev.: c 1999-09-14
2 (2)
GENERAL/ALLGEMEINES
1.518.3 ED rev.: d 2007-06-08
Hydraulic and Electric Symbols

Hydraulische und elektrische Bildzeichen
This section covers a part of the symbols and port markings commonly
used in MacGREGOR (SWE) AB, Service Division hydraulic and electric
circuits, divided into three parts:
Diese Sammlung umfat einen Teil der allgemeinen Bild- und
Anschluzeichen, die in MacGREGOR (SWE) AB, Service Division,
hydraulischen und elektrischen Schemas vorkommen, unterteilt in drei
Gruppen:
1. Hydraulic symbols, basic.

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

Hydraulische Bildzeichen, kombiniert.
3. Electric symbols.
Elektrische Schaltzeichen.
1 (30)
GENERAL/ALLGEMEINES
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.
Lecklleitung .
Plug, plugged connection (alternative symbols).

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

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

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

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

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

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

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

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

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

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

Filter mit Anzeiger.
Filter with by-pass valve.

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

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

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

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

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

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

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

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

Schieber, Grundzeichen.
Electrically controlled valve.

Schieber, elektromagnetisch gesteuert.
Pressure controlled valve.

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

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

Schieber, vorgesteuert, externer Steuerdruck.
Lever controlled valve.

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

Schieber, mechanisch gesteuert.
Valve with spring return.

Schieber mit Feder-Rckfhrung.
Valve with detent.

Schieber mit Lagehalter.
4/2 direction valve

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

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

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

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

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

Druckbegrenzungsventil, regelbar.
9 (30)
GENERAL/ALLGEMEINES
1.518.3 ED rev.: d 2007-06-08
Pressure limiting valve with remote opening or closing.

Druckbegrenzungsventil mit ferngesteuerter ffnung
oder Schlieung.
Pressure reducing valve.

Druckreduzierventil.
Pressure reducing valve with T-port.

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

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

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

Filtereinheit mit Druckbegrenzungsventil.
11 (30)
GENERAL/ALLGEMEINES
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 indication.

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

Pumpe fr Lastwinde.

Pumpe fr Lastwinde.
13 (30)
GENERAL/ALLGEMEINES
1.518.3 ED rev.: d 2007-06-08

Pumpe fr Lastwinde.
Pump for luffing winch.

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

Pumpe fr Einziehwinde.
Pump for luffing or slewing.

Pumpe fr Einziehwinde oder Schwenkantrieb.
15 (30)
GENERAL/ALLGEMEINES
1.518.3 ED rev.: d 2007-06-08
Pump for slewing or luffing.

Pumpe fr Schwenkantrieb oder Einziehwinde.
Pump for slewing.

Pumpe fr 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 Splventil, Schwenkantrieb.
Unloading and flushing unit, hoisting and slewing.

Entlastungs- und Splventil, Lastwinde und Schwenkantrieb.
Flushing valve.
Splventil.
19 (30)
GENERAL/ALLGEMEINES
1.518.3 ED rev.: d 2007-06-08
Valve unit for stabilizing winch.

Ventileinheit fr Stabilisierungswinde.
Unloading unit for feed pump.

Entlastungsventil fr 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 Brste.
Fuse, supply side indicated.

Sicherung, Zufhrungsseite markiert.
Magnetic relay, contactor.

Steuergert, 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 bettigt.
Contact, manually operated without automatic return.

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

Kontakt mit Ausschalt-Verzgerung.
Contact with delayed closing.

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

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

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

Temperaturwchter, Thermostat.
Touch free contact.

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

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

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

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

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

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

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

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

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

Steuerknppel, Einziehwinde und Schwenkantrieb.
29 (30)
GENERAL/ALLGEMEINES
1.518.3 ED rev.: d 2007-06-08
30 (30)
TECHNICAL DATA
(2.001.4 E)
Project No. 2/08006.01DAL-1 rev:-
2008-11-17
GENERAL
TYPE OF CRANE
HH400-1518-4
WO
2/08006.01DAL-1
SERIAL NUMBER
Crane 1 - 62509354
Crane 2 - 62509355
WEIGHT
TYPE OF CURRENT
3 ~ 60 Hz
CONTROL VOLTAGE
230 V
SUPPLY VOLTAGE
440 V
MECHANICAL DATA
SWL
15 tonnes
JIB RADIUS
MAX
18 m
JIB RADIUS
MIN
3,6 m
LIFTING HEIGHT HOOK TRAVEL

HOISTING CAPACITY, NORMAL OPERATION
40 m
MAX
15 tonnes
HOISTING SPEED, LOW, FULL LOAD
10 m/min
HOISTING SPEED, HIGH, NO LOAD
20 m/min
LUFFING TIME FROM MAX TO MIN JIB RADIUS

SLEWING SPEED
STEEL ROPE
80 sec
MAX 1,0 rev/min
18 mm L = 185 m
No 390 9790-807
ELECTRICAL DATA
EL. MOTOR
289 2428-801
TYPE OF FREQUENCY
3 ~ 60 Hz
RATED POWER, CONT.
63 kW
RATED POWER, S6 25% INT.
92 kW
SPEED
RATED VOLTAGE
STARTING CURRENT
1772 rev/min
440 V
Y/D 245 A
1 (2)
TECHNICAL DATA
(2.001.4 E)
Project No. 2/08006.01DAL-1 rev:-
2008-11-17
HYDRAULIC DATA
HOISTING
PUMP TYPE
188 1108-801
90 cm3/rev
DISPLACEMENT
MAX. SPEED
1800 rpm
HYDRAULIC MOTOR WINCH
288 0303-801
Vg: 54.8 0 cm3/rev
DISPLACEMENT
LUFFING CIRCUIT
HYDRAULIC CYLINDER
289 3195-801
SLEWING CIRCUIT
HYDRAULIC MOTOR
188 1223-801
56.1 cm3/rev
DISPLACEMENT
MAX. SPEED
5000 rpm
OIL TANK
OIL VOLUME; OIL FILLING
950 litres
SLEWING GEAR, PLANETARY GEAR BOX

16 litres
HOISTING WINCH
2.5 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 -20C.)
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
3.110.118 E rev.: - 2008-05-09
Hydraulic Function
General
The following description refers to the MacGREGOR
Cranes service crane type GP and hose handling
crane type HH.
Three hydraulic work circuits, ie, main hoisting circuit,

luffing circuit and slewing circuit make up the complete
crane operating system.
Minor variations in the hydraulic system may occur in

individual cranes of the same type.
All three hydraulic working circuits have a common

main pump. The main pump is located inside the
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
3.110.118 E rev.: - 2008-05-09
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 (LSsignal) 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.
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)
001
102
103
104
002
The high-speed motor has a variable 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.
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.
The brake opens by the system pressure via

sequence valve 104-2, see Fig. 2.
Function
Hoisting circuit
Component identification
Neutral/idling
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
2 (8)
The speed is controlled by the hand lever (direct

connected) integrated with the main directional valve
and also by the variable speed motor displacement
due to presssure level.
The control lever can be moved in two directions,
backwards or forwards, see Fig. 3.
Legend
MMHO
CLU
MSL
With the control lever in neutral and the pump running,

the hoisting winch performs no actual work.
Hydraulic motor, main hoisting circuit

