C7250
INSTRUCTION MANUAL
Project No.
Date: 2008-11-27
2/08006.01DAL-3
Page
1(3)
TABLE OF CONTENTS
No. of manuals
Certificate for
crane issued by:
DNV
Certificate for
foundation issued by:
DNV
IMO No.
L9408683
Name of ship
PROFIT
Newbuilding No.
1022
Shipyard
Owners
Geden
Project No.
2/08006.01DAL-3
Mfg. No.
Type of crane
GP 160-0516-2
Order specification
490 6594-803 /A
Mechanical spec.
490 5435-801 /-
Hydraulic spec.
490 6619-803 /B
Electrical spec.
490 6620-803 /-
Slewing spec.
SAFETY DOCUMENTS
Document names written with bold letters are documents with safety aspects.
INSTRUCTION NO.
GENERAL
TECHN. DESCRIP.
FUNCTION
OPERATION
MAINTENANCE
SERVICE
REV
NAME OF INSTRUCTION
1.005 E
PREFACE
1.009 E
1.102 E
CONVERSION FACTORS
1.518.3 ED
2/08006.01DAL-3
TECHNICAL DATA
2.007.56 E
TECHNICAL DESCRIPTION
3.110.70 E
HYDRAULIC FUNCTION
3.142.10 E
PM40 0815-E00
OPERATING INSTRUCTION
PM40 1822-E00
4.620.13 E
5.005.25 E
MAINTENANCE CHART
5.019 E
PM51 1217-E00
5.302.15 E
5.421.16 E
6.000 E
6.000.1 E
6.000.2 E
RETURN FORM
6
6.0
Dept. C7250
INSTRUCTION MANUAL
Project No.
Date: 2008-11-27
2/08006.01DAL-3
Page
2(3)
TABLE OF CONTENTS
6.0
6.1
6.2
6.3
INSTRUCTION NO.
6.004.1 E
ba
6.008.2 E
INTRODUCTION
6.100 E
6.120.15 E
SLEWING GEARSET
6.120.62 E
6.120.96 E
WINCH
6.142.5 E
6.214 E
6.216.69 E
6.222.1 E
625/1473 E
625/1560 E
LIFTING BLOCK/BEAM
625/1618 E
6.305.11 E
6.990.54 E
EXTRA EQUIPMENT 7
APPENDICES
SPARE PARTS
Dept. C7250
PARTS MANUAL
Project No.
Date: 2008-11-27
2/08006.01DAL-3
Page
3(3)
TABLE OF CONTENTS
GROUP DESCRIPTION
PART NUMBER
FIG
9
9.0
9.1
WINCH ASSEMBLY
WINCH
9.2
9.3
9.4
6.000 E
289 3951-801
A/
625-1440.102
289 3815-801
B/
625-1450.091
HYDRAULIC MOTOR
188 1769-801
A/
625-2205.016
SLEWING GEAR
289 3822-801
A/
625-3255.022
HYDRAULIC MOTOR
188 1227-801
A/
625-2205.017
PUMP DRIVE
289 0543-801
B/
625-4935.067A
PUMP
188 1097-801
A/
625-4945.012
CYLINDER ASSEMBLY
289 4027-801
-/
625-5882.037
JIB TOP
288 0136-801
A/
625-6244.001B
287 9974-801
B/
625-6253A
HOOK BLOCK
388 7531-801
E/
625-7013.005D
GENERAL ARRANGEMENT
189 7279-801
A/
189 7279
189 7315-801
-/
189 7315
SLEWING ASSEMBLY
289 3961-801
-/
289 3961
SLEWING BEARING
388 7097-801
C/
388 7097
390 9790-808
N/
DIRECTION VALVE
188 1338-801
-/
625-7322.011
BALANCE VALVE
388 6376-801
B/
625-7330.001
BALANCE VALVE
289 0839-801
B/
625-7330.006A
MOTOR VALVE
388 6358-801
D/
625-7331
LIMIT VALVE
388 6361-801
A/
625-7334
FILTER
287 9463-801
B/
625-7335
BALL VALVE
389 4128-801
-/
625-7620.004
HYDRAULIC CYLINDER
289 3178-801
A/
625-7990.044
289 5232
A/
289 5232
189 5696-801
A/
189 5696
189 5167
HYDRAULIC HOSES
9.5
9.7
625-7970G
189 5167-801
B/
189 7337-801
-/
EL. CENTRAL/STARTER
324 1150-801
A/
625-8630.050A
ELECTRICAL SYSTEM
324 1134
-/
324 1134
HAND PUMP
189 3090-801
D/
624-2494B
GENERAL
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.
1 (2)
GENERAL
2 (2)
GENERAL
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
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
2 (2)
GENERAL
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
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 =
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)
2 (2)
GENERAL/ALLGEMEINES
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:
3. Electric symbols.
Elektrische Schaltzeichen.
