User Manual for Crane

1 Introduction

Table of Contents
1. General ............................................................................................................................................1
2. Purchase Information .......................................................................................................................1
3. Contact Information ..........................................................................................................................1
4. General Security Conditions.............................................................................................................2
5. Training ............................................................................................................................................2
6. Guarantee Restrictions ....................................................................................................................2
7. HSE – Health, Safety and Environment ...........................................................................................3
7.1. Safety in Maintenance ...............................................................................................................3
7.2. Disconnection of Live Circuits ....................................................................................................3
7.3. Accidental Activation .................................................................................................................3
7.4. Electrical Supply Specification ...................................................................................................4
7.5. Replacement Parts ....................................................................................................................4
7.6. Software ....................................................................................................................................4
7.7. Observing the Installation Guidelines.........................................................................................4
7.8. Environment ..............................................................................................................................4

1 Introduction
MACGREGOR NORWAY AS
User Manual for Crane

Blank page.

1 Introduction
MACGREGOR NORWAY AS
 User Manual for Crane

1. General
This user manual is compiled in accordance with Norwegian Standard 5820.

Operators and maintenance personnel should read and understand this manual before operating or servicing the
equipment. The owner of the equipment is responsible for ensuring that no unauthorised personnel operate or
maintain the equipment.

The user manual is divided into three (3) volumes:

 SP2582-1-15-1 System Description

 SP2582-1-15-2 Hydraulic and Mechanical Drawings and Datasheets
 SP2582-1-15-3 Control system Diagrams

Note: Illustrations/photos used in the user manual may deviate from the actual delivery. Optional equipment
that may or may not be present is denoted with a star .

2. Purchase Information
Equipment: Offshore Knuckle Jib Crane
Type: HMC 3293 LKO 250-30 (700-16) (1000-11) AHC
Customer: Marigrest S.r.l
Machine number: SP2582-1

3. Contact Information
In case of any problems, please contact (remember equipment machine number for service advice):

+47 91 68 60 00

MacGregor Norway AS +47 38 01 87 01

Andøyfaret 15
N-4623 KRISTIANSAND
Norway
http://www.macgregor-
group.com/service krs.service@macgregor.com

24 hour service:
+47 91 68 97 51

1 Introduction
MACGREGOR NORWAY AS 1
 User Manual for Crane

After warranty period:

Contact your nearest MacGregor service office.

http://www.macgregor-group.com/service

4. General Security Conditions

No personnel are permitted in the equipment working area during operation.

All use of the equipment must comply with the company security regulations.

5. Training
MacGregor Norway AS can provide tailor-made operation and maintenance courses for all MacGregor Norway
equipment.

For more information, contact our head office in Kristiansand. We recommend all our customers to attend our
courses.

6. Guarantee Restrictions
During the warranty period, all necessary spare parts must be supplied by MacGregor Norway AS. Use of
spare parts from other suppliers violates and forfeits the warranty.

Unintended use and/or faulty/deficient maintenance of the equipment forfeits the warranty.

Removal and/or loss of equipment identification plates by customer also forfeits the warranty.

1 Introduction

2 MACGREGOR NORWAY AS
 User Manual for Crane

7. HSE – Health, Safety and Environment

7.1. Safety in Maintenance
Before carrying out any maintenance or repair work, maintenance personnel must be completely familiar with
equipment operation, technical drawings and procedures.

Secure the area of the maintenance operation to the degree and the extent necessary!

When replacing heavy parts and/or structural components, objects being lifted must be carefully secured to the
lifting appliances and safeguarded in order to avoid hazardous situations. Use only approved lifting equipment
of sufficient carrying capacity.

Do not stay underneath or in the vicinity of a suspended load.

Only personnel authorised according to applicable regulations are to perform work on the electrical installation
or the equipment.

If specifications for inspection, maintenance or repair require the equipment to be voltage-free, this can be
achieved in the following ways:

 For circuits above 50 VAC / 30 VDC, switch off and lock out the main circuit breaker on the supply
side.
 For instrumentation circuits (below 50 VAC / 30 VDC), isolate the control cabinet from the main
supply.
 Open the fuses in the control cabinet, referring to the relevant (loop) drawings.
 Isolate the relevant wires / cores from the terminal block in the control cabinet.
 Follow the relevant procedures to troubleshoot or repair the equipment in question.

Before work proceeds verify that all circuits are voltage-free.

7.2. Disconnection of Live Circuits

Do not disconnect any live circuits unless location is known to be non-hazardous.

7.3. Accidental Activation

Measures must be taken to prevent accidental activation of equipment, delivered by or controlled by a
MacGregor Norway AS product, during maintenance.

This may include locking our power supply, posting warning signs at relevant locations, informing other people
or organisations.

1 Introduction
MACGREGOR NORWAY AS 3
 User Manual for Crane

7.4. Electrical Supply Specification

In case of disturbances in the electrical supply (voltage, frequency, harmonic and other disturbances) the
equipment must be switched off immediately.

7.5. Replacement Parts

To maintain the integrity of the equipment delivered by MacGregor Norway AS it is important that all spare
parts have identical or better specifications than originally delivered. This is especially important for all
protective equipment such as fuses and circuit breakers. Computer hardware should not be altered or replaced
without consulting MacGregor Norway AS.

If in doubt – ASK!

7.6. Software
The software delivered with the system is programmed by MacGregor Norway AS, and is vital for safe and
dependable operation of the equipment.

Only qualified personnel from MacGregor Norway AS may alter or modify system software.

The software supplied with the system has unique reference numbers kept on file at MacGregor Norway AS. If
software modifications are detected in any system this will void any warranty responsibility with respect to the
safe and normal operation of the equipment. Consult MacGregor Norway AS prior to making any changes in the
software.

Use the attached Software Change Request formula whenever requiring a change in the application software.

7.7. Observing the Installation Guidelines

MacGregor Norway AS products meet the requirements of the contract as long as they are installed and
operated as described in the installation guidelines and documentation received from MacGregor Norway AS.

7.8. Environment
Environmental considerations should be kept in mind when disposing of any part of the equipment delivered by
MacGregor Norway AS.

1 Introduction

4 MACGREGOR NORWAY AS
 User Manual for Crane

2 Main Data
Table of Contents
1.1. General .....................................................................................................................................1
1.2. Regulations and Design Criteria ................................................................................................2
1.3. Foundation ................................................................................................................................2
1.4. Main Winch................................................................................................................................3
1.5. Whip Winch ...............................................................................................................................4
1.6. Tugger Winch ............................................................................................................................4
1.7. Hydraulics..................................................................................................................................5
1.8. Electrical....................................................................................................................................5
1.9. Crane Operation ........................................................................................................................5
1.10. Miscellaneous ..........................................................................................................................6
1.11. Dimensions, Weight and COGs ...............................................................................................6

2 Main Data
MACGREGOR NORWAY AS
User Manual for Crane

Blank page.

2 Main Data
MACGREGOR NORWAY AS
 User Manual for Crane

1.1. General
Project ID 2582-1
Customer Marigest S.r.l.
Equipment type HMC Offshore
Crane type HMC 3293
Size LKO 250-30 (700-16)(1000-11)
Current vessel name IEVOLI IVORY
Yard build number H67
Ship owner Marigest S.r.l.
Assembly site MacGregor Kristiansand
FAT site MacGregor Kristiansand
Commissioning site MacGregor Kristiansand

Dynamic factor and derating: Derating procedures are to be applied to lifts where the dynamic factor exceeds
the limit.

Subsea capacity: Net subsea lift capacity is reduced by the weight of the submerged wire and increased by the
buoyancy of the submerged load. Hydrodynamic loads are to be calculated and factored into the lift.