Hydraulic cylinder, luffing circuit
Hydraulic motor, slewing circuit
FUNCTION
3.110.118 E rev.: - 2008-05-09
Slewing
Slewing
Luffing
Luffing
Hoisting
Hoisting
Relief valve
Fig. 2. Hoisting winch circuit diagram.
3 (8)
FUNCTION
3.110.118 E rev.: - 2008-05-09
Hoisting and lowering
Luffing circuit
To hoist, move the control lever backwards from neutral position. This will move the spool for hoisting 0021A 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 at constant pressure level or constant
load. For different load the speed range will be
changed.
To lower the load the lever has to be moved forwards
in similar way as for hoisting.
Safety system
Pressure limiting functions: Main pressure limiting
valve 116.
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 0021B 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.
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.
Safety system
valve 216.
Slewing
Luffing
Hoisting
Fig. 3. Control lever movements.
4 (8)
FUNCTION
3.110.118 E rev.: - 2008-05-09
Fig. 4. Luffing circuit diagram.
5 (8)
FUNCTION
3.110.118 E rev.: - 2008-05-09
Slewing circuit
Introduction
Fig. 5 shows a slewing circuit diagram with the
following main components:
Hydraulic motor
Brake
Balance valve
302
303
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.
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
valve 316.
6 (8)
FUNCTION
3.110.118 E rev.: - 2008-05-09
Fig. 5. Slewing circuit diagram.
7 (8)
FUNCTION
3.110.118 E rev.: - 2008-05-09
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
condensation heater illuminates.
AFTER STOPPING
Set main switch in position "0".
STOP
Emergency stop
STARTER BOX
A. Main switch
B. Stop button
A
150
200
100
50
0
00000250 h
C. Start button
D. Crane running lamp
B C
D E
F
E. Main supply lamp
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.
2. Control lever Luffing

backwards will operate the luffing
movements.
3. Control lever Hoisting

backwards will operate the hoisting
movements.
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.
SWL (T)
Reeving
05
58
8 20
20 25
1-part
5
5
5
-
2-part
5
10
10
-
3-part
15
-
4-part
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 diagrams 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 discs.
Check according to instruction "Hoisting Winch"
under section 6.1.
Multiple disc brake, slewing gearset
Slewing gear, pinion

- 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 intervals according to the Maintenance Chart.

Note!
Rust on a painted surface does not necessarily
mean that there is a crack in the underlying material.
Remedy
When rust is found on top of or near a weld, grind
the topmost surface layer away to expose the crack
clearly. When in doubt, use 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
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.
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,

7
SEE DRWG. PARTS MANUAL SEC. 9.3
2)
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.
(1. Alternative to
central lubrication.)
2
9
5
22
10
(14. Alternative to
17
14
15
11
16
15
8
20
18
21
Jib support
3
19
3
(1. Alternative to
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 +100C.
Viscosity 9.8 cSt/40C
Example: FUCHS CEDRACON
Arctic climate: FUCHS Ceplattyn
Open spur gear units
Grease with good adhesion properties.
Example: SHELL MALLEUS GL95 (-15 to +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/40C.
NOTE!
MUST NOT contain molybdenum disulphide.
Example: SHELL CALITHA EP T2
1 (2)
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
E 2007-05-02
SERVICE
Address:
MacGREGOR (SWE) AB
SE-891 85 RNSKLDSVIK, 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
Telephone: 46 - 660 - 29 40 00
Telefax: 46 - 660 - 139 77
1 (2)
6.000 E rev.: c 2007-01-02 page 2 (2)
SE-891 85 RNSKLDSVIK, 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,
rnskldsvik, cannot supply separate spare parts
to hook blocks, swivels, lifting beams etc. to the
owner or managers. However, it is possible to
deliver such parts to the MacGREGOR service
organization, if they can guarantee that the proof
load test and appreciate inspection according to ILO
will be performed under their responsibility.
Paragraph A.1.1 stipulates that every lifting

appliance should be with the provisions of section
D.1:
(a)
(b)
(c)
before taking in to use the first time

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

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

be considered sufficient to subject that part,
by separate means, to the same stress as
would have been imposed on if it had been
tested in-situ during the testing of the
complete appliance.
Section D stipulates the Test loading is needed.
MacGREGOR (SWE) AB, rnskldsvik

Quality Department
Gunnar Tjrnstrm
Quality Manager
Section B
Paragraph B.1.2 stipulates that every item of loose
gear, including cargo blocks, lifting beams and lifting
frames, should be tested:
(a)
(b)
before it is taken in to use the first time

after any renewal or repair of a stress-bearing
part.
1 (2)
SERVICE
6.000.1 E rev.: c 2007-01-08
2 (2)
SERVICE
6.000.2 E rev.: 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
Bjrnavgen 2
SE-891 41 RNSKLDSVIK
SWEDEN
Transport means, if necessary: Advised by us on request.

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

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

have to be enclosed.
The above refers only to the return shipment as such.
1 (2)
SERVICE
6.000.2 E rev.: c 2007-05-16
RETURN FORM
To be packed inside return box or parcel
Date:
Sent by:
Newbuilding no.:
Ships name:
IMO no.:
Crane place on board:

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

from which the part
is taken:
Unit description:
Reason for return: *
*) Please note: To be filled in with short but specific details. Faulty is not enough, a much better
description is leaking, not adjustable, cracked, earthing fault, short circuit if the reason is obvious,
or, a circumstantial evidence pointing to the returned part as the reason for malfunction, like luffing
movement too slow in one direction.
(Service/guarantee: 662 5000-706)
2 (2)
SERVICE & PARTS
6.004.1 E rev.: ba 2008-05-08
MacGREGOR Global Services
BELGIUM
CHINA
DENMARK
Antwerpen, (S) (P)

MacGREGOR (NLD) B.V.
Hong Kong, (P)

MacGREGOR (SGP) Pte Ltd.
Copenhagen, (S) (P)

MacGREGOR (DNK) A/S
Luithagen-Haven 2E
B-2030 ANTWERPEN
Phone: (+32) 3-546 46 40
Telefax: (+32) 3-542 4772
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)
Smedeholm 11,
DK-2730 HERLEV
Phone: (+45) 44-53 84 84
Telefax: (+45) 44-53 84 10
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.
Limassol, (P)
MacGREGOR (CYPRUS) Ltd.
Titos Building, Office 201
58 Gladstone Street
CY 3041 LIMASSOL
Neveria 4444 - Piso 9

Las Condes
SANTIAGO
Phone: (+56) 2-207 65 90
Telefax (+56) 2-207 65 91
Phone: (+357) 25 763 670