1 (30)
GENERAL/ALLGEMEINES
1. Hydraulic Symbols
Hydraulische Bildzeichen
Fixed restriction.
Feste Blende, feste Drosselung.
Variable restriction.
Regelblende, regelbare Drosselung.
Flexible hose.
Schlauch, biegsame Leitung.
2 (30)
GENERAL/ALLGEMEINES
Pipe junction.
Leitungsverbindung.
Rotary connection.
Dreh-Verbindung.
Regulation or variability.
Regelbar oder nachstellbar.
Mechanical connection.
Mechanische Verbindung.
3 (30)
GENERAL/ALLGEMEINES
Electric motor.
Elektromotor.
Filter.
Filter.
4 (30)
GENERAL/ALLGEMEINES
Air breather.
Luftreiniger.
Non-return valve.
Rckschlagventil.
5 (30)
GENERAL/ALLGEMEINES
Gauge connection.
Meanschlu.
Ventilation valve.
Entlftungsventil.
Shuttle valve.
Wechselventil.
Brake cylinder.
Bremszylinder.
Pressure gauge.
Manometer.
Thermometer.
Thermometer.
6 (30)
GENERAL/ALLGEMEINES
Oli cooler.
lkhler.
Accumulator.
Druckspeicher.
Shut-off valve.
Absperrventil.
7 (30)
GENERAL/ALLGEMEINES
4/2-Wegeventil
4-Wegeschieber mit 2 Arbeitsstellungen, FederRckfhrung in die Nullstellung.
Proportional valve.
Proportionalventil.
Servo valve.
Servoventil.
8 (30)
GENERAL/ALLGEMEINES
Cartridge valve.
Patronenventil.
9 (30)
GENERAL/ALLGEMEINES
10 (30)
GENERAL/ALLGEMEINES
2. Valve Assemblies
Ventil-Baugruppen
11 (30)
GENERAL/ALLGEMEINES
12 (30)
GENERAL/ALLGEMEINES
13 (30)
GENERAL/ALLGEMEINES
14 (30)
GENERAL/ALLGEMEINES
15 (30)
GENERAL/ALLGEMEINES
16 (30)
GENERAL/ALLGEMEINES
17 (30)
GENERAL/ALLGEMEINES
18 (30)
GENERAL/ALLGEMEINES
Flushing valve.
Splventil.
19 (30)
GENERAL/ALLGEMEINES
20 (30)
GENERAL/ALLGEMEINES
21 (30)
GENERAL/ALLGEMEINES
3. Electric Symbols
Elektrische Schaltzeichen
Make contact.
Arbeitskontakt.
Break contact.
Schaltkontakt.
22 (30)
GENERAL/ALLGEMEINES
Main contact.
Hauptkontakt.
Emergency stop.
Notschalter.
Limit switch.
Endschalter.
23 (30)
GENERAL/ALLGEMEINES
Pressostat.
Pressostat.
Level switch.
lstandswchter.
Inductive contact.
Induktiver Geber.
Ammeter.
Strommesser.
Voltmeter.
Voltmesser.
Hour counter.
Stundenzhler.
24 (30)
GENERAL/ALLGEMEINES
Rectifier.
Gleichrichter.
Frequency converter.
Frequenzumformer.
25 (30)
GENERAL/ALLGEMEINES
Diode.
Diode.
Pilot lamp.
Meldeleuchte.
Light.
Beleuchtung.
Flood light.
Scheinwerfer.
Alarm signal.
Alarmsignal.
Alarmsiren.
Alarmhupe.
Single-phase outlet.
Steckdose, einphasig.
26 (30)
GENERAL/ALLGEMEINES
Position encoder.
Drehfeldgeber.
Puls/speed encoder
Geschwindigkeitsgeber
Resistor.
Widerstand.
Resistor, non-linear.
Widerstand, spannungsabhngig.
Variable resistor.
Widerstand, regelbar.
Heater.
Heizkrper.
Motor.
Motor.
27 (30)
GENERAL/ALLGEMEINES
Condenser.
Kondensator.
Heater, cabin.
Heizkrper in der Fahrerkabine.
Air condition.
Klimaanlageapparat.
VL . . . .
Solenoid valve.
Magnetventil.
28 (30)
GENERAL/ALLGEMEINES
Controller, hoisting.
Steuerknppel, Lastwinde.
29 (30)
GENERAL/ALLGEMEINES
30 (30)
TECHNICAL DATA
(2.001.4 E)
GENERAL
TYPE OF CRANE
GP 160-0516-2
WO
2/08006.01DAL-3
SERIAL NUMBER
WEIGHT
TYPE OF FREQUENCY
3 ~ 60 Hz
SUPPLY VOLTAGE
440 V
CONTROL VOLTAGE
230 V
MECHANICAL DATA
SWL
5,0 tonnes
JIB RADIUS
MAX
16,0 m
JIB RADIUS
MIN
3.2 m
45 m
MAX 5,0 tonnes
10 m/min
40 sec.