2 Main Data
MACGREGOR NORWAY AS 1
 User Manual for Crane

1.2. Regulations and Design Criteria

Regulations DNV Lifting appliances 2.22
Area classification Safe zone
Operation temp (°C) -20 to +45
Max operation wind speed (m/s) 25
Max trim/list 5+2

Minimum working radius MW (m) 6,5 m

Minimum working radius WW (m) 6,5 m

Shipboard Singlefall 25t @ 30m

Capacity Shipboard Single fall 70t @16m
Capacity shipboard double fall 100t @ 11m
Capacity Offshore Single fall 20t @ 30 m
Capacity Offshore Single fall 70t @13
Capacity Offshore double fall 100t @ 9m
WW Capacity Shipboard Single fall 10t @ 32m
WW Capacity offshore Single fall 10t @ 32m

1.3. Foundation
Height of foundation (m) 5,0
Counter foundation height 530 mm
Cooling of foundation Air ventilation

2 Main Data

2 MACGREGOR NORWAY AS
 User Manual for Crane

1.4. Main Winch

Main winch SWL (t) 70t

Wire diameter (mm) 56

Wire type Galvanized, non rotating type
Wire MBL (kN) 2912
Wire weight dry (kg/m) 15,2
Wire weight in seawater (kg/m) 13,2
Drum diameter, PCD layer 1 (mm) 2278
Drum width (mm) 1316
Drum barrel Lebus
Hook travel (m) 3000
Drum capacity (m) 3170

Wirelength included (m) 3080

Lifting speed 1 0-35- t , 0 - 60 m/min
Lifting speed 2 35-70t, 60 -30m/min

Weight of hook (kg) 1500

Multiple falls Double fall

AT top tension, case 1 (t) 0-35 ton

AT speed, case 1 (m/s) 2
AT top tension, case 2 (t) 35-70 ton
AT speed, case 2 (m/s) 1
AHC system type Active boost
AHC max wire load, case 1 (t) 0-35 ton
AHC heave period, case 1 (s) 10
AHC nominal displacement, case 1
(+/-) (m) +/- 3,2 m

AHC max speed, case 1 (m/s) 2

AHC max wire load, case 2 (t) 35-70 ton
AHC heave period, case 2 (s) 12
AHC nominal displacement, case 2
(+/-) (m) +/- 2 m

AHC max speed, case 2 (m/s) 1

2 Main Data
MACGREGOR NORWAY AS 3
 User Manual for Crane

1.5. Whip Winch

WW SWL (t) 10

WW Wire diameter (mm) 24

Wire type Galvanized, non rotating type
WW Wire MBL (kN) 574
WW Wire weight dry (kg/m) 2,79
WW Wire weight in seawater (kg/m) 2,42
WW Drum width (mm) 650
WW Hook travel (m) 150
WW Drum capacity (m) 150

WW Wirelength included (m) 220

WW Lifting speed 1 0-10 t, 0-60m/min

WW Weight of hook (kg) 500

WW Personnel lift SWL 5t

WW CT Ship-Ship (tension setpoint) 1,5 t

1.6. Tugger Winch

Number of tugger winches 2
Tugger SWL (t) 4
TW Wire diameter (mm) 16
TW Wire MBL (kN) 255
TW Wirelength included (m) 60
Side lift function +/- 15 degreees
CT settings top tension 0-4 ton
Tugger speed (m/s) 0-60
Overload protection/ reduced brake
capacity Yes
Note! Not load lifting winch

2 Main Data

4 MACGREGOR NORWAY AS
 User Manual for Crane

1.7. Hydraulics
Main jib topping speed 80 sec in/out
Knuckle jib topping speed 60 sec in/out
Slew sector 360 degrees unlimited
Slew speed 0-1 rpm (Rmin-15m), 0-0,5 rpm (20m-Rmax)

1.8. Electrical
Main supply 3 x 690V/ 60 Hz/
Main electro motor 3 x 300kW
Emergency supply 3x440V/60Hz

Main motor enclosure IP 55

SPM nipples in electro motor YES
Oil cooler motors 4x3,5kW(S1-100%) DOL
Circulation/Feeding motor 1x11kw(S1-100%)DOL
CJC motor 1x0,5kW(S1-100%)DOL
Emergency HPU motor 1x50kW(S1-100%)DOL

Power Request interface system

(PRS) Yes

1.9. Crane Operation

Operating controls: Joysticks on operator’s seat in cabin
Control and monitoring functions: Siemens PLC-based system with graphic user interface (LCD touch-screen)

2 Main Data
MACGREGOR NORWAY AS 5
 User Manual for Crane

1.10. Miscellaneous
Crane lubrication system Automatic central system(manual on slew cogwheel)
Winch lubrication system Automatic central system

Top layer color White RAL9010

1.11. Dimensions, Weight and COGs

See drawing No. SP2582-1-R-XD-01 General Arrangement

2 Main Data

6 MACGREGOR NORWAY AS
 User Manual for Crane

3 System Description
Table of Contents
1. General ............................................................................................................................................1
1.1. Illustration of Main Components ................................................................................................2
2. Main Components ............................................................................................................................3
2.1. Crane Pedestal..........................................................................................................................3
2.2. Slew Bearing .............................................................................................................................3
2.3. Crane King ................................................................................................................................3
2.4. Slew Gear..................................................................................................................................4
2.5. Operator Cabin ..........................................................................................................................4
2.5.1. Communication System / ROV Monitor Signals ..................................................................5
2.5.2. Monitor for Remote Installation ...........................................................................................5
2.6. Crane Jib System ......................................................................................................................5
2.7. Luffing Main and Knuckle Jib Cylinders .....................................................................................6
2.8. Winches ....................................................................................................................................7
2.8.1. General ...............................................................................................................................7
2.8.2. Main Winch .........................................................................................................................9
2.8.3. Whip Winch .........................................................................................................................9
3. Generic Hydraulic System Design ..................................................................................................11
3.1. General ...................................................................................................................................12
4. Electrical System Design ...............................................................................................................13
4.1. Electric Slip-Ring Unit ..............................................................................................................13
4.2. Main Electric Motors ................................................................................................................13
5. Control System Design ..................................................................................................................14

Annex A - Technical Description of the Hydraulic System...................................................................A1

3 System Description
MACGREGOR NORWAY AS
User Manual for Crane

Blank page.

3 System Description
MACGREGOR NORWAY AS
 User Manual for Crane

1. General
The HMC 3293 LKO 250-30 (700-16) (1000-11) AHC MacGregor offshore knuckle jib crane is designed for
sustained operation and long periods of inactivity in a tough and corrosive offshore marine environment. The
crane is designed with a substantial structural and mechanical capacity margin for heavy offshore/ subsea
operation from open decks on offshore vessels and for secure parking when not in use.

An active heave compensation system on the main winch enables the crane to place and retrieve loads on the
seabed with virtually no heave motion on the load relative to the seabed. The heave compensation system is an
active system based on direct winch compensation for vessel motion. The crane is a self-contained unit built for
independent hydraulic operation. It is supplied as a complete, fully pre-assembled, adjusted and function-tested
unit with a pedestal readied for installation to the vessel’s substructure by MacGregor Norway in accordance
with our procedures.

Knuckle jib cranes were originally designed to keep the jib end, including load, as low as possible to reduce
pendulum motion caused by vessel movement. However, when these cranes are used to lift large and heavy
objects, it is sometimes necessary to have more free-hook height to provide increased space for lifting
arrangements, slings etc.

All our knuckle jib cranes are designed to lift high loads with an extended knuckle jib. This includes sufficient
strength in the structure and cylinder system to deal with these forces. This feature provides operators with great
flexibility during planning of lifting operations.

When the crane is in the over-side working position, with active heave-compensation (AHC) activated and the
crane hook in the water, it is still possible to operate jib and slew crane functions. This makes load positioning
possible and optimizes other crane functions without shutting down the AHC mode or moving the vessel.

On all larger MacGregor cranes the slew drive system components, including drive gears and motors, are
located inside the crane’s king. This simplifies maintenance and inspections throughout the entire lifetime of the
crane and protects the components from the aggressive environment/surroundings. The crane is operated from a
fully insulated operator’s cabin on the king. All equipment is chosen and installed to insure the lowest possible
emission of sound and to allow easy access for service and repair.

3 System Description
MACGREGOR NORWAY AS 1
 User Manual for Crane

1.1. Illustration of Main Components

The major parts of an offshore
knuckle-jib crane

3 System Description

2 MACGREGOR NORWAY AS
 User Manual for Crane

2. Main Components
2.1. Crane Pedestal
The crane pedestal is a fixed cylindrical structure bolted or welded to the underlying vessel structure to provide
a foundation for the rest of the crane. The slew ring on the top carries the king – the rotating part of the crane.
The pedestal houses the electric slip-ring unit through which all electric power and signal circuits pass between
the ship and the crane. The cables are all mounted on cable trays.

Powerful electric motors that drive the main HPU pumps inside the king are mounted on the underside of the
king bottom plate, protruding down into the pedestal. An access hatch in the king bottom plate opens into the
pedestal, where a ladder and platform facilitate inspection and maintenance. A walkway platform encircles the
pedestal on the outside approximately 2 m from the top ensuring access to the crane in all positions. Access to
this platform is by a ladder which also has a safety frame.

2.2. Slew Bearing

The slew bearing is a heavy duty marine slew ring, with internal gearing for the transfer of torque from the
slewing gear.

As the slewing pinions in the underside of the

crane king engage with the stationary internal
gearing, the crane is turned. Slewing motors
and gearing are described later. Such rotation
of the crane may be unlimited or limited to a
specified slewing arc depending on the needs
and placement of the crane onboard the vessel.

Photo at right: a slew pinion under the crane

king engages with the stationary part of the
slew bearing.

A crane's size is specified based on the slew

bearing's diameter in millimetres.