Telefax (+357) 25 763 671
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 Khne & Nagel (AG & Co.) KG
Altenwerder Hauptstrae 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
Address
Sweden
Telephone
(+46) 660-29 40 00
Telefax
(+46) 660-139 77
1 (4)
SERVICE & PARTS
6.004.1 E rev.: ba 2008-05-08
GREECE
KOREA
Piraeus, (S) (P)

MacGREGOR (GRC) Ltd.
SINGAPORE
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
Singapore, (S) (P) (LC)

MacGREGOR (SGP) Pte. Ltd.
173-5, Songjeong-dong
Haeundae-gu
612-040 BUSAN
Phone: (+82) 51-704 0844
Telefax: (+82) 51-704 0414
9 Kian Teck Drive

628826 SINGAPORE
Phone: (+65) 626 52 322
Telefax: (+65) 626 41 261
INDIA
SPAIN
NETHERLANDS
Bombay, (S)
Renascent Enterprises
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
Rotterdam, (S) (P)

MacGREGOR (NLD) B.V.
Albert Plesmanweg 95-97
3088 GC ROTTERDAM
Phone: (+31) 10-283 2121
Telefax: (+31) 10-42 93 219
Bilbao, (P)
MacGREGOR (ESP) S.A.
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
Oslo, (P)
MacGREGOR (NOR) A/S
Skur 39, Vippetangen
NOR-0150 OSLO
Phone: (+47) 23-10 34 00
Telefax: (+47) 23-10 34 01
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
ITALY
Bergen, (S)
MacGREGOR (NOR) A/S
Genoa, (S) (P)

MacGREGOR (ITA) S.p.A.
Bleivassvegen 105
N-5363 GOTNES
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
SWEDEN
rnskldsvik, (S) (P)
MacGREGOR (SWE) AB
Service Division
Sjgatan 4 G
Phone: (+46) 660-29 40 00
Telefax: (+46) 660-139 77
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
Gothenburg, (S) (P)

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

(S)
(P)
(S) (P)
MacGREGOR (SWE) AB
Service Division
2 (4)
Address
Sweden
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

(S)
(P)
(S) (P)
MacGREGOR (SWE) AB
Service Division
Address
Sweden
Telephone
(+46) 660-29 40 00
Telefax
(+46) 660-139 77
3 (4)
SERVICE & PARTS
6.004.1 E rev.: ba 2008-05-08

(S)
(P)
(S) (P)
MacGREGOR (SWE) AB
Service Division
4 (4)
Address
Sweden
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

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.
2 (2)
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
ships 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.
1 (2)
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.
1 (4)
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 ) 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

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 ).
If the contamination keeps within these limits,
continued operation of the gearset is permitted after
the oil has been changed.
2 (4)
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.
3 (4)
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.
4 (4)
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.

Displacement:
56.1 cm3/rev.
T1 alternatively T2 can be used as oil filling and drain
connections.
1 (4)
SERVICE
6.120.62 E rev.: f 2003-02-19

Displacement:
28.1 cm3/rev.
Oil filling/Drain
connection
Oil filling/
Drain connection

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

Displacement:
56.1 cm3/rev.
Oil filling/
Drain connection
2 (4)
SERVICE
6.120.62 E rev.: f 2003-03-19
Oil filling/
Drain connection

Displacement:
63.0 cm3/rev.
Hydraulic Motor
288 0303-801
288 2158-801
Oil filling/
Drain connection
Oil filling/
Drain connection

Displacement Vg: 54.8 - 0 cm3/rev.
Oil filling/
Drain connection
Oil filling/
Drain connection

Displacement:
59.8 cm3/rev.
3 (4)
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.
1 (4)
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 100C 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.
2 (4)
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
m). 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 m) 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

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.
3 (4)
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.
1 (2)
SERVICE
6.142.5 E rev.: a 2002-01-09
2 (2)
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
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
Tightening torque in Nm
10 Nm 1 kpm
8.8
10.9
12.9
2.5
4.9
8.4
13.8
20.6
40.4
69.7
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
Thread
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
10 Nm 1 kpm
8.8
10.9
12.9
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
1 (4)
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
Screw
3/4"
1"
1 1/4"
1 1/2"
2"
M10
M12
M14
M16
UNC 3/4
2 (4)
10 Nm 1 kpm
Class H 10.9 and 12.9
54
94
150
230
377
Stainless bolts and hydraulic pipe couplings

greased with Gleitmo paste
Thread
d
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39
10 Nm 1 kpm
Austenite (A)
50
70
80
3.3
7
9.3
7.8
17
22
15
33
44
27
57
76
43
91
121
65
140
187
91
195
260
127
273
364
171
367
490
220
472
629
318
682
909
434
930
1240
585
1250
1670
755
1620
2160
969
2080
2770
SERVICE
6.214 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
Min. tensile strength

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

Forged
3 (4)
SERVICE
6.214 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

2-Parts Rigging
Hoisting wire rope
Locking plate
Lock washer
Screw
Spacer
Wire thimble
Note! The wire rope thimble should be safely secured.
2 (4)
SERVICE
6.216.69 E rev.: d 2005-06-23

3-Parts Rigging
Hoisting wire rope
Spacer
Bolt
Nut
Split pin
3 (4)
SERVICE
6.216.69 E rev.: d 2005-06-23

4-Parts Rigging
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
1 (12)
SERVICE
6.222.1 E rev.: a 1998-04-17
Unloading steel wire ropes
It is advisable to lift a reel by means of a shaft which

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

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

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

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

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

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

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

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

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

one or by a thinner rope
If the new rope is pulled in by the old one or by a
thinner rope one must make sure that the connection between these ropes is absolutely safe. In addition it must be ensured that the thinner rope cannot rotate. Rotation-resistant steel wire ropes or
three-strand ibre ropes for instance, can be recommended for this purpose. When using conven-
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 intervals,
depending on their use, particularly along the zones
subjected to bending. If for operational reasons
relubrication cannot be carried out, shorter service
life of the rope is to be expected and the inspection
intervals have to be arranged accordingly."
When choosing the relubricant, it must be ensured
that it is in accordance with the recommendations
of the rope manufacturer.
It is important with all different methods of

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

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

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

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

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

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

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

Very often wire ropes must be discarded although
only short rope sections, e. g. the one that climbs
to the second layer on the drum, are seriously damaged, while the rest of the rope is still in perfect
condition.
In cases such as this the service life of wire ropes
can be enormously increased by shortening, shifting them at the fixing point by a span that removes
the section of the rope which has had most abuse
out of the critical zone.
After this procedure an adjacent section will be subjected to the abuse.
Another typical local damage occurs on the drum
at those sections where the rope rubs against the
adjacent winding (crossover point) and must be
deflected to the side. If the damage caused in these
sections is the main reason for discarding the rope,
several cuttings or shiftings will move the stresses
to different rope zones and possibly multiply the
service life of the rope.
9 (12)
SERVICE
6.222.1 E rev.: a 1998-04-17
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)
SERVICE
6.222.1 E rev.: a 1998-04-17
Some examples of wire rupture
Contraction rupture caused by excessive stress,