MAX 1.6 rev/min
STEEL ROPE
13 mm L = 110 m
No 390 9790-808
ELECTRICAL DATA
EL. MOTOR
289 2428-801
TYPE OF FREQUENCY
3 ~ 60 Hz
63 kW
92 kW
SPEED
1772 rev/min
RATED VOLTAGE
440 V
STARTING CURRENT
435 A
1 (2)
TECHNICAL DATA
(2.001.4 E)
HYDRAULIC DATA
PUMP TYPE
188 1108-801
90 cm3/rev
DISPLACEMENT
MAX. SPEED
1800 rpm
HOISTING CIRCUIT
HYDRAULIC MOTOR
188 1769-801
56.1 cm3/rev
DISPLACEMENT
LUFFING CIRCUIT
HYDRAULIC CYLINDER
289 3178-801
SLEWING CIRCUIT
HYDRAULIC MOTOR
188 1227-801
28.1 cm3/rev
DISPLACEMENT
OIL TANK
OIL VOLUME; OIL FILLING
550 litres
6.5 litres
HOISTING WINCH
OIL VOLUME; OIL FILLING
1.5 litres
2 (2)
TECHNICAL DESCRIPTION
Technical Description
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
1 (4)
TECHNICAL DESCRIPTION
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 starter
Limit switches
Hook Travel Up: The crane is provided with an automatic hook stop at the top position.
2 (4)
TECHNICAL DESCRIPTION
Jib cylinder
Surface treatment
Steel structure
The steel quality selected is in accordance with
classification society recommendations to obtain
necessary ductility for the lower temperature design
limit.
3 (4)
TECHNICAL DESCRIPTION
4 (4)
FUNCTION
Hydraulic Function
General
The following description refers to
MacGREGOR service crane type GP/HH.
the
Hoisting
Luffing
Slewing
Pump
1 (8)
FUNCTION
Component identification
The main components are identified by three-digit
numbers in the diagram and on the actual
components in the crane. The first digit of each
number signifies the circuit to which the component
belongs, as follows:
1...
2...
3...
Legend
MMHO
CLU
MSL
2 (8)
001
102
103
104
002
FUNCTION
3 (8)
FUNCTION
Safety system
Function
Hoisting circuit
Neutral/idling
With the control lever in neutral and the pump
running, the hoisting winch performs no actual work.
The speed is controlled by the hand lever (direct
connected) integrated with the main directional
valve.
The control lever can be moved in two directions,
backwards or forwards, see Fig. 3.
Hoisting and lowering
To hoist, move the control lever backwards from
neutral position. This will move the spool for hoisting
002-1A and connect the pump to the motor. The
system pressure increases up to the needed level
for the current load and the winch brake will open
at a certain system pressure level and the winch
starts to move in hoisting direction.
Increased movement of the lever increases the
amount of flow from the pump through the spool
and to the winch motor and the speed increases in
the same manner. The speed is controlled by the
control lever and increases continously in proportion
to the lever position.
To lower the load the lever has to be moved
forwards in similar way as for hoisting.
Luffing circuit
Introduction
Fig. 4 shows a luffing circuit diagram, i.e. the circuit
that controls the movement of the jib and with the
following main components:
Cylinder
202
Balance valve
204
Pump (common) 001 and main directional valve
(common) 002, see Fig. 2.
Luffing
To luff in, move the control lever backwards from
neutral position. This will move the spool for luffing
002-1B and connect the pump to the cylinder. The
system pressure increases up to the needed level
for the current load and the jib starts to move in
hoisting direction.
Increased movement of the lever increases the
amount of flow from the pump through the spool
and to the winch motor and the speed increases in
the same manner. The speed control is controlled
by the control lever and increases continously in
proportion to the lever position.
To luff out the jib the lever has to be moved forwards
in similar way as for luffing in.
Slewing
Luffing
Hoisting
Safety system
Pressure limiting functions: Main pressure limiting
valves 002-6B and 002-7B.
4 (8)
FUNCTION
002
5 (8)
FUNCTION
Slewing circuit
Introduction
Fig. 5 shows a slewing circuit diagram with the
following main components:
Hydraulic motor
Brake
Balance valve
302
303
304
6 (8)
FUNCTION
002
7 (8)
FUNCTION
8 (8)
FUNCTION
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.
1 (2)
FUNCTION
2 (2)
OPERATION
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
START
START
STOP
STOP
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
1 (2)
OPERATION
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.
EMERGENCY STOP
Turn Emergency stop lever (4) to
stop crane movements.
1. Slewing
2. Luffing
3. Hoisting
2 (2)
OPERATION
List
Verify that ship does not
list more than 5 degrees.
Oil level
MAX
MIN
1 (2)
OPERATION
2 (2)
OPERATION
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. 2. Wire rope must not slack between winch and jib top.