2.3. Crane King

The king is mounted on top of the slew ring. It
is the structural element on which the jib
system is mounted. The main jib is connected
to the top of the king, with twin luffing
cylinders on the underside attached to the
lower part of the king. The hydraulic tanks are
built into the king structure, which also
functions as a machine room where various
cabinets, panels and most control valves are
located. Access to this machine room is via a
door behind the cabin. The operator’s cabin is
mounted on the front right side of the king.

3 System Description
MACGREGOR NORWAY AS 3
 User Manual for Crane

2.4. Slew Gear

The crane's slewing function is provided by a number of
slewing gears interacting with the toothed ring of the slew
bearing described earlier. Brakes are dimensioned to take the
full load at the maximum list, plus any additional dynamic
force acting on the slew gear. A heavy duty, hydraulic motor is
flanged onto each gearbox. The slewing gear motors generate
smooth, accurate and proportional slewing motion for the
crane.

In cases where the crane has a defined slewing sector, slewing

may be limited by a slew-stop system.

2.5. Operator Cabin

A spacious operator cabin located on the front right side of the crane king provides a comfortable working
environment for the crane operator. The cabin is often furnished with one operator’s seat and one fold-down
“co-pilot’s” seat for an instructor, for instance. The operator’s seat is of ergonomic design and is vibration-
dampened. The main manoeuvring controls consist of spring-centred joysticks fitted to consoles mounted on the
operator’s seat – winch and knuckle jib operation on right-hand joystick, main jib and slew on the left.

Steel bars on the front window and a

grille over the top window protect
occupant and equipment against injury
and damage if heavy objects strike the
cabin area. All windows are fitted with
adjustable roller blinds to shield the crane
operator from direct sunlight. Several of
the windows may be opened, and there
are catwalks outside for cleaning the
windows. Other cabin equipment
includes window wipers, a signal horn,
inside lighting, heating and air
conditioning. A fire extinguisher is
mounted in compliance with regulations,
and the cabin meets official noise and
working environment standards.

3 System Description

4 MACGREGOR NORWAY AS
 User Manual for Crane

2.5.1. Communication System / ROV Monitor Signals

The crane cabin is equipped with VHF/UHF radios for communication. The slip-ring unit has spare slip-rings
available for connecting to vessel intercom systems or a ROV monitor system. Available signal lines are routed
from the cabin to the slip-ring junction box in the pedestal.

2.5.2. Monitor for Remote Installation

The crane is supplied with a separate LCD slave panel for remote monitoring of crane status and selected data.
This panel can be installed in a suitable location elsewhere on the vessel according to the diagram supplied by
MacGregor Norway AS.

2.6. Crane Jib System

The jib system consists of a main jib and a knuckle jib. Both jib elements are built of steel plate and steel
sections, and both are manoeuvred by twin heavy-duty double acting marine-grade hydraulic cylinders fitted
with counterbalance valves. The knuckle jib is manoeuvred by a similar set of cylinders that are especially made
for knuckle jib operation. All cylinders are connected to the jibs with spherical bearings. Wire retainers on the
sheaves nearest the knuckle prevent the wires (both main and whip) from slipping off the sheaves.

Suspension lugs are welded to the underside of the main jib which can be used to support the tugger winch
system spreader beam.

Contact Buffer

Although smaller active boost cranes may be delivered without any contact buffer, most knuckle jibs are
equipped with a contact buffer. During heavy lifts with buffer contact, some of the force is transferred to the
main jib. Ergo, the crane is able to perform heavier lifts due to reduced force on the knuckle jib cylinders.
However, when contact is lost, the lifting capacity drops. Refer to the specific user manual for load curves.

Aircraft Warning Lights

Red aviation warning lights are mounted atop the main winch and at
the knuckle-end of the main jib to mark crane position in hours of
darkness.

Jib Floodlight

Two heavy-duty marine-grade pendulum floodlights are fitted to the

knuckle jib.

3 System Description
MACGREGOR NORWAY AS 5
 User Manual for Crane

2.7. Luffing Main and Knuckle Jib Cylinders

Each jib is hydraulically operated by a pair of double acting
cylinders with integrated counter balance valves. In addition, a
safety valve is hydraulically connected to the rod side of all jib
cylinders to protect them in the event of incorrect operation.

The cylinders are connected with spherical bearings. A load

holding valve is mounted directly to the cylinder ports on the
load holding side of both cylinder pairs to maintain safety in
case of a hose failure.

Bondura bolts are typically used to connect the hydraulic

cylinders to the crane. A cone is fitted to each side of the
conical bolt ends. These cones expand in place when the
locking plates are fitted and the locking plate bolts are
tightened to the specified value.

3 System Description

6 MACGREGOR NORWAY AS
 User Manual for Crane

2.8. Winches
2.8.1. General
The crane has three separate winch systems – one main winch on a platform mounted on the back of the crane
king at the top, one whip winch mounted near the inner end of the main jib, and a tugger winch mounted on the
king front below the cabin. Oil coolers, the accumulators for the Active Heave Compensation (AHC) system
and other items of equipment associated with the winch systems are located on the platform below the main
winch platform.

Main winch system is equipped with two hook stops – a mechanical one that uses a proximity switch suspended
from the jib tip, and an electronic system based on system monitoring of pay out length. The software controlled
hook stop is programmed into the control system and utilises continuous feedback from a rotational encoder on
the winch to calculate the length of wire paid out at any given time. The control system thus “knows” when the
hook is about to be pulled into the sheave, or when the wire is about to be paid out beyond the preset limit and
stops the winch accordingly. The mechanical hook stop simply sends a signal when the hook makes contact
with the switch, and the control system halts the winch. Line load is monitored by a load cell fitted to one of the
wire sheaves. Whip winch system is equipped with electronic hook stop.

AHC is a position-control system that provides smooth landing and pick-up from the seabed. The purpose of
this system is to offset jib tip motion caused by the normal motion of a ship on a dynamic sea surface by paying
out / hauling in wire. An MRU (Motion Reference Unit) located in the pedestal registers vessel heave, pitch and
roll movements in reference to a specific position. The crane’s control system uses input from this system to
calculate the resultant motion of the knuckle jib tip in any position, and a set of servo valves compensates
directly by paying out / hauling in wire to keep the hook (load) steady relative to the seabed.

Auto-tension (AT), a sub-mode of AHC, facilitates retrieval operations by allowing the operator to step up the
tension force in order to overcome suction forces when loosening a load from the seabed. Applicable winches
are equipped with automatic and manual emergency release systems – AOPS (Automatic Overload Protection
System) and MOPS (Manual Overload Protection System). An Emergency Power System provides capabilities
for operating either winch at reduced capacity in the event of a main power failure.

3 System Description
MACGREGOR NORWAY AS 7
 User Manual for Crane

Figure below: Standard winch layout of a MacGregor AHC crane.

Galvanized non-rotating wire rope.

Wire desalting device

Main winch gearbox
assemblies on both sides
equipped with individual
hydraulic motor/valve blocks.

1 whip winch gearbox

assembly each side. Each
equipped with a hydraulic
motor/valve block.

Galvanized non-
rotating wire rope

Whip winch spooling guide system controlled by crane

control system.

(Emergency operation from Emergency Panel)

3 System Description

8 MACGREGOR NORWAY AS
 User Manual for Crane

2.8.2. Main Winch

The main winch consists of a flanged steel drum on an axle that turns on bearings set into the winch’s frame-
plates. A large gear ring on each of the drum’s flanges is driven by drive gears mounted on the winch’s frame
plates. Each drive gear is driven by a variable-displacement hydraulic motor and fitted with fail-safe multidisc
brakes. Failsafe here means that any hose or pipe failure or loss of operating pressure will cause the brakes to
lock the load immediately. The brakes are dimensioned to take the full load plus the additional dynamic forces
acting on the winch. A set of counterbalance valves in the winch loop ensure safe, smooth and precise winch
operation.

A high quality galvanized, non-rotating, subsea wire rope is

included, together with a subsea counterweight/swivel hook. A
desalting device consisting of six spray nozzles mounted in a
horizontal frame on the winch rinse the wire with freshwater as the
drum turns.

Rotational encoder
2.8.3. Whip Winch
The whip winch consists of a steel drum with an axle that turns on bearings set into the winch’s frame-plates. A
large gear rim bolted to one of the drum’s flanges is driven by four drive gears mounted on the winch’s frame
plate. Each gear is driven by a variable-displacement hydraulic motor and fitted with failsafe multidisc brakes.

Failsafe here means that any hose or pipe failure or loss of operating pressure will cause the brakes to lock the
load immediately. The brakes are dimensioned to take the full load plus the additional dynamic forces acting on
the winch. A set of counterbalance valves in the winch loop ensures smooth, accurate and safe winch operation.
The winch is provided with a high-quality galvanized, non-rotating subsea wire rope and a subsea
counterweight/swivel/hook block of required capacity.