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

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

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

safety measure, inspect ropes regularly and carefully to prevent catastrophes; observe manufacturer's instructions
Rupture from fatigue will often occur when undersize sheaves are used. Vibrations and torsional
stress loads in the rope accelerate fatigue rupture.
11 (12)
SERVICE
6.222.1 E rev.: a 1998-04-17
12 (12)
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 on Wire Sheaves

General
To ensure safe working conditions and long lifetime of
the wire rope it is important to inspect the condition of
the wire sheaves.
The wear, see Table 1, can certainly occur on every

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

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

certain spots, see Fig. 2. After some time the
indentation will have the shape shown in Fig. 3. This
is considered as normal wear.
Fig. 1. Wear on wire sheave.
Fig. 2. Contact spots.
a
max
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)
SERVICE INFORMATION
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)
SERVICE INFORMATION
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
SERVICE INFORMATION
625/1618 E rev.: b 2007-01-02
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)
SERVICE INFORMATION
625/1618 E rev.: b 2007-01-02
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)
SERVICE INFORMATION
625/1618 E rev.: b 2007-01-02
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

Date
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

Date
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)
SERVICE INFORMATION
625/1618 E rev.: b 2007-01-02
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 ships 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
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.
2
3
16
33 bar
15
17
1.
2.
3.
5.
9.
Pump
Pressure relief valve
Safety valve
Hydraulic hose
Quick connection
14.
15.
16.
17.
Pressure gauge
Oil filling and air filter
Valve block
Tank
Fig. 1. Hand pump.

Oil cap/filling, with air filter
Pressure relief valve
Safety valve button
Handle
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.
105
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:
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 protective cap.
- Note measure A, see Fig. 9.
- Loosen the locking nut, then carefully loosen 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 the locking
nut.
Fig. 10. Part of luffing circuit.
Example:
Cap
Locking
Set
screw
nut
Fig. 9. Valve 204.
5 (6)
SERVICE
6.990.54 E rev.: - 2008-04-02
Slewing circuit, Fig. 12

307
Slewing machinery with high speed motor and multiple

disc brake.
Preparation
- Close the brake line to tank by closing the shut-off
valve 307, Figs. 11 and 12.
- Open valve 309.
- Connect the hand pump to the quick coupling 308,
Figs. 11 and 12.
309
Quick
coupling 308
Operation
- Release the brake by pumping oil from the hand
pump into the disc brake so that slewing machinery
is released.
- The crane may now be slewed to the desired
position by means of another crane.
Hand pump
After operation
- Close valve 309.
Fig. 11. Hand pump connected to the slewing
machinery.
Example:
Fig. 12. Part of slewing circuit.
6 (6)
Spare Parts Manual
9.0
How to order
spare parts
9.1
Machinery
9.2
Pump unit
Oil cooler
9.3
Mechanical
equipment
9.4
Hydraulic
components
9.5
Electric
components
2007-09-14
9.6
Address:
MacGREGOR (SWE) AB
Telephone: 46 - 660 - 29 40 00
Telefax:
46 - 660 - 139 77
(Spare Parts, Technical Services &
(Technical Documentation Services)
9.7
Extra equipment
PARTS MANUAL
WINCH ASSEMBLY
Date
Group
Fig.
Page
2005-10-10
9.1
625-1260.156
1 (2)
PARTS MANUAL
Date
Group
Fig.
2005-10-10
9.1
625-1260.156
WINCH ASSEMBLY
Item
Qty
Article no
Description
Supplementary data
000
289 3955-801
WINCH ASSEMBLY
001
289 3818-801
. WINCH
SEE FIG. 625-1450.095
002
288 0303-801
. HYDRAULIC MOTOR
SEE FIG. 625-2205.003
003
489 4472-001
. WASHER
004
2151 2052-178
. WASHER
TBRB 13 x 24 FZB
005
2121 2030-789
. SCREW
M6S 30 x 160 -10.9
006
2121 2034-540
. SCREW
M6S 12 x 40 A4-80
007
2126 2038-130
. NUT
M6M 30 -10
Page
2 (2)
PARTS MANUAL
WINCH
Date
Group
Fig.
Page
2006-12-18
9.1
625-1450.095A
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2006-12-18
9.1
625-1450.095A
2 (2)
WINCH
Item
Qty
000
001
Article no
Description
Supplementary data
289 3818-801
WINCH
15 T, Right-hand
875 13019-103
. GEAR, COMPLETE
SEE FIG. 625-1451.096
022
875 13021-034
. FLANGE, COMPLETE
SEE FIG. 625-1451.097
024
875 13004-105
. DRIVE IN, COMPLETE
SEE FIG. 625-1451.098
060
875 13009-078
. OIL PIPE, COMPLETE
SEE FIG. 625-1451.099
097
875 13035-003
. CAM LIMIT SWITCH, COMPLETE
SEE FIG. 625-1451.091
205
875 13017-020
. CABLE FIXING
220
24
2121 2032-536
. SCREW
M6S 12 x 30 -8.8 FZB; DIN 933
221
24
2121 2032-536
. SCREW
M6S 12 x 30 -8.8 FZB; DIN 933
223
875 13018-019
. SCREW
M12 x 35
402
2121 2032-495
. SCREW
M6S 10 x 30 -8.8 FZB; DIN 933
404
16
2121 2030-628
. SCREW
M6S 16 x 40 - 10.9; DIN 933
405
16
875 13014-022
. WASHER
PARTS MANUAL
WINCH ASSEMBLY
Date
Group
Fig.
Page
2005-10-10
9.1
625-1260.157
1 (2)
PARTS MANUAL
Date
Group
Fig.
2005-10-10
9.1
625-1260.157
WINCH ASSEMBLY
Item
Qty
Article no
Description
Supplementary data
000
289 3955-802
WINCH ASSEMBLY
002
288 0303-801
. HYDRAULIC MOTOR
003
489 4472-001
. WASHER
004
2151 2052-178
. WASHER
TBRB 13 x 24 FZB
005
2121 2030-789
. SCREW
M6S 30 x 160 -10.9
006
2121 2034-540
. SCREW
M6S 12 x 40 A4-80
007
2126 2038-130
. NUT
M6M 30 -10
010
289 3818-802
. WINCH
SEE FIG. 625-1450.096
SEE FIG. 625-2205.003
Page
2 (2)
PARTS MANUAL
WINCH
Date
Group
Fig.
Page
2006-12-22
9.1
625-1450.096A
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2006-12-22
9.1
625-1450.096A
2 (2)
WINCH
Item
Qty
000
001
Article no
Description
Supplementary data
289 3818-802
WINCH
15 T, Left-hand
875 13019-103
. GEAR, COMPLETE
SEE FIG. 625-1451.096
022
875 13021-034
. FLANGE, COMPLETE
SEE FIG. 625-1451.097
024
875 13004-105
SEE FIG. 625-1451.098
060
875 13009-078
. OIL PIPE, COMPLETE
SEE FIG. 625-1451.099
097
875 13035-003
. CAM LIMIT SWITCH, COMPLETE
SEE FIG. 625-1451.091
205
875 13017-020
. CABLE FIXING
220
24
2121 2032-536
. SCREW
M6S 12 x 30 -8.8 FZB; DIN 933
221
24
2121 2032-536
. SCREW
M6S 12 x 30 -8.8 FZB; DIN 933
223
875 13018-019
. SCREW
M12 x 35
402
2121 2032-495
. SCREW
M6S 10 x 30 -8.8 FZB; DIN 933
404
16
2121 2030-628
. SCREW
M6S 16 x 40 - 10.9; DIN 933
405
16
875 13014-022
. WASHER
PARTS MANUAL
Date
Group
Fig.
Page
2006-10-16
9.1
625-1451.096
1 (2)
GEAR, COMPLETE
NOTE:
In order to replace item 31 and 41,
the complete gearbox must be disassembled.
41
520 521
31
444
473
454
491
11
192002932
46 Nm
2
21
875 13019-103
625-1451.096 /0
Weight 89 kg
110 Nm
80 Nm
PARTS MANUAL
Date
Group
Fig.
Page
2006-10-16
9.1
625-1451.096
2 (2)
GEAR, COMPLETE
Item
Qty
Article no
Description
Supplementary data
000
875 13019-103
GEAR, COMPLETE
002
18
2121 2532-554
. SCREW
MC6S 12x110 -8.8 FZB; DIN 912
011
2121 2532-502
. SCREW
MC6S 10 x 55 -8.8 FZB; DIN 912
021
18
2121 2545-548
. SCREW
MC6S 12 x 80 -10.9; DIN 912
031
875 13007-045
. SHAFT SEALING
041
875 13020-011
. SEALING BAND
444
875 13012-032
. CIRCLIP
454
875 13007-032
. SHAFT SEALING
473
875 13014-074
. SHIM
491
875 13014-044
. WASHER
520
875 13038-001
. PLUG WITH OIL VALVE
521
875 13007-008
. SEALING
L = 0.9 m
M18
PARTS MANUAL
Date
Group
Fig.
Page
2006-10-20
9.1
625-1451.097
1 (2)
FLANGE, COMPLETE
401
13
12
10
191000397
23 Nm
875 13021-034
625-1451.097 /0
Weight 21 kg
PARTS MANUAL
Date
Group
Fig.
Page
2006-10-20
9.1
625-1451.097
2 (2)
FLANGE, COMPLETE
Item
Qty
Article no
Description
Supplementary data
000
875 13021-034
FLANGE, COMPLETE
001
875 13026-014
. FLANGE
003
875 13014-046
. WASHER
004
875 13012-009
. CIRCLIP
005
875 13022-001
. FELT STRIP
006
875 13011-027
. BEARING
008
875 13023-011
. COVER
009
875 13024-003
. DRIVER
010
2121 2532-459
. SCREW
MC6S 8 x 40 -8.8 FZB; DIN 912
012
875 13025-008
. PIN
3 x 12; DIN 1481
013
875 13025-003
. PIN
5 x 16; DIN 1481
401
875 13032-002
. GREASE NIPPLE
M10 x 1; DIN 71412
L = 300 mm
PARTS MANUAL
Date
Group
Fig.
Page
2008-03-25
9.1
625-1451.098A
1 (2)
DRIVE IN, COMPLETE
60 61
75
97
46 Nm
46 Nm
76
98
22
20
67
58
59
40
30
53
41
50
70
192001251
43
64
Disc arrangement,
item 97 + 98
Gear side
Motor side
Outer discs
Inner discs
Center line
875 13004-105
625-1451.098 /A
Weight 23 kg
65
95
96
69
PARTS MANUAL
Date
Group
Fig.
Page
2008-03-25
9.1
625-1451.098A
2 (2)
DRIVE IN, COMPLETE

