Hydraulic Function
Symbols
Every hydraulic component is represented by a special
symbol in the circuit diagram. The meaning of the
symbols is explained in section "General" in the Manual.
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.
Component identification
The main components are identified by four-digit
numbers in the diagram and on the actual components
FEED AND CONTROL CIRCUIT
in the cfane. The first digit of each number signifies the
circuit to which the component belongs: Fig. 1. Identifying hydraulic circuits
NOTE.
For exact pressure settings, see pressure list in the
hydraulic diagram.
Control pressure
Pump case drain Feed pressure outlet
\ • • \
indicator
•O-cxa
Introduction
Low speed High speed
Figure 6 shows a hoisting winch circuit diagram, with
the following main components:
Function
With the control lever in neutral, Figure 3, and the Lowering
pump running, the hoisting circuit performs no actual
work. A continuous supply of fluid flushes the circuit
and leakage is compensated by fluid from the feed Low speed High speed
circuit.
HOISTING CIRCUIT
1112
1255 ^2
A
—-4
Lowering
Hoisting and lowering
Pulling the control lever backwards from the brake
release position will start the winch to lift the load,
Low speed High speed
Figure 9. The servo valves 1111-9 and 1112-9 affect
the servo and thus the pump displacement. The pumps
1111 and 1112 thereby produce a flow of fluid that is
proportional to deflection of the control lever. Hoisting Control lever
Safety functions
The hoisting winch circuit embodies three safety
features:
Note! jt is not allowed to adjust sealed safety valves Fig. 9. Control lever, hoisting, high-speed hoisting
without contacting MacGREGOR Cranes, Service
Department.
LUFFING CIRCUIT
Introduction
Figure 10 shows a luffing winch circuit diagram, with Luffing-out (lowering jib)
the following main components:
Brake release
Moving the control lever from neutral, eg, rearward to Fig. 11. Control lever, luffing/slewing
raise the jib, causes the valves 2221 and 2226 (2226
slightly delayed in relation to 2221) to shift position and
control pressure is admitted to the brake 2211 and to
valve 4326 which shifts position from the relief mode.
Safety functions
The luffing winch circuit embodies three safely features:
SLEWING CIRCUIT
2
1
3- 1 Feed pressure, inlet
5- 2 Control pressure
2
4- 3 Feed pressure, outlet
4 Pump case flushing
5 Pump case drain
Brake release
Fig. 13. Control lever, luffing/slewing
Moving the control lever, eg, to the left for slewing left
(anti-clockwise), will affect valve 3221. The brakes will
be released and the unloading valve 3127-1 will be
blocked.
Safety functions
The slewing circuit embodies two safety features:
Introduction
- If the switch A34 is in "winter" connection, feed The crane house lighting is operated by switches
pump motor DD does not stop but is switched to 4- under the bottom plate. The cab lighting and the jib
pole configuration and continues to run at its lower light are operated by switches in the cab.
speed of 1450 rpm (50 Hz) or 1750 rpm (60 Hz). Control system error
- The feed pump motor and the ventilation fan mo-
If an error is detected by the crane control system in
tor stops only when the main switch HA is switched
the MB-box pilot light XA4 illuminates and all crane
OFF.
movements are stopped. Then, press pushbutton
XA10 "0" (Stop) and check MB-box. See separate
instruction "Crane Control System CC2000" under
Other electric functions Section 6.3.
Overheating protection
A thermostat FB in the hydraulic system of the crane
opens the control circuits of the main electric motor
and the oil cooler fan motor when the oil temperature
exceeds +85°C.
Siren
A pushbutton "SIREN" in the cab allows the operator
to warn people on deck.
Ventilation fan
For all cranes a ventilation fan is fittediin the
cranehouse. This is controlled by a +25°C thermostat
A99 which is located in the A-box.
General
The following description refers to the microcomputer For detailed information about the control system a
based crane control system CC2000 for complete electric circuit diagram, relating specifically
MacGREGOR Cranes hydraulic deck cranes, single to your crane, will be found in the instruction manual,
crane versions. section "Spare Parts", Group 9.5. Also for detailed
information about the hydraulic system a complete
Minor variations in the use of control system input hydraulic circuit diagram will be found in section
and output signals due to differences in hydraulic and "Spare Parts", Group 9.4.
electric system may occur, the objective of this
description is only to provide a general orientation
concerning the principles of the control system.