A software hook stop implemented by the control system utilises continuous feedback from a rotational encoder
on the winch to calculate the length of wire paid out. The control system then stops the winch from pulling the
hook into the sheave or paying out the full length of the wire. Line load is monitored by a load cell fitted to one
of the wire sheaves.

3 System Description
MACGREGOR NORWAY AS 9
 User Manual for Crane

Whip Winch Constant Tension Mode

In this mode, wire tension is kept constant at a force adjusted manually by the operator. Its working principle is
based on the response of the hydraulic system to load deviations caused by vessel motion. The system provides
a measure of heave compensation by maintaining a reasonably steady lift in operations that do not require the
precision offered by AHC/AT.

Spooling Guide
The whip winch system includes a fully automatic spooling guide mounted directly in front of the winch. The
function of this device is to ensure that the wire lies correctly on the winch drum as it is pulled in.

3 System Description

10 MACGREGOR NORWAY AS
 User Manual for Crane

3. Generic Hydraulic System Design

Note: All features may not be present on this particular MacGregor crane.

Breathers x 4
Return filters x 2

Circulation pump Drain filters x 3

High pressure
filters x 5

Main pump
(single) x 3
Emergency pump

King floor plate Main pump (double) x 1

Slew motor/gear/brake
assembly x 4

Main HPU motor Slew ring

(300 kW) x 3

Main HPU motor

(550kW) x 1

CJC offline filter

system

3 System Description
MACGREGOR NORWAY AS 11
 User Manual for Crane

3.1. General
The hydraulic oil tanks are built into the crane king structure. The king machine room also houses the hydraulic
main pumps which are mounted on rubber flanges on the king bottom plate for low-noise operation. The
hydraulic pumps are of low noise variable displacement type operating in Load Sense mode (LS mode).
Emergency unit power is normally taken from the vessel’s emergency generator.

The main hydraulic control valve block is located in the king machine room. It is a pressure-compensated,
electro-servo-hydraulic operated type controlled by joysticks (servo pilot levers) located on panels mounted on
the operator’s seat inside the crane cabin. The main control valve block distributes oil to each relevant crane
motion as determined by the joystick position. When the joysticks are not operated, oil pressure stops at the
main control valve and the variable pumps de-stroke to zero flow. As soon as one joystick is operated, a stepless
variable oil flow is directed to the relevant crane motion giving the motion the required speed.

The hydraulic system has a separate circulation pump that ensures full filtration and cooling capacity, even
when the crane is operated at creep speeds for extended periods. This is necessary since the main pumps are of
variable displacement type and will de-stroke and circulate oil only as needed by the crane operation. Cooling is
provided by forced-air oil coolers located on a platform at the rear of the crane. This ensures constant filtration
and cooling under all crane operating modes.

The pressure-compensated control valve system enables execution of multiple crane manoeuvres simultaneously
regardless of variations in actual crane loads. Hydraulic oil level, oil temperature, filter status and operation
pressures are all general operating parameters displayed on the LCD control screen in the operator cabin. Any
abnormal values will trigger audio/ visual alarms in the cabin as well as appropriate responses by the control
system.

A more detailed technical description of the hydraulic system is provided in Annex A - "Technical
Description of the Hydraulic System".

3 System Description

12 MACGREGOR NORWAY AS
 User Manual for Crane

4. Electrical System Design

4.1. Electric Slip-Ring Unit
The slip-ring unit transfers power and communication signals to and from the rotating part of the crane. Its
rotating part (top end) is contained in an enclosed unit mounted on a bracket attached to the underside of the
king bottom-plate and extending down inside the pedestal. Its stationary part (bottom end) is also a closed unit,
mounted on a fixed framework attached to the pedestal. Individual rings carry separate power circuits supplying
each main HPU motor, the crane utilities, the control system UPS and aircraft warning lights as well as a
number of signal and communications circuits. A heating element inside the slip-ring unit prevents moisture
build-up during prolonged periods of inactivity.

4.2. Main Electric Motors

Electric power cables (one for each HPU motor) are laid
from the slip-ring assembly (rotating side) to the starter
cabinets inside the king machine room and thence to the
motors mounted beneath the bottom-plate. All electric
motors are fitted with heating elements to prevent
moisture build-up during extended periods of inactivity.

3 System Description
MACGREGOR NORWAY AS 13
 User Manual for Crane

5. Control System Design

The control system is based on an industrial-grade PLC that communicates with other system components on
the winches, in the HPU, king and other parts of the crane. Crane motions are controlled by means of joysticks
mounted on consoles on the operator’s seat in the cabin. Joystick movements send signals to the PLC, which
processes them and sends the appropriate control signals to system components. Safety functions such as MOPS
and emergency stops are hardwired into the electrical circuitry with dual/ parallel contacts.

The PLC is connected to a computer (industrial-grade PC) to provide an intuitive, easily-accessible graphic
HMI (Human Machine Interface) via a 17” high-definition LCD touch screen for control and monitoring of all
crane functions. The operator’s screen is backlit to ensure readability under all conditions. The HMI application
displays alarms, system status and parameters. The touch screen also provides a means for operator feedback
and command input. Load information is displayed in analogue bar graphs, and pay out lengths and sensor
information are displayed in digital form. The PLC and the PC are both located in control cabinet CC-100 in the
rear wall of the cabin.

Full system information is available in real time, and all relevant parameters are logged to provide history for
documentation of normal operation and abnormal events. Redundancy is built into many points in the system
through the use of dual sensors.

The control system receives important information from the following heavy-duty marine-grade field sensors:

 Knuckle (2x) and main jib (2x) position encoders

 Slew position (2 rotational encoders)
 Main winch payout (1 rotational encoder)
 Main winch mechanical hook stop (dual switches)
 Whip winch mechanical hook stop (dual switches)
 Main (1x) and whip winch (1x) wire load sensor (dual signals)
 Hydraulic oil temperature (dual sensors/switches)
 Hydraulic oil level (dual sensors/switches)
 Oil filter DPI sensors
 MRU (Motion Reference Unit)

Remote access: A dedicated router in CC-100 is programmed with predefined IP addresses for remote access to
the control system. A standard router has 16 preset addresses – 10 for use by system components, 3 for DHCP
provision for mobile computers and similar devices and 3 for the router itself. The customer’s network must
have Internet access to IP-address 80.239.94.33 (MacGregor Norway AS).

To be able to connect, the customer’s firewall must have the following ports available:

 UDP 500
 UDP 4500
 ESP
 AHP

3 System Description

14 MACGREGOR NORWAY AS
Name: SP2582-1-L-MB-001, Number: 260675, Version: 0.3, State: RELEASED, Modifier: hollaan

Doc type: PROJECT DOCUMENT

Doc name: SP2582-1-L-MB-001 System Description

Customer Supplier Project number, supplier

Marigest S.r.l. Cargotec Norway AS SP2582-1
Via Santa Brigada 39 Andøyveien 23
80133 NO-4623 Kristiansand Project name, customer
NORWAY NA

P.O. number, customer

NA

Technical Description of the Hydraulic System

Equipment: MacGregor Offshore Knuckle Jib Crane
Type: HMC 3293 LKO 250-30 (700-16) (1000-11) AHC

Revision Description Date Author Checked by

0 Issued for DC 29.07.2014 AHO EVB

This document and all information and data herein or herewith is the confidential and proprietary property of Cargotec Norway AS and is not to be
used, reproduced or disclosed in whole or in part by or to anyone without the written confirmation from Cargotec Norway AS.