Item
Qty
Article no
Description
Supplementary data
000
875 13004-105
DRIVE IN, COMPLETE
004
875 13013-016
. DRIVING SLEEVE
007
875 13027-006
. MOTOR FLANGE
020
2121 2532-518
. SCREW
MC6S 10 x140 -8.8 FZB; DIN 912
022
2121 2532-515
. SCREW
MC6S 10x120 -8.8 FZB; DIN 912
030
875 13011-003
. BEARING
040
875 13012-006
. CIRCLIP
041
875 13012-005
. CIRCLIP
043
875 13012-038
. CIRCLIP
050
875 13007-022
. SHAFT SEALING
053
875 13007-023
. SHAFT SEALING
058
875 13015-030
. O-RING
130 x 3.0
059
875 13015-009
. O-RING
126 x 3.0
060
875 13006-003
. PLUG
M10
061
875 13007-007
. SEALING
064
875 13006-004
. PLUG
065
875 13007-008
. SEALING
067
875 13020-012
. SEALING PLUG
069
875 13008-011
. VENTILATION FILTER
070
875 13014-047
. SHIM
075
18
875 13002-001
. SPRING
Change all springs at the same time.
076
18
875 13002-002
. SPRING
Change all springs at the same time.
095
875 13003-001
. PRESSURE UNIT
096
875 13028-002
. DISC CARRIER
097
875 13001-001
. MULTIPLE DISC, OUTER
Change all discs at the same time.
098
875 13001-002
. MULTIPLE DISC, INNER
Change all discs at the same time.
M18
M10
PARTS MANUAL
OIL PIPE, COMPLETE
Date
Group
Fig.
Page
2006-11-22
9.1
625-1451.099
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2006-11-22
9.1
625-1451.099
2 (2)
OIL PIPE, COMPLETE

Item
Qty
Article no
Description
000
875 13009-078
OIL PIPE, COMPLETE
051
2528 2762-150
. PLUG
052
2528 2772-150
. NUT
080
875 13007-017
. SEALING
090
875 13008-009
. OIL DIPSTICK
100
875 13007-008
. SEALING
Supplementary data
1/2"
PARTS MANUAL
Date
Group
Fig.
Page
2006-12-04
9.1
625-1451.091
1 (2)
6 Nm
11
Full drum
Empty drum
6 Nm
6 Nm
10
22
7 26
5
20
8
17 18
6 Nm
60
50
10 Nm
1000000007172
23
10 Nm
20
27 28
875 13035-003
625-1451.091 /0
Ratio 197,75
Weight 7 kg
PARTS MANUAL
Date
Group
Fig.
Page
2006-12-04
9.1
625-1451.091
2 (2)