Unloading/displacement
shift valve
Control lever
hoisting winch Cubicle MB
Hojsting winch
HOISTING
Limit switch
Unloading Brake
v valve Unloading
a valve box
valve
Memory card
Luffing winch J
Control lever
luffing/slewing LUFFING
Slewing gear
•I
SLEWING ;-
Unloading valve
Limit switch
box
Fig.1. Crane control system with interfaces to control levers and hydraulic system
The control lever for hoisting also gives 24V signals Hydraulic motors
for selection of low speed/high speed and hoisting/ The hydraulic motors may be reversed by changing
lowering. the direction of the hydraulic pump oil flow. Each
The control lever for luffing/slewing also gives 24V motor also having a low and a high speed range
signals for selecting luffing in/luffing out and slewing selected from the driver's control lever.
left/slewing right.
Limit Switch Box, Hoisting
Crane control system in cubicle MB The limit switch box controls speed reduction and
The Crane control system consists mainly of four stop function for full or empty drum.
MPC - Micro Processor Cards. One MPC-card is used
for internal communication between the cards and a
Limit switch box, luffing
parameter Memory Card. Three of the MPC-cards
The limit switch box controls speed reduction and
are controlling all input and output signals for one
stop function for all max. and min. outreach, and stop
crane movement each, hoisting, luffing or slewing.
parking, if fitted.
Each MPC-card feeds a potentiometer in the control
lever for the crane movement in control. Potentio-
meter and control lever direction signals go to a Limit switches, slackwire
microprocessor with a software control program that The limit switch for hoisting slackwire stops the
handles brake release logic, overload logic and lowering movement, and the limit switch luffing slack-
rampforming. The output from the microprocessor is wire stops the luffing out movement when each wire
fed to an voltage to current amplifier on the card. is slacken.
\ Fl A I
Each card can fully handle all input and output sign- • Parameter memory card
als needed for one hydraulic circuit, i.e. one crane
All parameter values from the parameter list are sto-
movement. A separate safety system on each card
red into the parameter memory card. The informa-
gives processor-independent protection against
tion is stored into electronic memories on the card.
hazardous operation at low feed pressure and
Stored parameter values are not dependent of power
overload pressure as well as it ensures stopping of supply or battery. There are, however, a battery on
the crane movement due to activated limit switches. the card used for a calendar, giving all MPC-cards
date and time information. The card is located inside
Software the rack and is mounted on the backplane card that
All four MPC-cards,are programmed with the same also holds all the MPC-card connectors.
crane control software. Each card is sensing which The lifetime of the battery is 10 years.
rack-position and therefore which crane movement it
is controlling. Cables from MPC-cards
Each MPC-card has a maximum of 42 cables
All MPC-cards identifies themselves by showing a
connecting all the inputs and outputs between the
two-character abbreviation of the function/movement-
card and its part of the plinth row. Cables are
name on the front panel display: Sc - supervisor, Ho
numbered 1 to 42 and put together into a braid.
- hoisting, Lu - luffing, SL - slewing.
The leftmost MPC-card, the MPC "Sc", is only used
for supervisory functions such as communication with Plinths
other MPC-cards and distribution of control system All external connections are made to a row of plinths
parameters from the parameter Memory Card. in the lower part of the enclosure.
New versions of the crane control software can be Each MPC-card has its own series of plinths. 101 -
loaded/programmed into the MPC-cards by using a 142 for the MPC "Sc", 201-242 for the MPC "Ho",
standard notebook-PC. 301-342 for the MPC u Lu" and 401-442 for the MPC
"SL". Note that there are not plinths for all numbers
and that all plinths are not used on all types of cranes.
Parameter list
The parameter list specifies all information details
Plinth numbers from 1 to 99 are used for power and
about the crane needed for the control system. It sta-
cross-connections for external limit-switches, key-
tes the software version and software configuration
switches, overload-switches etc.
parameters such as number of pumps, type of pumps,
maximum speed, extra equipment etc.
Anti condensation heating
Parameter values have both normal operation values To avoid condensation on the electronic cards the
and default values. Default values are used at "MPC temperature inside the enclosure is kept a few
default operation mode", see page 6. degrees higher than the temperature outside. Heating
elements are therefore mounted behind the row of
The parameter list identification number 625XXXXX, plinths. They are powered with 24V AC when the
is the same as the crane manufacturing number seen control system is switched off, when the crane is not
on the sign in the driver's cabin (MFG NO.). All para- operated.
meters are stored in the parameter memory card.
Signal overview CC2000 connections to pumps and valves are detected when
the output is activated. Signal levels that does not
correspond to normal levels, i. e. the potentiometer
Coloured LEDs
input from the driver's handle, are also detected.
Signals to and from each MPC-card are indicated
with green, yellow and red LEDs (Light-Emitting When any type of malfunction is detected, the MPC-
Diodes) on each MPC-card front panel. card flashes with its error LED, no 28. All MPC-card
error LEDs are wired together to an error lamp in the
Green are used for normal input and outputs. Yellow drivers cabin, the "Control system error in MB-box"
indicates that the crane motion concerned is driven lamp. To get the corresponding error message
with slower speed. Red indicates that the motion is number, push the STEP push-button on the MPC-
stopped. card with flashing LED.