1 (2)
OPERATION
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
2 (2)
MAINTENANCE
Maintenance Chart
Winch
- The first oil change.
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
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.
- Check backlash.
Air filter
- Check and change air filter.
2 (4)
MAINTENANCE
3 (4)
MAINTENANCE
4 (4)
MAINTENANCE
1 (2)
MAINTENANCE
2 (2)
LUBRICATING CHART
PART OF CRANE
1)
2)
Key to symbols
12 13
14
3)
4)
17 OIL FILTER
18 CARDAN SHAFT, 2 NIPPLES
19 OPEN GEAR
20 DRAIN COCK, HYDRAULIC OIL DRAIN
21
22 OIL FILLING
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
central lubrication.)
17
14
15
11
16
15
8
20
18
21
Jib support
3
19
3
(1. Alternative to
central lubrication.)
CAUTION! Filling of oil and checking oil level in oil tank and winch
to be made at horizontal jib and/or cylinder in bottom position.
1 (2)
MAINTENANCE
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
Table 2.
NA = Not applicable.
2 (2)
MAINTENANCE
Inspection
Oil sight
Oil filling
Max
Drain
cock
Min
1 (2)
MAINTENANCE
2 (2)
MAINTENANCE
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
1 (2)
MAINTENANCE
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
The more you can provide us with above details the faster and more reliable replies and deliveries will be made.
Address:
MacGREGOR (SWE) AB, Service Division
SE-891 85 RNSKLDSVIK, Sweden
Telephone: 46 - 660 - 29 40 00
Telefax: 46 - 660 - 139 77
1 (2)
Tel: 46 - 660 - 29 40 00
Direct: Fax: 46 - 660 - 139 77
Date: ................................................
Service request
Confirmation of
phone call/conv.
From: .. .............................................................
..............................................................
Fax no:
......................................
Tlx no:
......................................
..............................................................
Re:
M/V ........................................................
Crane type:.............................................
Our ref.:
..............................................
.......................................................
Part no.
Qty
Description
Fig./Drwg.
Item
1. ..........................................
.....
............................................
..............................
..............
2. ...........................................
.....
............................................
..............................
..............
3. ...........................................
.....
............................................
..............................
..............
4. ...........................................
.....
............................................
..............................
..............
5. ...........................................
.....
............................................
..............................
..............
6. See enclosure
Delivery/Agent's address:
............................................................................................................
............................................................................................................
............................................................................................................
...................................................................................................................
Name/
Title/
SERVICE
Section D
Section A
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)
1 (2)
SERVICE
2 (2)
SERVICE
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
Identification:
Claim:
1 (2)
SERVICE
RETURN FORM
To be packed inside return box or parcel
Date:
Sent by:
Newbuilding no.:
Ships name:
IMO no.:
Returned parts
drawing or article
no, serial no.:
Part description:
*) 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)
BELGIUM
CHINA
DENMARK
Luithagen-Haven 2E
B-2030 ANTWERPEN
Phone: (+32) 3-546 46 40
Telefax: (+32) 3-542 4772
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
CANADA
CROATIA
Vancouver, (S)
Nagesco Ltd.
CHILE
CYPRUS
Limassol, (P)
MacGREGOR (CYPRUS) Ltd.
Titos Building, Office 201
58 Gladstone Street
CY 3041 LIMASSOL
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
(S) (P)
MacGREGOR (SWE) AB
Service Division
www.macgregor-group.com/cranes
Address
SE-891 85 RNSKLDSVIK
Sweden
Telephone
(+46) 660-29 40 00
Telefax
(+46) 660-139 77
1 (4)
GREECE
KOREA
SINGAPORE
173-5, Songjeong-dong
Haeundae-gu
612-040 BUSAN
Phone: (+82) 51-704 0844
Telefax: (+82) 51-704 0414
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
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)
Oslo, (P)
MacGREGOR (NOR) A/S
Skur 39, Vippetangen
NOR-0150 OSLO
Phone: (+47) 23-10 34 00
Telefax: (+47) 23-10 34 01
ITALY
Bergen, (S)
MacGREGOR (NOR) A/S
Bleivassvegen 105
N-5363 GOTNES
Phone: (+47) 55-56-31 33 00
Telefax: (+47) 55-56-31 33 23
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
SE-891 85 RNSKLDSVIK
Phone: (+46) 660-29 40 00
Telefax: (+46) 660-139 77
Gdynia, (P)
MacGREGOR (POL) Sp. z. o.o.