Item
Qty
000
005
Article no
Description
Supplementary data
875 13035-003
Ratio 197.75
875 13026-018
. FLANGE
007
875 13035-004
. COVER
008
875 13025-009
. PIN
4.0 x 26; DIN 1481
009
2121 2532-333
. SCREW
MC6S 5 x 25 - 8.8 fzb; DIN 912
010
2126 2032-114
. NUT
M6M 5 -8 FZB; DIN 934
011
2121 2536-325
. SCREW
MLC6S 5x10 - 8.8 fzb; DIN 7984
017
2121 2032-337
. SCREW
M6S 5 x 35 - 8.8 fzb; DIN 933
018
2151 2022-146
. WASHER
BRB 5.3 x 10 FZB; DIN 125
020
875 13018-020
. SCREW
M5 x 20, spec.
022
2121 2032-325
. SCREW
M6S 5 x 10 -8.8 FZB; DIN 933
023
2121 2532-382
. SCREW
MC6S 6 x 60 - 8.8 fzb; DIN 912
026
875 13035-005
. SEALING
027
875 13006-003
. PLUG
028
875 13007-007
. SEALING
050
2121 2532-370
. SCREW
060
875 13035-006
. CONTROL BLOCK
M10
MC6S 6 x 20 -8.8 FZB; DIN 912
PARTS MANUAL
HYDRAULIC MOTOR
Date
Group
Fig.
Page
2006-01-09
9.1
625-2205.003A
1 (2)
PARTS MANUAL
Date
Group
Fig.
2006-01-09
9.1
625-2205.003A
HYDRAULIC MOTOR
Item
Qty
Article no
Description
000
288 0303-801
HYDRAULIC MOTOR
001
489 3786-801
. GASKET SET
Supplementary data
Page
2 (2)
PARTS MANUAL
SLEWING GEAR
Date
Group
Fig.
Page
1999-02-11
9.1
625-3255.002C
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
1999-02-11
9.1
625-3255.002C
2 (2)
SLEWING GEAR
Item
Qty
000
001
Article no
Description
Supplementary data
288 0867-801
SLEWING GEAR
MODULE 16
875 13004-001
Includes item 2-24. Also order springs
002
875 13001-001
.. MULTIPLE DISC, OUTER
Change all 16 discs at the same time
003
875 13001-002
.. MULTIPLE DISC, INNER
Change all 16 discs at the same time
006
875 13003-001
.. PRESSURE UNIT
007
12
2121 2532-515
.. SCREW
MC6S 10 x 120 -8.8 FZB; DIN 912
008
18
2121 2532-554
.. SCREW
MC6S 12 x 110 -8.8 FZB; DIN 912
009
875 13007-002
.. SHAFT SEALING
010
875 13011-001
.. BEARING
011
875 13012-001
.. CIRCLIP
012
875 13012-002
.. CIRCLIP
021
875 13027-006
.. MOTOR FLANGE
022
875 13028-002
.. DISC CARRIER
023
.. BRAKE FLANGE
Not sold separately. See item 1.
024
.. DRIVING SLEEVE
Not sold separately. See item 1.
025
18
875 13002-001
. SPRING
Change all 36 springs at the same time
026
18
875 13002-002
. SPRING
Change all 36 springs at the same time
031
. SUN WHEEL
Not sold as spare part.
041
875 13006-001
. PLUG, MAGNETIC
M22
042
875 13006-002
. PLUG
M22
043
875 13007-001
. SEALING
044
875 13005-001
. OIL SIGHT GLASS
M22
045
875 13008-002
M22
046
875 13008-001
M10
047
875 13009-001
. PIPE
048
875 13010-001
. COUPLING
PARTS MANUAL
HYDRAULIC MOTOR
Date
Group
Fig.
Page
1998-10-09
9.1
625-2205.010
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
1998-10-09
9.1
625-2205.010
2 (2)
HYDRAULIC MOTOR
Item
Qty
001
002
Article no
Description
Supplementary data
188 1223-801
HYDRAULIC MOTOR
SLEWING
489 6118-801
. GASKET SET
PARTS MANUAL
PUMP DRIVE
Date
Group
Fig.
Page
2005-02-11
9.2
625-4935.141
1 (2)
PARTS MANUAL
Date
Group
Fig.
2005-02-11
9.2
625-4935.141
PUMP DRIVE
Item
Qty
Article no
Description
Supplementary data
000
289 3511-801
PUMP DRIVE
001
188 1108-801
. PUMP
003
289 2428-801
. ELECTRIC MOTOR
005
388 6363-801
. CARDAN SHAFT
006
388 6365-001
. FLANGE
007
388 6367-002
. FLANGE
008
388 9264-001
. PUMP BRACKET
009
389 4437-801
. INTAKE PIPE
011
489 4370-801
. MOUNTING BOLT SET
012
489 4417-003
. WASHER
013
489 4451-001
. SIGN ARROW
015
0662 0882-004
. PROTECTIVE FOIL
024
2121 2032-493
. SCREW
M6S 10 x 25 -8.8 FZB; DIN 933
025
2121 2032-624
. SCREW
M6S 16 x 30 -8.8 FZB; DIN 933
026
12
2121 2032-540
. SCREW
M6S 12 x 40 -8.8 FZB; DIN 933
027
2121 2032-634
. SCREW
M6S 16 x 70 -8.8 FZB
030
2126 2636-124
. LOCKING NUT
NYLOC-M6M 16 -8 FZB; DIN 982
032
12
2151 2022-178
. WASHER
BRB 13 x 24 FZB
033
2151 2022-185
. WASHER
BRB 17 x 30 FZB
034
2152 2115-526
. O-RING
035
2152 2115-555
. O-RING
036
2183 2022-126
. EYE BOLT
037
2522 2105-012
. PLUG WITH SEAL
M20; DIN 580
Page
2 (2)
PARTS MANUAL
PUMP
Date
Group
Fig.
Page
2005-02-14
9.2
625-4945.013A
1 (2)
PARTS MANUAL
Date
Group
Fig.
2005-02-14
9.2
625-4945.013A
PUMP
Item
Qty
Article no
Description
001
188 1108-801
PUMP
002
489 6125-801
. GASKET SET
Supplementary data
Page
2 (2)
PARTS MANUAL
JIB BEARING
Date
Group
Fig.
Page
2004-04-23
9.3
625-6170.004A
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2004-04-23
9.3
625-6170.004A
2 (2)
JIB BEARING
Item
Qty
Article no
Description
Supplementary data
000
288 0348-801
JIB BEARING
001
388 7848-001
. SHAFT
002
489 4658-001
. BEARING
003
489 4345-005
. LOCKING PLATE
004
489 4346-005
. LOCKING PLATE
WELDED
005
2121 2034-672
. SCREW
M6S 20 x 40 -A4-80
006
2151 2027-192
. WASHER
RB 21 x 37 -A4
007
489 4453-001
. BOLT
008
2545 2110-001
. GREASE NIPPLE
G 1/4 A2-50
PARTS MANUAL
JIB TOP
Date
Group
Fig.
Page
2004-04-23
9.3
625-6239B
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2004-04-23
9.3
625-6239B
2 (2)
JIB TOP
Item
Qty
Article no
Description
Supplementary data
000
288 0094-801
JIB TOP
001
388 7346-001
. SHAFT
002
388 7224-001
. SHAFT
003
388 7278-002
. CLIMB PROTECTION
004
489 4474-801
. WIRE SHEAVE
005
489 4345-002
. LOCKING PLATE
006
489 4345-003
. LOCKING PLATE
007
489 4465-001
. SPACER
008
2545 2110-001
. GREASE NIPPLE
G 1/4 A2-50
010
2114 2014-201
. SPLIT PIN
SP 4 x 40 RF
011
2121 2034-532
. SCREW
M6S 12 x 20 -A2 -70
012
2121 2034-622
. SCREW
M6S 16 x 25 -A4-80
013
2154 2233-178
. WASHER
13 RF
014
2154 2233-186
. LOCKING WASHER
17 BR = 30 RF
015
15
489 4473-001
. WASHER
016
388 7347-001
. SHAFT
017
489 4465-002
. SPACER
PARTS MANUAL
CYLINDER ASSEMBLY
Date
Group
Fig.
Page
2005-04-18
9.3
625-5882.032
1 (2)
PARTS MANUAL
Date
Group
Fig.
2005-04-18
9.3
625-5882.032
CYLINDER ASSEMBLY
Item
Qty
Article no
Description
Supplementary data
000
289 3675-801
CYLINDER ASSEMBLY
002
388 7834-001
. SHAFT
003
489 4345-004
. LOCKING PLATE
004
489 4346-004
. LOCKING PLATE
WELDED
005
2121 2034-672