Signal overview sign If there are several errors, they are shown one at a
All signals indicated with LEDs are listed on the sign time for each push on the STEP push-button. When
SIGNAL OVERVIEW inside cubicle MB, see section there are no more error messages to read the dis-
"Service", Group 6.3. play shows two hyphens "—". The error LED is now
either on or off. If it is on the error is still present but
Identifying the plinth number corresponding to now acknowledged. If it is off the errors are not pre-
a LED sent at the time. When a new error is detected the
The plinth number is identified by a three digit number. error LED starts flashing again to indicate that a new
The first digit of each number signifies the MPC-card error is found.
to which the signal is connected:
Error message sign
1. Supervisory MPC-card, "Sc" The corresponding error message text can be found
2. Hoisting MPC-card, "Ho" on the sign ERROR MESSAGES in cubicle MB, see
3. Luffing MPC-card, "Lu" section "Service", Group 6.3.
4. Slewing MPC-card, "SLU
Error messages - PRI1 is only for information and does not stop any
crane operation.
- PRI2 stops the MPC-card that detected the error
Built-in diagnostics system
but it can be operated in "MPC default operation
i
mode".
The CC2000 control system has its own built-in
diagnostics system. The system is capable of - PRI3 stops the MPC-card both in normal and in
detecting several types of malfunctions. default operation mode.
- PRI4 stops all the MPC-cards in the crane.
The system checks itself and external input and out-
puf^. signals. Internal problems like missing
communication are continuously checked. Loose
A single crane normally uses four MPC-cards, but if In case of MPC-card problems, there are also a
one card is broken it is still possible to fully operate possibility to replace the card with an Emergency
the crane with only three MPCs. The speed control operation card which is much less complex than the
is still stepless and safety functions as limit switches MPC-card. It is built up with relays that activates the
and overload protection are still working. The maxi- outputs for brake, displacement/unloading and pump
mum speed of the crane is reduced but is still at least from the control levers 24V signals. The pump output
50% of normal operation. is fixed, giving a constant speed of about 30% of
maximum speed. Each motion is controlled by
When one MPC-card is broken that card can be overload and limit switches, except the limit switch
replaced by the leftmost MPC-card "Sc". It perfor- for high hook.
mes supervisory tasks but does not control any out-
put signals. It distributes parameter values from the
parameter memory card to the other MPC-cards,
handles logged error messages etc. WARNING
When the emergency operation card is installed in
Each crane movement can be operated stand-alone the hoisting or luffing circuit, bear in mind that the
by its own MPC-card. The MPC "Sc" must then be high hook switch is inoperative.
removed from its normal rack-position (probably
replacing the broken card). An internal control signal
then tells the MPC "Ho", "Lu" and "SL" to operate
slowly in "MPC default operation mode", because the
MPC "Sc" is missing. Default operation means that
each MPC-card uses its in-built default values for all
control system parameters instead of the missing
parameter values from the parameter memory card,
normally distributed by the MPC "Sc".
E
JXLy _, g^ 1229
KRAN/CRANE GL3025-2/2425g
1311 /I 31 2 /I 31 3 /I 31 4
KRAN/CRANE GL302S-2/2426gr
671
KRAN/CRANE GL3025-2/2426gr
/I 311 n 31 2 /I 313 n 314
1241-1
KRAN/CRANE GL3025-2/242Sg:
MacGREGOR Hydraulic Component Specification Status
This document remains our property. II must not be reproduced or made accessible to our compelilors or olhers who could make undue use of ft, without our written permission.
LO99041
- Circuit diagram Crano type
This document remains our properly. It must not be reproduced or made accessible to our competitors or others who could make undue use of It, without our written permission.
LO99041
Cirri lit diagram Cinnft type
This document remains our property. It must not be reproduced or made accessible lo our compeliiors or others who could make undue use of il, without our written permission.
LO99041
Circuit diagram Crane type
This document rnmnlns our property. II must not bq reproduced or madn accessible to our romp n I Kara or others who could innke undue use of It, wflhont our written permission.
10990^11
Circuit diagrsr» Cratte type
• t •
rills document remains our properly II must not be reproduced or made accessible to our compelllors or others wlio could make undue use ol It, without our wrillen permission.
LO99041
Circuit diagram Crann type
This document remains our property. It must not be reproduced or made accessible to our competitors or others who could make undue use of It, without our written permission.
LO99041
Circuit disp^nm Crane type
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