www.macgregor-group.com/cranes
ul. Luzycka 8
PL-81-537 GDYNIA
Phone: (+48) 58-7855 110
Telefax: (+48) 58-7855 111
(S) (P)
MacGREGOR (SWE) AB
Service Division
www.macgregor-group.com/cranes
2 (4)
Address
SE-891 85 RNSKLDSVIK
Sweden
Telephone
(+46) 660-29 40 00
Telefax
(+46) 660-139 77
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
(S) (P)
MacGREGOR (SWE) AB
Service Division
www.macgregor-group.com/cranes
Address
SE-891 85 RNSKLDSVIK
Sweden
Telephone
(+46) 660-29 40 00
Telefax
(+46) 660-139 77
3 (4)
(S) (P)
MacGREGOR (SWE) AB
Service Division
www.macgregor-group.com/cranes
4 (4)
Address
SE-891 85 RNSKLDSVIK
Sweden
Telephone
(+46) 660-29 40 00
Telefax
(+46) 660-139 77
SERVICE
Introduction
1 (2)
SERVICE
2 (2)
SERVICE
1 (2)
SERVICE
2 (2)
SERVICE
Slewing Gearset
Oil filling
Plug
Air filter
Expansion tank
a
Expansion pipe
Disc brake
Screws holding
gearset to crane
house floor
Oil outlet
Maintenance
Lubrication
Fig. 1. Slewing gearset.
1 (4)
SERVICE
Overall assessment
2 (4)
SERVICE
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
Checking
backlash
and
setting
slewing
rim
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
Upper part
Screws
Screws holding
gearset to crane
house floor
4 (4)
SERVICE
1 (4)
SERVICE
Oil filling/Drain
connection
Oil filling/
Drain connection
Displacement:
63.0 cm3/rev.
Pre-filling volume: 1.0 litre. (Approx.)
Oil filling/
Drain connection
Oil filling/
Drain connection
2 (4)
SERVICE
Oil filling/
Drain connection
Hydraulic Motor
288 0303-801
288 2158-801
Oil filling/
Drain connection
Oil filling/
Drain connection
Oil filling/
Drain connection
3 (4)
SERVICE
4 (4)
SERVICE
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
1 (4)
SERVICE
Oil changes
Oil discoloration
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.
Sampling oil
Overall assessment
2 (4)
SERVICE
Trouble-shooting
following
major
Brake piston
Brake cylinder
Disc carrier
Inner discs
Outer discs
Hydr. part for disc brake
Compression spring
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
3 (4)
SERVICE
4 (4)
SERVICE
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.
Hose coupling
Mating coupling
O-ring
Screw
1 (2)
SERVICE
2 (2)
SERVICE
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.
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
Tightening torque in Nm
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
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.
Screw
3/4"
1"
1 1/4"
1 1/2"
2"
M10
M12
M14
M16
UNC 3/4
2 (4)
Tightening torque in Nm
10 Nm 1 kpm
Class H 10.9 and 12.9
54
94
150
230
377
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39
Tightening torque in Nm
10 Nm 1 kpm
Austenite (A)
50
70
80
3.3
7
9.3
7.8
17
22
15
33
44
27
57
76
43
91
121
65
140
187
91
195
260
127
273
364
171
367
490
220
472
629
318
682
909
434
930
1240
585
1250
1670
755
1620
2160
969
2080
2770
SERVICE
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
BH 12 9 M
Hexagonal nut
Strength class 8:
M-thread
UNC- and
UNF-thread
Cold forged
UNC- and
UNF-thread
Forged
M-thread
3 (4)
SERVICE
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
1 (4)
SERVICE
Locking plate
Lock washer
Screw
Spacer
Wire thimble
2 (4)
SERVICE
Spacer
Bolt
Nut
Split pin
3 (4)
SERVICE
Locking plate
Lock washer
Screw
Spacer
Wire thimble
4 (4)
SERVICE
1 (12)
SERVICE
2 (12)
SERVICE
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.
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.
3 (12)
SERVICE
4 (12)
SERVICE
5 (12)
SERVICE
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.
6 (12)
SERVICE
The rope and this wire end are now wrapped moving away from the location of the intended cut.
7 (12)
SERVICE
There are several techniques of lubricant application: The most common ones at present are painting or swabbing.
8 (12)
SERVICE
9 (12)
SERVICE
Severe corrosion.
10 (12)
SERVICE
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
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
Wear criterias
Indentation
a
max
4
3
2.5
2
1.5
t
16
12
10
8
6
Table 1.
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
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
1 (2)
SERVICE INFORMATION
625/1560 E rev.: e 2007-01-02
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.