. SCREW
M6S 20 x 40 -A4-80
006
2151 2027-192
. WASHER
RB 21 x 37 -A4
007
2545 2110-001
. GREASE NIPPLE
G 1/4 A2-50
Page
2 (2)
PARTS MANUAL
HOOK BLOCK
Date
Group
Fig.
Page
2006-12-21
9.3
625-7010C
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2006-12-21
9.3
625-7010C
2 (2)
HOOK BLOCK
Item
Qty
000
001
Article no
Description
Supplementary data
388 7571-801
HOOK BLOCK
SWL 15 tonnes
875 12401-007
. SHEAVE, COMPLETE
Incl. bearing and lock rings.
002
875 12054-007
.. BEARING
003
875 12062-005
.. LOCK RING
004
875 12009-009
. SPACER
005
875 12404-005
. SHAFT, COMPLETE
Incl. retainer, screw, nipple.
006
2545 2011-025
.. GREASE NIPPLE
M10 x 1; DIN 71412
007
875 12406-007
. SPACER, COMPLETE
Incl. spacer tube, screw, nut.
008
875 12409-003
. CABLE LEADER, COMPLETE
Incl. screws, nuts.
009
875 12073-004
. SHACKLE
010
875 12001-007
. HOOK, COMPLETE
Incl. safety latch kit.
011
875 12064-008
.. SAFETY LATCH KIT
Incl. spring, screw, nut.
PARTS MANUAL
PENNANT
Date
Group
Fig.
Page
1999-06-08
9.3
625-6915.007A
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
1999-06-08
9.3
625-6915.007A
2 (2)
PENNANT
Item
Qty
000
001
Article no
Description
Supplementary data
389 1689-803
PENNANT
SWL 15 tonnes
875 12070-009
. MASTER LINK
002
875 12070-003
. CHAIN LINK
003
875 12104-003
. CHAIN
004
875 12001-012
. HOOK, COMPLETE
Incl. safety latch kit.
005
875 12064-012
.. SAFETY LATCH KIT
Incl. spring, screw, nut.
PARTS MANUAL
DIRECTIONAL VALVE
Date
Group
Fig.
Page
2005-02-14
9.4
625-7322.017A
1 (2)
PARTS MANUAL
Date
Group
Fig.
2005-02-14
9.4
625-7322.017A
DIRECTIONAL VALVE
Item
Qty
Article no
Description
000
189 0523-801
DIRECTIONAL VALVE
001
489 4648-801
. GASKET SET
Supplementary data
Page
2 (2)
PARTS MANUAL
MOTOR VALVE
Date
Group
Fig.
Page
1999-06-29
9.4
625-7327A
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
1999-06-29
9.4
625-7327A
2 (2)
MOTOR VALVE
Item
Qty
Article no
Description
000
287 9489-802
MOTOR VALVE
001
489 5088-801
. GASKET SET
Supplementary data
PARTS MANUAL
BALANCE VALVE
Date
Group
Fig.
Page
2003-06-19
9.4
625-7330.004A
1 (2)
PARTS MANUAL
Date
Group
Fig.
2003-06-19
9.4
625-7330.004A
BALANCE VALVE
Item
Qty
Article no
Description
001
289 0687-801
BALANCE VALVE
002
490 0195-801
. GASKET SET
Supplementary data
Page
2 (2)
PARTS MANUAL
BALANCE VALVE
Date
Group
Fig.
Page
1999-11-04
9.4
625-7330.005
1 (2)
PARTS MANUAL
Date
Group
Fig.
1999-11-04
9.4
625-7330.005
BALANCE VALVE
Item
Qty
Article no
Description
001
289 0840-801
BALANCE VALVE
002
489 5703-801
. GASKET SET
Supplementary data
Page
2 (2)
P
AR
TS MANU
AL
PAR
ARTS
MANUAL
FILTER
Date
Group
Fig.
Page
1995-07-06
9.4
625-7335
1 (2)
P
AR
TS MANU
AL
PAR
ARTS
MANUAL
Date
Group
Fig.
Page
1995-07-06
9.4
625-7335
2 (2)
FILTER
Item
Qty
Article no
Description
000
287 9463-801
FILTER
001
489 4436-801
. FILTER ELEMENT
Supplementary data
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
2004-04-28
9.4
625-7990.052
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2004-04-28
9.4
625-7990.052
2 (2)
HYDRAULIC CYLINDER
Item
Qty
Article no
Description
Supplementary data
000
289 3195-801
HYDRAULIC CYLINDER
280 / 200
001
875 16403-005
. GASKET SET
Includes item 7-25.
007
.. BEARING RING
011
.. PISTON SEAL
012
.. O-RING
013
.. BEARING RING
014
.. O-RING
015
.. SUPPORT RING
016
.. ROD SEAL
019
.. ROD WIPER
023
.. BEARING RING
025
.. O-RING
(approx. 200)
106
2121 2550-447
. SCREW
MC6S 8 x 12 -A4-80; DIN 912
108
875 16401-005
. BEARING
109
2545 2110-003
. GREASE NIPPLE
A-M 10 x 1 -A2-50; DIN 71412
110
2122 2519-489
. SCREW
MSK6SS 10 x 16 -A4; DIN 916
117
2121 2550-542
. SCREW
MC6S 12 x 50 -A4-80; DIN 912
121
2522 2105-014
. PLUG WITH SEAL
G 1/4; DIN 908
122
2545 2112-003
. GREASE NIPPLE
C-M 10 x 1 -A2-50; DIN 71412
(approx. 140)
(approx. 270)
PARTS MANUAL
EL. CENTRAL/STARTER
324 1660-801
625-8630.067
Date
Group
Fig.
Page
2007-12-04
9.5
625-8630.067
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2007-12-04
9.5
625-8630.067
2 (2)
EL. CENTRAL/STARTER
Item
Qty
Article no
Description
Supplementary data
000
324 1660-801
EL. CENTRAL/STARTER
002
324 1165-801
. TRANSFORMER
003
5354 4273-067
. CONTACTOR
004
5627 4216-054
. OVERLOAD RELAY
005
5381 4227-125
. LOAD SWITCH
006
4762 4105-320
. CURRENT TRANSFORMER
007
5347 4262-203
. CIRCUIT BREAKER
008
5692 4740-221
. HOUR METER
009
5697 4337-200
. AMMETER
010
5298 2071-221
. PILOT LIGHT
GREEN
011
5298 2071-220
. PILOT LIGHT
WHITE
012
5298 2071-222
. PILOT LIGHT
YELLOW
013
5354 4273-040
. CONTACTOR
014
5347 4263-203
. CIRCUIT BREAKER
015
5372 2210-002
. PUSH BUTTON
RED
016
5372 2210-001
. PUSH BUTTON
GREEN
017
5632 4212-001
. ELECTRONIC TIME DELAYER
019
2669 4160-015
. END HOLDER
022
2647 4160-040
. EARTH CLAMP
023
2647 4160-350
. EARTH CLAMP
027
20
2663 4382-025
. TERMINAL BLOCK
028
2669 4160-015
. END HOLDER
029
2631 4123-252
. BRIDGE CONNECTOR
034
5354 4137-510
. AUXILIARY CONTACT BLOCK
035
5354 4137-501
. AUXILIARY CONTACT BLOCK
037
5381 4227-001
. HANDLE
038
5381 4227-002
. SHAFT
039
5381 4227-011
. SHROUD
061
424 0494-801
. SIGN
Main switch
064
2183 2022-122
. LIFTING EYE BOLT
M12; DIN 580
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
PARTS MANUAL
Date
Group
Fig.
Page
2007-06-13
9.7
624-2494B
2 (2)
HAND PUMP
Item
Qty
Article no
Description
Supplementary data
000
189 3090-801
HAND PUMP
010
875 29031-011
. PUMP
011
875 29031-012
. HANDLE
020
875 29031-006
. PRESSURE RELIEF VALVE
030
875 29031-015
. SAFETY VALVE, COMPLETE
090
2522 2132-108
. PLUG
NPTF 1/16"
130
2522 2105-012
. PLUG WITH SEAL
G 1/2"
140
875 29031-005
. MANOMETER
60 bar
150
875 29031-013
. OIL CAP WITH AIR FILTER
G 1/2"
500
875 29031-017
. HYDRAULIC HOSE WITH COUPLINGS
3/8" L = 3000
560
2529 2458-111
. QUICK COUPLING
G 3/8"
D = 45 cc
Setting 33 bar, seal-locked