© Cargotec Norway AS
www.cargotec.com
Name: SP2582-1-L-MB-001, Number: 260675, Version: 0.3, State: RELEASED, Modifier: hollaan

Doc type: PROJECT DOCUMENT

Doc name: SP2582-1-L-MB-001 System Description

INDEX
SYSTEM DESCRIPTION .......................................................................................................................................... 3
1 HPU (HYDRAULIC POWER UNIT) ................................................................................................................ 3
1.1 RESERVOIR WITH ACCESSORIES ................................................................................................................ 3
1.2 OIL COOLERS .............................................................................................................................................. 4
1.3 FILTRATION UNIT ASSEMBLY....................................................................................................................... 4
1.4 MAIN MOTOR/PUMP ASSEMBLY .................................................................................................................. 4
1.5 MAIN SYSTEM, LOAD SENSE LS CONTROL ................................................................................................. 4
1.6 EMERGENCY MOTOR/PUMP ASSEMBLY ..................................................................................................... 5
1.7 HIGH PRESSURE FILTERS ........................................................................................................................... 5
1.8 MAIN CONTROL VALVE ................................................................................................................................ 5
2 JIB SYSTEM ...................................................................................................................................................... 6
2.1 MAIN JIB ...................................................................................................................................................... 6
2.2 KNUCKLE JIB................................................................................................................................................ 6
3 SLEW SYSTEM ................................................................................................................................................. 7
3.1 SLEW GEARS ............................................................................................................................................... 7
3.2 HYDRAULIC MOTORS................................................................................................................................... 7
3.3 SLEW MOTOR VALVE BLOCKS .................................................................................................................... 7
4 TUGGER WINCHES & TURNTABLES ......................................................................................................... 8
4.1 GEARBOX..................................................................................................................................................... 8
4.2 HYDRAULIC MOTOR ..................................................................................................................................... 8
4.3 W INCH MOTOR VALVE BLOCK ...................................................................................................................... 8
4.4 CONTROL VALVE ......................................................................................................................................... 9
4.5 HYDRAULIC VALVES .................................................................................................................................... 9
4.6 TURN TABLES............................................................................................................................................. 10
4.7 SHUT OFF VALVE ....................................................................................................................................... 10
5 MAIN WINCH SYSTEM.................................................................................................................................. 11
5.1 GEARBOXES .............................................................................................................................................. 11
5.2 HYDRAULIC MOTORS ................................................................................................................................. 11
5.3 W INCH MOTOR VALVE BLOCKS .................................................................................................................. 11
5.4 ACTIVE HEAVE COMPENSATION VALVE BLOCK ......................................................................................... 12
5.5 HYDRAULIC COMPONENTS ........................................................................................................................ 14
5.6 MANUAL OVERLOAD PROTECTION SYSTEM (MOPS) .............................................................................. 15
5.7 AUTOMATIC OVERLOAD PROTECTION SYSTEM (AOPS) ......................................................................... 15
6 WHIP WINCH SYSTEM ................................................................................................................................. 16
6.1 GEARBOX................................................................................................................................................... 16
6.2 HYDRAULIC MOTORS................................................................................................................................. 16
6.3 W INCH MOTOR VALVE BLOCK .................................................................................................................. 16
6.4 HYDRAULIC VALVES .................................................................................................................................. 16
6.5 MANUAL OVERLOAD PROTECTION SYSTEM (MOPS) .............................................................................. 17
6.6 AUTOMATIC OVERLOAD PROTECTION SYSTEM (AOPS) ......................................................................... 18

Page 2 of 18
Name: SP2582-1-L-MB-001, Number: 260675, Version: 0.3, State: RELEASED, Modifier: hollaan

Doc type: PROJECT DOCUMENT

Doc name: SP2582-1-L-MB-001 System Description

System Description

1 HPU (Hydraulic Power Unit)

The HPU on this crane is located inside the rotating Crane King. The main components of the
HPU are described below:

1.1 Reservoir with Accessories

The reservoir or tank is divided into two main chambers. One chamber is where the oil enters
the tank from the filters and the other chamber is where the suction ports for the pumps are
located. This allows the oil to settle before entering the self suction pumps and reduces the
threat of cavitation.

The reservoirs are equipped with the following accessories:

 Suction Valves (Butterfly valves and ball valves)

 Drain Valves
 Visual thermometer
 Electric temperature sensors
 Pressure transmitter for level control
 Visual level gauges
 Temperature/Level switch(low level and low low level)
 Return filters
 Drain filters
 Air Breather Filters
 Hatch for entering the reservoir

The Suction Valves (butterfly valves) are mounted on the tank wall by flanges. There is one for
each suction line and they are used to hydraulically isolate the pumps for maintenance. The
suction valve for the Filtration Unit is located underneath the tank along with two small ball
valves which are used to drain the hydraulic oil from the tank.

On the tank wall in the King there is a visual level gauge and a thermometer. In addition, there
is a pressure transmitter for continuous monitoring of the oil level. The electrical signal from the
transmitter is connected to the control system where the signal is converted in the PLC. The
level is indicated on the operators screen by means of a bar graph.

There is a temperature/level switch located on top of the tank. The level indication is achieved
by means of two floating elements sliding on a rod inside the tank. The highest floating switch
indicates the Low level and will give an alarm on the operators screen if this level is reached.
The lowest floating switch indicates the Low Low level, which if activated will automatically shut
down the pumps as well as sending an alarm to the operators screen. The biggest variations in
oil level changes are when the crane’s jib is operated. The switch also includes two temperature
sensors which are used to indicate High oil temperature and High High oil temperature. In both
cases an alarm will be given on the operator screen if activated.

The electric temperature sensor that is mounted on the tank wall is also connected to the
control system and the signal is used to show the continuous oil temperature on the operator
screen in the crane cabin.

On the top of the reservoir are two return oil filters, equipped with an electrical clogging indicator
which sends an alarm to the operator’s screen via the control system if the pressure drop over

Page 3 of 18
Name: SP2582-1-L-MB-001, Number: 260675, Version: 0.3, State: RELEASED, Modifier: hollaan

Doc type: PROJECT DOCUMENT

Doc name: SP2582-1-L-MB-001 System Description

the filter element becomes too high. The well-dimensioned return filters ensure good quality oil.

There are three drain line filters also situated on the top of the tank. One of these filters is for
the drain lines from the main and whip winch motors, one for the Main Pumps drain lines and
the other from the Slew and Tugger Winch motors. One common drain manifold gathers all
other drain oil from the system and returns this back to the tank.

Air Breather Filters are installed on top of the tank to stop the build up of gases and fumes as
well as insuring that atmospheric pressure is kept in the tank regardless of oil volume variations.
The breathers also have a filter to ensure contaminated air does not enter the tank.

The reservoir can be accessed for inspection or maintenance by means of a hatch on top of the
tank.

1.2 Oil Coolers

The oil coolers (4 off) are located on the platform outside of the rotating crane king beneath the
winch. They consist of a cooling element, a fan and an electric motor. The coolers are
hydraulically connected by means of flexible hoses. The coolers have a check valve to ensure a
certain oil flow (pressure drop). They can easily be opened for inspection and cleaning.

1.3 Filtration Unit Assembly

A filtration unit is mounted in the pedestal attached to the crane king bottom plate. It consists of
an electric motor, a fixed displacement pump and a filtration package. The unit has a special
filter element for absorbing water and removing particles in the oil. Both visual and electrical
clogging indicators are included to monitor the overall condition of the filter.

1.4 Main Motor/Pump assembly

The three main motor/pump assemblies (3 single pumps) are mounted vertically inside the King.
The electric motor and the adapter flange are bolted upright underneath a thick plate at the
bottom of the king. The pump is mounted on top of the adapter flange, which has a flexible
rubber flange. Between the shafts on the motor and the pump there is a flexible coupling which
reduces torsion vibrations, as well as compensating for axial, radial and any angular shaft
misalignments.

The hydraulic pumps are axial piston pumps with a variable swash plate design for adjusting the
displacement/delivery volume from the pumps. The pumps deliver a flow proportional to the
swash plate angle and are designed for use in open loop circuits. Each pump is equipped with a
pressure compensated load sense (LS) regulator. A common LS system controlled by the PLC,
adjusts the compensating pressure depending on the maximum load/pressure reading in the
system. Maximum operating pressure for this main pump system is 330 bar.

The electric motors, all equipped with heating element and thermistor, operate at a constant
speed.

1.5 Main system, Load Sense LS control

To control the main pumps an electric operated proportional control valve is used. This valve is
tuned in the control system so that when the joystick is moved out of centre the pumps will
automatically increase from an idle pressure of approximately 40 bars to a pressure level of
approx 150 bars.

When a crane function is used the LS pressure is read by two pressure transmitters mounted in
parallel. The control system will then automatically set the required pump pressure by regulating

Page 4 of 18
Name: SP2582-1-L-MB-001, Number: 260675, Version: 0.3, State: RELEASED, Modifier: hollaan

Doc type: PROJECT DOCUMENT

Doc name: SP2582-1-L-MB-001 System Description

the electric operated proportional control valve to a calculated pressure.

1.6 Emergency Motor/Pump Assembly

The emergency motor/pump assembly is mounted vertically inside the crane king. It consists of
a variable displacement axial piston pump, an electric motor (equipped with heating element
and thermistor), an adapter flange and a flexible coupling. The hydraulic pump is isolated from
the main system by manually operated shut off valves.

1.7 High Pressure Filters

The high pressure filters are mounted on the front wall of the tank inside the rotating crane king.
All main pump outlets are connected to a high pressure filter. Each filter has a by-pass valve
and both a visual and electric clogging indicator. An alarm signal is given on the operator screen
if any clogging indicator is activated. Pressure relief valves are located on every pump outlet to
limit the pressure in the system.