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
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
Machined surface/
reference point
Jib
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
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
3 (6)
SERVICE INFORMATION
625/1618 E rev.: b 2007-01-02
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
4 (6)
SERVICE INFORMATION
625/1618 E rev.: b 2007-01-02
Fore
Vessel name:
Ps
Stb
Aft
Initial Measurement (accuracy 0.1 mm)
Date
Jib direction
A1 (front of crane)
Fore
mm
mm
mm
Stb
mm
mm
mm
Aft
mm
mm
mm
Ps
mm
mm
mm
Measured wear
Jib direction
A (front of crane)
B (back of crane)
A - A1
Fore
mm
mm
mm
mm
Stb
mm
mm
mm
mm
Aft
mm
mm
mm
mm
Ps
mm
mm
mm
mm
Measured wear
Jib direction
A (front of crane)
B (back of crane)
A - A1
B1 - B
Fore
mm
mm
mm
mm
Stb
mm
mm
mm
mm
Aft
mm
mm
mm
mm
Ps
mm
mm
mm
mm
Measured wear
B1 - B
Jib direction
A (front of crane)
B (back of crane)
A - A1
B1 - B
Fore
mm
mm
mm
mm
Stb
mm
mm
mm
mm
Aft
mm
mm
mm
mm
Ps
mm
mm
mm
mm
5 (6)
SERVICE INFORMATION
625/1618 E rev.: b 2007-01-02
6 (6)
SERVICE
6.305.11 E rev.: -
1999-06-08
1 (2)
SERVICE
6.305.11 E rev.: -
2 (2)
1999-06-08
SERVICE
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
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
Handle
Pressure gauge
1 (6)
SERVICE
105
19.5
After operation
- When the operation has been completed, close
the ball valve 105.
- Remove hand pump.
1A
105
002
Hand pump
2 (6)
SERVICE
Example:
A complete hydraulic circuit diagram relating
specifically to your crane will be found in section
9.4 in the parts manual.
3 (6)
SERVICE
Example:
A complete hydraulic circuit diagram relating
specifically to your crane will be found in section
9.4 in the parts manual.
4 (6)
SERVICE
Cap
Locking
Set
screw
nut
5 (6)
SERVICE
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:
A complete hydraulic circuit diagram relating
specifically to your crane will be found in section
9.4 in the parts manual.
6 (6)
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
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
9.7
Extra equipment
PARTS MANUAL
WINCH MOUNTING
Date
Group
Fig.
Page
2006-01-23
9.1
625-1440.102
1 (2)
PARTS MANUAL
Date
Group
Fig.
2006-01-23
9.1
625-1440.102
WINCH MOUNTING
Item
Qty
Article no
Description
Supplementary data
000
289 3951-801
WINCH MOUNTING
001
289 3815-801
. WINCH
002
188 1769-801
. HYDRAULIC MOTOR
003
489 4472-001
. WASHER
004
2151 2052-178
. WASHER
TBRB 13 x 24 FZB
005
2121 2030-789
. SCREW
006
2121 2034-540
. SCREW
M6S 12 x 40 -A4-70
007
2126 2038-130
. NUT
M6M 30 -10
Page
2 (2)
PARTS MANUAL
WINCH
Date
Group
Fig.
Page
2006-01-23
9.1
625-1450.091
1 (2)
PARTS MANUAL
Date
Group
Fig.
2006-01-23
9.1
625-1450.091
WINCH
Item
Qty
000
Article no
289 3815-801
Description
Supplementary data
WINCH
5 tonnes
Page
2 (2)
PARTS MANUAL
HYDRAULIC MOTOR
Date
Group
Fig.
Page
1999-06-28
9.1
625-2205.016
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
1999-06-28
9.1
625-2205.016
2 (2)
HYDRAULIC MOTOR
Item
Qty
Article no
Description
001
188 1769-801
HYDRAULIC MOTOR
002
489 6118-801
. GASKET SET
Supplementary data
PARTS MANUAL
SLEWING GEAR
Date
Group
Fig.
Page
2005-11-14
9.1
625-3255.022
1 (2)
PARTS MANUAL
Date
Group
Fig.
2005-11-14
9.1
625-3255.022
SLEWING GEAR
Item
Qty
001
Article no
289 3822-801
Description
SLEWING GEAR
Supplementary data
Page
2 (2)
PARTS MANUAL
HYDRAULIC MOTOR
Date
Group
Fig.
Page
2000-03-07
9.1
625-2205.017
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2000-03-07
9.1
625-2205.017
2 (2)
HYDRAULIC MOTOR
Item
Qty
Article no
Description
001
188 1227-801
HYDRAULIC MOTOR
002
489 6120-801
. GASKET SET
Supplementary data
PARTS MANUAL
PUMP DRIVE
Date
Group
Fig.
Page
2005-12-19
9.2
625-4935.067A
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2005-12-19
9.2
625-4935.067A
2 (2)
PUMP DRIVE
Item
Qty
Article no
Description
Supplementary data
000
289 0543-801
PUMP DRIVE
001
188 1097-801
. PUMP
002
288 1629-801
. ELECTRIC MOTOR
003
388 6362-801
. CARDAN SHAFT
004
388 7217-001
. PUMP BRACKET
005
489 4369-801
006
2152 2115-555
. O-RING
007
2152 2115-526
. O-RING
008
2183 2022-126
010
12
2121 2032-540
. SCREW
011
12
2151 2022-178
. WASHER
BRB 13 x 24 FZB
012
2121 2032-544
. SCREW
013
2126 2636-122
. NUT
014
2151 2022-178
. WASHER
BRB 13 x 24 FZB
PARTS MANUAL
PUMP
Date
Group
Fig.