Crane 1 2 HH400-1518-4

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Crane 1 2 HH400-1518-4

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6 pcs, CD-ROM 2 pcs

Jiangsu Rongsheng Heavy Ind.

62509354 - Right crane; 62509355 - Left crane

490 6594-801, -802 /A

490 5946-801, -802 /-

490 6619-801, -802 /B

490 6620-801, -802 /-

GENERAL INSTRUCTIONS, CLEANLINESS IN HYDRAULIC SYSTEMS

HYDRAULIC AND ELECTRIC SYMBOLS

CRANE CONTROL SYSTEM

CREW CHECKLIST BEFORE TAKING CRANE INTO OPERATION

PARKING THE CRANE, SEA STOWING

INSPECTION OF STRESSED COMPONENTS AND STRUCTURES

LUBRICATING CHART, GP AND HH CRANES

CRANE HOUSING / HYDRAULIC OIL TANK

LUBRICANTS FOR DECK MACHINERY

HOW TO ORDER SPARE PARTS

STATEMENT REGARDING DELIVERY OF SPARE PARTS TO SWIVELS, LIFTING B

The Original Manufacturer of HGGLUNDS Cranes

REV NAME OF INSTRUCTION

MacGREGOR GLOBAL SERVICES

MEASURES BEFORE STARTING, DURING AND AFTER COMPLETED SERVICE/M

HYDRAULIC MOTORS, HOISTING AND SLEWING

RECOMMENDATION FOR INSPECTION AND REPLACEMENT OF HYDRAULIC HO

TIGHTENING TORQUES STUDS/SCREWS AND BOLTS

ROPE REEVING DIAGRAM FOR CRANES TYPE GP AND HH

HANDLING, INSTALLATION AND MAINTENANCE OF STEEL WIRE ROPES

INDENTATION AND WEAR ON WIRE SHEAVES

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

ELECTRICAL EQUIPMENT, GENERAL MAINTENANCE

EMERGENCY LOWERING IN CASE OF COMPLETE POWER FAILURE OPERAT

SEE SEPARATE TABLE OF CONTENTS

The Original Manufacturer of HGGLUNDS Cranes

HOW TO ORDER SPARE PARTS

DRIVE IN, COMPLETE

OIL PIPE, COMPLETE

CAM LIMIT SWITCH, COMPLETE

LOAD WIRE ROPE W. THIMBLE; SEE

CRANE ASSEMBLY, RIGHT

CRANE ASSEMBLY, LEFT

HYDRAULIC CIRCUIT DIAGRAM

The Original Manufacturer of HGGLUNDS Cranes

1.005 E rev.: e 2003-09-09

Every manual belongs to a specific crane or piece of

The Original Manufacturer of HGGLUNDS Cranes

1.005 E rev.: e 2003-09-09

THIS PAGE IS INTENTIONALLY LEFT BLANK

The Original Manufacturer of HGGLUNDS Cranes

1.009 E rev.: a 1996-05-20

This also applies for components that have been

The Original Manufacturer of HGGLUNDS Cranes

1.009 E rev.: a 1996-05-20

THIS PAGE IS INTENTIONALLY LEFT BLANK

The Original Manufacturer of HGGLUNDS Cranes

1.102 E rev.: c 1999-09-14

= 1 litre = 0,219969 gallon (UK)

14,6959 lbf/in2 (psi)

The Original Manufacturer of HGGLUNDS Cranes

1.102 E rev.: c 1999-09-14

THIS PAGE IS INTENTIONALLY LEFT BLANK

The Original Manufacturer of HGGLUNDS Cranes

1.518.3 ED rev.: d 2007-06-08