1.8 Main Control Valve

The main control valve located in the rotating crane king consists of several standard modules
that are bolted together. The modules are as follows:

 One inlet section

 One module for the Main Winch.
 One module for the Main Jib up/down function.
 One module for the Knuckle Jib out/in function
 One module for the Slew clock-wise/counter clockwise function.
 One module for the Whip Winch
 End cover with inlet connection plate

The inlet section houses two different pressure control valves of cartridge type, which are
inserted into cavities. The largest one is a direct operated pressure relief valve. The upstream
side of this valve is connected to the common oil supply line and the downstream side is
connected to the common return line. This limits the pressure in the system if an unintentional
pressure built up should occur.

The smallest valve in the inlet section is a direct operated pressure reducing valve. The
upstream side of the valve is connected to the common oil supply line. The valve reduces the
pressure down to 45bar (as long as the oil supply pressure is above 45 bar) and is used to feed
oil to the pilot valves via the external port “PP”.

Each working module contains the same type of main components.

The main spool inside each working module directs the oil from the oil supply line to the actual
working port and from the actual working port to the return line. The position of the spool is
controlled by hydraulic pressure acting on the cross sectional area at the end of the spool. The
opposite side of the spool is then connected to drain. The spool is spring centred, which means
that when the pressures on both sides of the spool are zero, the spool is centred by means of
two springs, one at each end of the spool. In this position the oil supply port is closed.

Two pilot valves are used to control the position of the main spools in the main control valve.
The pilot valve is a proportional electric operated pressure-reducing valve. All pilot valves for the
crane functions such as slew, main jib, knuckle jib and winch are controlled via the control

Page 5 of 18
Name: SP2582-1-L-MB-001, Number: 260675, Version: 0.3, State: RELEASED, Modifier: hollaan

Doc type: PROJECT DOCUMENT

Doc name: SP2582-1-L-MB-001 System Description

system, connected to the joystick located on the operator chair in the crane cabin. When one of
the joysticks is taken out of neutral position a pilot pressure is applied to one side of the spool
and the other side is connected to drain by means of the actual pilot valve.

Each working module has a pressure compensator mounted in the oil supply line upstream of
the main spool. The purpose of this valve is to always keep a constant pressure drop across the
main spool ensuring that the oil flow to an individual function is independent of the load
pressure of this function.

Pilot pressure relief valves limit the pressure in the two outlet ports, A and B by closing the
compensator. The pressure setting is set individually for the A and B ports on each module.

2 Jib System
The Jib System is used to handle the load hanging from the hook from minimum to maximum
working radius and mainly consists of two main jib hydraulic cylinders and two knuckle jib
hydraulic cylinders.

2.1 Main Jib

The Jib is connected to the rotating crane king structure by two main bearings at the top of the
crane king and to the rod bearing of the two hydraulic cylinders at the lower end of the Jib
structure. The two hydraulic Main Jib cylinders are equipped with spherical bearings at both
ends and are built especially for use in a marine environment, with chrome nickel (Cr/Ni) plated
piston rods in order to obtain good protection against corrosion.

A valve block including a load control valve (over centre valve/counter balance valve) is flanged
to the hydraulic connection on the piston side of the cylinder. Since the cylinders are always
exposed to external forces in one direction (compression forces), there are only load control
valves on the piston side of the cylinders which have the following functions:

 Locking of the flow from the piston side of the cylinders in case of a hose or pipe rupture
or if the pumps are stopped during operation.

 Cavitation free load lowering controlled by the lowering pressure i.e. the rod pressure
supplied via the main spool in the main control valve. This prevents the cylinders from
accelerating downwards.

 Free flow through the check valve function for lifting of the load.

The two cylinder rod sides are also connected together inside the crane king and have a
pressure relief valve to limit the pressure on the rod side of the cylinders. The downstream side
(return line) of the valve is connected to a common return line that is routed to the oil reservoir.

2.2 Knuckle Jib

The two hydraulic knuckle jib cylinders are equipped with spherical bearings at both ends which
support them to the outer end of the main jib and the lower end of the knuckle jib structure. The
cylinders are built especially for use in marine environment with chrome nickel (Cr/Ni) plated
piston rods in order to obtain good protection against corrosion.

Page 6 of 18
Name: SP2582-1-L-MB-001, Number: 260675, Version: 0.3, State: RELEASED, Modifier: hollaan

Doc type: PROJECT DOCUMENT

Doc name: SP2582-1-L-MB-001 System Description

The knuckle jib cylinders are exposed to external forces in both directions (compression and
tension forces), so it is necessary to have a load control valve (over centre valve/counter
balance valve) flanged to the hydraulic connection at both ends of the cylinders. The load
control valves on the knuckle jib cylinders have the same functions as for the main jib cylinders.

Additionally, the rod side of the cylinder also contains a pressure relief valve which limits the
pressure on the rod side of the cylinder. The downstream side (return) of the valve is connected
to a common return line that is routed to the oil reservoir.

3 Slew System
The slew system consists mainly of slew gears, hydraulic motors and hydraulic valves.

3.1 Slew Gears

Between the rotating crane king and the top of the foundation sits a slew bearing equipped with
an internal gear ring. The slew torque is transferred to the gear ring from the output pinions of
the gearboxes which are located inside the rotating crane king and mounted with the pinion at
the lower end of the gearbox. The five slew gears are hydraulically driven with a built in fail-safe
dynamic multidisc brake, which are disengaged by means of a hydraulic pressure taken from
the common A- or B lines of the hydraulic motors. In the case of a hose or pipe rupture the
brake locks the slew function immediately. The brakes are dimensioned to take the full load plus
any additional dynamic force acting on the slew gears.

3.2 Hydraulic Motors

Each of the five slew gears is equipped with a fixed displacement hydraulic motor with axial
piston rotary group of bent axis design. All motors are controlled by means of a working section
in the main control valve.

3.3 Slew Motor Valve Blocks

Each hydraulic motor on the slew has a valve block flanged to the A and B ports. The valve
block consists of two load control valves which close the return or downstream flow when the
spool in the main control valve is in neutral position or when the pumps are stopped during
operation. The valves also ensure cavitation free movement when the crane is slewing
“downwards”.

The motor valve block also contains shock valves from A to B and B to A. When the crane is in
a parked position the motors are hydraulically short circuited and it is only the static brake that is
preventing the crane from slewing. The static brake capacity is calculated by multiplying the
maximum dynamic torque by 1.3.

Page 7 of 18
Name: SP2582-1-L-MB-001, Number: 260675, Version: 0.3, State: RELEASED, Modifier: hollaan

Doc type: PROJECT DOCUMENT

Doc name: SP2582-1-L-MB-001 System Description

4 Tugger Winches & Turntables

The two tugger winches (one left and one right side version) are each designed to guide loads
on the main and whip winch wire. They contain a steel drum with a flanged on gearbox located
on one side of the drum. The Tugger winches are located near the lowest end of each of the
two main jib cylinders and they are mounted on turn tables.

The main components on each tugger winch are listed below.

4.1 Gearbox
The gearbox is horizontally mounted on one of the side plates and the torque is transferred via
a rotating flange on the gearbox. The gearbox is equipped with a fail-safe multi-disc brake which
has to be released hydraulically in order to move the winch wire in or out. A fail-safe brake
means that the brake is engaged if no hydraulic pressure is applied, meaning that the brakes
will lock immediately if a hose or pipe should rupture. The brakes are dimensioned to take the
full load acting on the winch.

4.2 Hydraulic motor

Since the gearbox is hydraulically driven a hydraulic motor is located on the gearbox. The motor
has fixed displacement with axial piston rotary group of bent axis design. The output speed is
proportional to the input flow and the motor is equipped with main ports at the rear end.

4.3 Winch motor valve block

Each hydraulic motor on the Tugger winch is equipped with a valve block, which is flanged to
the main A- and B port on the motor. The valve block mainly consists of a pilot operated
pressure relief valve, a load control valve and a 2/2 way directional valve. The valves are of
cartridge valve types and they are inserted into cavities in the valve block.

The pilot operated pressure relief valve is mounted between the “Winch Up” port on the motor
and the load control valve. The upstream side (P) of the valve is connected to the “Winch In”
line and the downstream side is connected to the “Winch Out” line. The pressure setting of the
valve is done in two ways i.e. either via the external pilot port MX or by the setting of the
adjustment screw on top of the cartridge valve. The valve is mainly opened when the winch is
operated in the Constant Tension (CT) mode. In order to pay out wire in this mode, the valve
opens and oil flows through the valve. The pressure setting of the valve is then determined via
the pilot port, MX. If the winch is operated in Normal mode the MX-port is closed. In this case
the valve acts as an ordinary pressure relief valve i.e. it limits the pressure drop or maximum
output torque across the motor. If an increase of the load should occur and the brakes are
disengaged, the oil will flow through the valve if the pre-set pressure adjustment is reached. As
a result of this the load will be lowered.

The load control valve is mounted between the “Winch In” port on the motor and the B-port on
the working section in the main control valve. The functions of this valve are as follows:

 Locking of the downstream flow or return flow if the pumps on the HPU are stopped.