Page
1999-06-09
9.2
625-4945.012
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
1999-06-09
9.2
625-4945.012
2 (2)
PUMP
Item
Qty
Article no
Description
001
188 1097-801
PUMP
002
489 6144-801
. GASKET SET
Supplementary data
PARTS MANUAL
CYLINDER ASSEMBLY
Date
Group
Fig.
Page
2004-11-17
9.3
625-5882.037
1 (2)
PARTS MANUAL
Date
Group
Fig.
2004-11-17
9.3
625-5882.037
CYLINDER ASSEMBLY
Item
Qty
Article no
Description
Supplementary data
000
289 4027-801
CYLINDER ASSEMBLY
002
388 7100-001
. SHAFT
003
489 4345-003
. LOCKING PLATE
004
489 4346-003
. LOCKING PLATE
WELDED
005
2121 2034-624
. SCREW
M6S 16 x 30 -A4-80
006
2151 2027-185
. WASHER
RB 17 x 30 -A4-80
007
2545 2110-001
. GREASE NIPPLE
G 1/4 A2-50
Page
2 (2)
PARTS MANUAL
JIB TOP
Date
Group
Fig.
Page
2004-08-03
9.3
625-6244.001B
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2004-08-03
9.3
625-6244.001B
2 (2)
JIB TOP
Item
Qty
Article no
Description
Supplementary data
000
288 0136-801
JIB TOP
001
388 7440-001
. SHAFT
002
388 7441-001
. SHAFT
003
388 7278-001
. CLIMB PROTECTION
004
489 4488-801
. WIRE SHEAVE
005
489 4345-002
. LOCKING PLATE
006
489 4345-001
. LOCKING PLATE
007
489 4465-008
. SPACER
008
2545 2110-001
. GREASE NIPPLE
G 1/4 A2-50
010
2114 2014-201
. SPLIT PIN
SP 4 x 40 A4
011
2121 2034-491
. SCREW
M6S 10 x 20 -A4-80
012
2121 2034-532
. SCREW
013
2154 2233-178
. LOCK WASHER
13 RF
014
2154 2233-173
. LOCK WASHER
10.5 BR = 20 RF
015
15
489 4473-002
. WASHER
PARTS MANUAL
Date
Group
Fig.
Page
2004-06-04
9.3
625-6253A
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2004-06-04
9.3
625-6253A
2 (2)
Qty
Article no
Description
Supplementary data
000
287 9974-801
001
388 7099-001
002
489 4371-001
. FLANGE, BEARING
003
489 4345-004
. LOCKING PLATE
004
2151 2027-192
. WASHER
RB 21 x 37 -A4
005
2121 2034-672
. SCREW
M6S 20 x 40 -A4-80
006
489 4453-001
. BOLT
007
2545 2110-001
. GREASE NIPPLE
G 1/4 A2-50
PARTS MANUAL
HOOK BLOCK
Date
Group
Fig.
Page
1999-05-27
9.3
625-7013.005D
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
1999-05-27
9.3
625-7013.005D
2 (2)
HOOK BLOCK
Item
Qty
000
001
Article no
Description
Supplementary data
388 7531-801
HOOK BLOCK
SWL 5 tonnes
875 12401-005
. SHEAVE, COMPLETE
002
875 12054-006
.. BEARING
003
875 12062-004
.. LOCK RING
004
875 12009-001
.. SPACER
005
875 12404-003
. SHAFT, COMPLETE
006
2545 2011-025
.. GREASE NIPPLE
007
875 12406-004
. SPACER, COMPLETE
008
875 12409-004
009
875 12073-002
. SHACKLE
010
875 12001-004
. HOOK, COMPLETE
PARTS MANUAL
DIRECTION VALVE
Date
Group
Fig.
Page
1998-09-29
9.4
625-7322.011
1 (2)
PARTS MANUAL
Date
Group
Fig.
1998-09-29
9.4
625-7322.011
DIRECTION VALVE
Item
Qty
Article no
Description
Supplementary data
000
188 1338-801
DIRECTION VALVE
001
489 4422-801
. GASKET SET
002
003
004
005
SLEWING
006
LUFFING
007
HOISTING
008
Page
2 (2)
PARTS MANUAL
BALANCE VALVE
Date
Group
Fig.
Page
1997-12-04
9.4
625-7330.001
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
1997-12-04
9.4
625-7330.001
2 (2)
BALANCE VALVE
Item
Qty
Article no
Description
001
388 6376-801
BALANCE VALVE
002
489 4539-801
. GASKET SET
Supplementary data
PARTS MANUAL
BALANCE VALVE
Date
Group
Fig.
Page
2004-03-03
9.4
625-7330.006A
1 (2)
PARTS MANUAL
Date
Group
Fig.