 Cavitation free load outwards movement controlled by means of the pilot pressure that is
supplied in the “Winch Out” line via the spools in the main control valve. This prevents
the load from accelerating outwards.

 Free upstream flow for load retraction through the built-in check valve.

Page 8 of 18
Name: SP2582-1-L-MB-001, Number: 260675, Version: 0.3, State: RELEASED, Modifier: hollaan

Doc type: PROJECT DOCUMENT

Doc name: SP2582-1-L-MB-001 System Description

Close to the MX-port on the motor valve block there is a hydraulic pilot operated 2/2 way valve.
The valve is normally closed i.e. when there is no pilot pressure available in the pilot port Pil2,
the valve is closed and the pilot operated pressure relief valve in the motor valve block is sat to
its maximum. The valve is activated and opened when the winch is operated in the Constant
Tension (CT) mode.

4.4 Control Valve

The control valve is located close to the starter cabinet inside the rotating crane king and is
common for both of the tugger winches and the turn tables. It consists of an inlet section, four
working sections (one for each tugger winch and one for each turn table), a mid section and one
end section.

The inlet section consists mainly of a pressure relief valve between the oil supply (“P”) and the
tank line (“T”) and a pressure-reducing valve. The inlet section is also equipped with an external
“M” port that is connected to the main oil supply port (“P”).

The two working sections for the tugger winches contain a pressure compensator that keeps a
constant pressure drop across the spool. Keeping the pressure drop across the spool constant
means that the flow through the valve is proportional to the spool position i.e. it is independent
of the load and supply pressure. The proportional electro hydraulic control module at the end of
each spool shifts position of the spool precisely in proportion to an electric signal generated by
the actual joystick located in the crane cabin. The spool is shifted by means of the hydraulic
pressure generated by the pressure-reduction proportional solenoid valves.

The mid section contains a pressure reducing valve located in the pilot supply line for the
electro hydraulic control modules. Downstream the pressure-reducing valve there is also an
external pilot oil supply port “PP”.

The two working sections for the turn tables contain a pressure compensator that keeps a
constant pressure drop across the spool. The on/off electro hydraulic control module at the end
of each spool, shifts the position of the spool. The valves are controlled from the operator
terminal in the crane cabin.

Each working port A and B is equipped with a pressure-limiting valve that limits the maximum
working pressure. In case of a power failure in the electro hydraulic control module the valve
can be operated mechanically by means of a lever located at the opposite side of the electro
hydraulic control module.

4.5 Hydraulic Valves

In addition to what is mentioned above, the Tugger winch system contains the following
hydraulic valves:

 A 3/2 way electric operated directional valve.

 A pressure reducing valve.
 A proportional pressure relief valve.

The 3/2 way electric operated directional valve located near the main control valve, is a pilot
valve related to the CT function. The “B” port is connected via a flexible hose to the outlet port
on the pressure reducing valve mentioned above. The oil supply to the pressure reducing valve

Page 9 of 18
Name: SP2582-1-L-MB-001, Number: 260675, Version: 0.3, State: RELEASED, Modifier: hollaan

Doc type: PROJECT DOCUMENT

Doc name: SP2582-1-L-MB-001 System Description

is taken from the “M” port on the main control valve.

The “A” port on the 3/2 way electric operated directional valve is connected to a separate drain
line and the “P” port is routed to the pilot port, Pil2, for the 2/2 way valve located in the motor
valve block. The same line is also via a T-connection and a shuttle valve routed to the brake on
the tugger winch. When the 3/2 way valve is deactivated there is no pilot pressure available in
the “P” port. If the CT mode is selected the valve is activated and the pilot pressure available in
the “P” port switches the 2/2 way valve in the motor valve block and disengages the brakes on
the tugger winch. When the 2/2 way valve is opened the pilot pressure in the MX-port in the
motor valve block is via hoses, guided to the proportional pressure relief valve located near the
main control valve. This valve is electric operated and it is connected to the control system. The
setting of the valve determines the actual tension force in the wire. The valve setting is entered
by the crane operator on the operator terminal. Higher tension setting value means lower output
to the proportional pressure relief valve.

4.6 Turn tables

The main hydraulic components in each Turn table system are listed below.

 hydraulic cylinder.
 load control valve.

The hydraulic double acting cylinder has spherical bearings at both ends and is built especially
for use in marine environment. It has a dual load control valve (over centre valve/counter
balance valve) connected to the two cylinder ports. The reason for using a dual load control
valve is that the turn table cylinder is exposed for external forces in both directions (both press
and tension forces). The dual load control valve has the following main function:

 Locking of the flow from the piston or rod side of the cylinder in case of a hose or pipe
rupture or if the pumps are stopped during operation.

 Free flow through the check valve function when moving the cylinder.

4.7 Shut off valve

Upstream from the oil supply port on the main control valve there is a 2/2 way directional valve
of cartridge valve design. The valve consists of a manifold a main stage including a cone, a
bushing and a valve cover. On top of the valve cover there is a 4/2 way electric operated pilot
valve. The valve is used to hydraulically isolate the tugger winches from the rest of the system
when they are not in use. Opening and closing of the valve is done from the operator terminal in
crane cabin.

Page 10 of 18
Name: SP2582-1-L-MB-001, Number: 260675, Version: 0.3, State: RELEASED, Modifier: hollaan

Doc type: PROJECT DOCUMENT

Doc name: SP2582-1-L-MB-001 System Description

5 Main Winch System

The crane is equipped with an Active Heave Compensated (AHC) Main Winch that is mounted
to the upper/aft part of the rotating crane structure. It contains a steel drum with a flanged-on
gear-ring with a side plate located on the side of the drum. The drum is via a rotating shaft and
roller bearing connected to the side plate. The main hydraulic components on the main winch
are listed below.

5.1 Gearboxes
There are 7 off gear boxes are mounted horizontally on the side plate and the torque is
transferred from the gear box to the gear-ring via a pinion. Each gear box is equipped with a
fail-safe multi-disc brake and a sprag clutch. The brakes are disengaged by means of hydraulic
pressure taken from the common “Winch Down” lines connected to the hydraulic motors. Fail-
safe brakes means that the brakes are engaged if no hydraulic pressure is applied, a result of
this is that the brakes will lock immediately if a hose or pipe rupture should occur while lowering
the winch. The brakes are dimensioned to take the full load plus any additional dynamic forces
acting on the winch. Since the gear box houses a sprag clutch there is no need to apply a
hydraulic pressure to the brakes when the winch is used for hoisting.

5.2 Hydraulic motors

Since the gear boxes are hydraulically driven, a hydraulic motor is located on each gear box.
The motor is a variable displacement motor with axial piston rotary group of bent axis design. All
motors are hydraulically connected together and they are controlled by means of a working
section in the main control valve (see chapter 1). One motor contains a speed sensor to monitor
the motor speed and this is fed back to the PLC to compare data received from the winch
encoder. The control device on each motor is a combination of external pilot pressure control
and an internal constant pressure control. The external pilot pressure control allows an infinite
variation of the motor displacement in relation to a pilot pressure signal applied to the X-port on
the motor. All individual X-ports are connected together into one common pilot line routed to the
AHC valve block. On this block there is a common pressure reducing valve that is used to
control the motor displacement pressure. The pressure in the X-ports varies from 0 to approx 45
bar.

5.3 Winch motor valve blocks

Each hydraulic motor on the winch is equipped with a valve block, which is flanged to the main
A and B port on the motor. Six of these valve blocks consist of the same set of valves, including
a pilot operated pressure relief valve, a load control valve and a 2/2 way directional valve, all of
cartridge type inserted into cavities in the valve block, as well as a hydraulic pilot operated 2/2
way valve. The other motor valve block that differs from the others, has in addition to the valves
described above, built-in valves for the emergency lowering function and the MOPS function.

The pilot operated relief valve is mounted between the “Winch Up” and the “Winch Down” main
drilling. The upstream side (P) of the valve is connected to the “Winch Up” line and the
downstream side is connected to the “Winch Down” line. The pressure setting of the valve is
done in two ways i.e. either via the external pilot port MX or by the setting of the adjustment
screw on top of the cartridge valve. When the crane is operated in Normal or AHC mode, the
hydraulic pilot operated 2/2 way valve is closed. In this state the pilot operated relief valve acts
as a normal relief valve, which is, limiting the pressure drop or maximum torque across the
motor. If an increase in load should occur and the brakes are disengaged, the oil will flow
through the valve when the preset pressure is reached. As a result of this, the load will be
lowered. When the Manual Overload Protection System (MOPS) is activated the pressure
setting of the pilot operated relief valve is determined via the MX port, when the 2/2 way valve is

Page 11 of 18
Name: SP2582-1-L-MB-001, Number: 260675, Version: 0.3, State: RELEASED, Modifier: hollaan

Doc type: PROJECT DOCUMENT

Doc name: SP2582-1-L-MB-001 System Description

opened. (For a more detailed description of the MOPS function, please see section 5.6)

The load control valve is mounted between the “Winch Up” port on the motor and the A-port on
the working section in the main control valve. The functions of this valve are as follows:

 Locking of the downstream flow or return flow if the pumps on the HPU are stopped.