2004-03-03
9.4
625-7330.006A
BALANCE VALVE
Item
Qty
Article no
Description
001
289 0839-801
BALANCE VALVE
002
489 5703-801
. GASKET SET
Supplementary data
Page
2 (2)
PARTS MANUAL
MOTOR VALVE
Date
Group
Fig.
Page
1995-07-06
9.4
625-7331
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
1995-07-06
9.4
625-7331
2 (2)
MOTOR VALVE
Item
Qty
Article no
Description
000
388 6358-801
MOTOR VALVE
001
489 4437-801
. GASKET SET
Supplementary data
PARTS MANUAL
LIMIT VALVE
Date
Group
Fig.
Page
1995-07-06
9.4
625-7334
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
1995-07-06
9.4
625-7334
2 (2)
LIMIT VALVE
Item
Qty
Article no
Description
000
388 6361-801
LIMIT VALVE
001
489 4439-801
. GASKET SET
Supplementary data
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
BALL VALVE
Date
Group
Fig.
Page
1999-09-08
9.4
625-7620.004
1 (2)
PARTS MANUAL
Date
Group
Fig.
1999-09-08
9.4
625-7620.004
BALL VALVE
Item
Qty
Article no
Description
Supplementary data
000
389 4128-801
BALL VALVE
001
389 3199-001
. BRACKET
002
389 3201-801
. HANDLE
003
389 3352-801
. BALL VALVE
004
389 3369-801
005
489 6086-801
. BRACKET
006
489 6127-001
. TENSION SPRING
007
2121 2550-325
. SCREW
MC6S 5 x 10 A4-80
008
2121 2550-341
. SCREW
MC6S 5 x 50 A4-80
009
2126 2634-114
. NUT
010
2151 2027-146
. WASHER
RB 5.3 x 10 -A4
Page
2 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2003-06-10
9.4
625-7970G
1 (2)
HYDRAULIC HOSES
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.
PARTS MANUAL
HYDRAULIC CYLINDER
Date
Group
Fig.
Page
2004-05-11
9.4
625-7990.044
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2004-05-11
9.4
625-7990.044
2 (2)
HYDRAULIC CYLINDER
Item
Qty
Article no
Description
Supplementary data
000
289 3178-801
HYDRAULIC CYLINDER
180 / 125
001
875 16403-002
. GASKET SET
011
.. PISTON SEAL
012
.. O-RING
013
.. BEARING RING
014
.. O-RING
015
.. SUPPORT RING
016
.. ROD SEAL
019
.. ROD WIPER
025
.. O-RING
108
875 16401-002
. BEARING
109
2545 2110-003
. GREASE NIPPLE
110
2122 2519-445
. SCREW
120
2121 2550-374
. SCREW
MC6S 6 x 30 -A4-80
121
2522 2105-014
122
2545 2112-003
. GREASE NIPPLE
(approx. 90)
(approx. 170)
(approx. 125)
PARTS MANUAL
Date
Group
Fig.
Page
2007-11-09
9.5
625-8630.050A
1 (2)
PARTS MANUAL
Date
Group
Fig.
Page
2007-11-09
9.5
625-8630.050A
2 (2)
Qty
Article no
Description
Supplementary data
000
324 1150-801
001
5829 4196-101
. EL. CABINET
002
324 1165-801
. TRANSFORMER
003
5354 4273-065
. CONTACTOR
004
5627 4216-054
. OVERLOAD RELAY
005
5381 4227-080
. LOAD SWITCH
006
4762 4105-075
. CURRENT TRANSFORMER
007
5347 4262-203
. CIRCUIT BREAKER
008
5692 4740-221
. HOUR METER
009
5697 4337-075
. AMMETER
010
5298 2071-221
. PILOT LIGHT
GREEN
011
5298 2071-220
. PILOT LIGHT
WHITE
012
5298 2071-222
. PILOT LIGHT
YELLOW
014
5347 4263-203
. CIRCUIT BREAKER
015
5372 2210-002
. PUSH BUTTON
RED
016
5372 2210-001
. PUSH BUTTON
GREEN
022
2647 4160-040
. EARTH CLAMP
023
2647 4160-350
. EARTH CLAMP
027
20
2663 4382-025
. TERMINAL BLOCK
029
2631 4123-252
. BRIDGE CONNECTOR
034
5354 4137-510
035
5354 4137-501
037
5381 4227-001
. HANDLE
038
5381 4227-002
. SHAFT
061
424 0494-801
. SIGN
064
2183 2022-122
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
030
875 29031-015
090
2522 2132-108
. PLUG
NPTF 1/16"
130
2522 2105-012
G 1/2"
140
875 29031-005
. MANOMETER
60 bar
150
875 29031-013
G 1/2"
500
875 29031-017
3/8" L = 3000
560
2529 2458-111
. QUICK COUPLING
G 3/8"
D = 45 cc