 Cavitation free load lowering controlled by means of the pilot pressure that is supplied in
the “Winch Down” line via the spools in the main control valve. This prevents the load
from accelerating downwards.

 Free upstream flow for load hoisting through the built-in check valve.

 Locking of the downstream flow or return flow when AHC mode or Auto Tension (AT)
mode is activated.

 Locking of the downstream flow or return flow when MOPS is activated.

A 2/2-way directional valve of cartridge type is mounted close to a branching point inside the
valve block (between the “Winch Up” port on the motor and the load control valve.) The 2/2-way
directional valve is hydraulic pilot operated and used to open and close the connection between
the “Winch Up” port on the motor and the external “A” port. When the main winch is operated in
the AHC/AT mode, the 2/2-way directional valve is opened. The “A” port is connected to the
AHC valve block via a flexible hose to a common pilot valve, located on the AHC valve block
which opens all of the 2/2-way valves when AHC or AT is activated. The 2/2-way valves are of
so called fail-safe closed type, which means that when there is no pressure in the pilot port the
valve is closed.

In order to achieve a more or less equal load on each hydraulic motor the “Winch Up” ports on
the motors are connected together via port “PE” (Pressure Equalising) located on each winch
valve block.

5.4 Active Heave Compensation valve block

An Active Heave Compensation (AHC) valve block is part of the main winch system and it is
located on top of the rotating crane king. The parts integrated in this type of valve block relate to
the AHC/AT function, CT function, the emergency lowering function and the emergency release
function. The main parts in the valve block are listed below.

Two 4/3 way electric operated directional valves.

Four 2/2 way hydraulic operated directional valves.
Four electric operated pilot valves.
Three pressure reducing valves.
A proportional pressure reducing valve.
Two needle valves
Two pressure transmitters.

The 4/3 way electric operated directional valves have proportional control and are of spool valve
design. They consist of a pilot stage and a main stage and are bolted on top of the AHC valve

Page 12 of 18
Name: SP2582-1-L-MB-001, Number: 260675, Version: 0.3, State: RELEASED, Modifier: hollaan

Doc type: PROJECT DOCUMENT

Doc name: SP2582-1-L-MB-001 System Description

block, the mounting pattern is NG32 according to the ISO 4401 standard. An integrated position
transducer measures the main stage spool position and the built-in valve amplifier and the pilot
valve control the position of the main spool in a closed loop circuit. For this reason the valve has
extremely low hysteresis and the response time is very short. These are very important features
since it is this valve that is used to control the position of the hook when the AHC/AT system is
activated.

The four 2/2 way hydraulic operated directional valves are of cartridge valve type and they
consist of a main stage including a valve cone, a bushing and a valve cover. On top of the cover
there is a hydraulic operated pilot valve.

The first of these valves is located in the oil supply line upstream the “P” ports on the 4/3 way
proportional valves mentioned above. The valve is used to isolate the AHC/AT system
hydraulically from the rest of the system when the crane is operated in Normal mode. The valve
is fail-safe closed, which means that when there is no hydraulic pilot pressure available the main
cone is closed.

The second 2/2 way valve is mounted in the line that connects the accumulator unit to the main
supply line upstream of the isolation valve mentioned above. The accumulator unit consists of
several equal bladder accumulators (50 litres each) connected together by means of a manifold.
The stored energy in the accumulator unit is used when the main winch is operated in AHC/AT
mode.

The third 2/2 way valve is mounted in the same line that is routed from the winch valve block to
the B port on working section for the main winch on the main control valve inside the rotating
crane king. It is used to close the connection between the “Lowering/Low pressure” ports on the
hydraulic motors and the working section in the main control valve when the main winch is
operated in the AHC/ AT mode or Emergency release mode. In these modes the valve prevents
oil to flow to the reservoir via the spool in the main control valve (The A- and B ports are
connected to the T port when the spool is in neutral position). The valve is normally open i.e.
when there is no pilot pressure available, the main cone is open.

The fourth 2/2 way valve is mounted in the B-line close to the B-port on the 4/3 way proportional
valve mentioned above. The valve is used to close the connection between the “Lowering/Low
pressure” ports on the hydraulic motors and the main spool in the 4/3 way proportional valve
when the main winch is operated in Normal mode and Emergency release (MOPS) mode. The
valve is normally closed that means that when the pilot pressure is zero the main cone is
closed.

The four electric operated pilot valves are of on/off type. Three are 4/2 way spool valves with
NG6 mounting pattern and one is a 3/2 way poppet valve.

The first 4/2 way spool valve is connected to internal pilot channels in the hydraulic operated
pilot valves on top of the covers on the four 2/2 way directional valves mentioned above. The
pilot valve is activated when the main winch is operated in the AHC/AT mode. In normal mode
(hoisting and lowering) the pilot valve is deactivated.

The second 4/2 way pilot valve is connected to the brakes on each gear box via flexible hoses.
When no current is applied to the solenoid there is no pilot pressure in the port that is routed to
the brakes. The valve is only activated when the main winch is operated in

Page 13 of 18
Name: SP2582-1-L-MB-001, Number: 260675, Version: 0.3, State: RELEASED, Modifier: hollaan

Doc type: PROJECT DOCUMENT

Doc name: SP2582-1-L-MB-001 System Description

AHC/AT mode.

The third 4/2 way pilot valve is connected to pilot valves for the 2/2 way valve located in each
motor valve blocks. The valve is activated in AHC – and AT mode and it opens the connection
between the “Hoisting/High pressure” ports on the motors and two 4/3 way electric operated
directional valves mentioned above. The pilot oil supply for the 4/2 way valves is taken from the
main supply line “P1”. The “P1” port is via hard piping routed to the main pumps in the crane
king.

The fourth electric operated pilot valve is a 3/2 way valve of poppet valve design. The pressure
port (“P”) on this valve is connected to the bladder accumulator unit and the outlet port “A” is
connected to the “Lowering/Low pressure” ports on the hydraulic motors via two check valves, a
pressure reducing and a needle valve. In addition, the outlet port is via internal channels and
shuttle valves connected to the hydraulic operated pilot valves on the 2/2 way valve located in
the line between the “B” port on the working section in the main control valve in the crane king
and the “Lowering/Low pressure” ports on the hydraulic motors. The electric operated pilot valve
is only activated when the Emergency release function (MOPS) is activated.

Between the 2/2 way directional valve in the main oil supply line and the “P” port on the 4/3 way
electric operated directional valves, there is a pressure-reducing valve. The valve reduces the
pressure in main supply line to a sufficient supply pressure for the pilot valve located on top of
the 4/3 way directional valve (servo valve).

The second pressure reducing valve is located in the oil supply line to a proportional pressure-
reducing valve. The proportional pressure-reducing valve is electric operated and it is used to
adjust the displacement of the hydraulic motors on the main winch. The valve is common for all
of the main winch motors.

The AHC valve block is fitted with two pressure transmitters, one of which is used to monitor the
pressure in the bladder accumulators unit. If the accumulator pressure becomes too low in the
AHC/AT mode, an alarm is activated on the operator’s panel in the crane cabin.

The other pressure transmitter is used to monitor the 4/3 way directional valve (servo valve)
load pressure in relation to the Main Winch ship-to-ship CT function.

The pressure relief valve is a direct operated valve that is located between the accumulator unit
and the 2/2 way valve between the main supply line and the accumulator unit. The valve
protects the accumulators against a pressure build up. The needle valve located close to the
pressure relief valve is used to drain the oil in the accumulators prior to maintenance.

5.5 Hydraulic Components

In addition to what is mentioned above, the Main Winch system also consists of the following
hydraulic components:

• A main control valve (see chapter 1.8)

• A sequence valve
• Two pressure reducing valves
• Two pressure transmitters

Page 14 of 18
Name: SP2582-1-L-MB-001, Number: 260675, Version: 0.3, State: RELEASED, Modifier: hollaan

Doc type: PROJECT DOCUMENT

Doc name: SP2582-1-L-MB-001 System Description

The main control valve is located above the Internal Tank inside the rotating crane king. For a
detailed description see Chapter 1.8.

The sequence valve ensures that 30 bar is present before the brakes are released.

One of the pressure reducing valve supplies a flow to each hydraulic winch motor to keep the
motors topped up with hydraulic oil. The other pressure reducing valve is mounted in the brake
lines to protect the brakes from high pressure surges.

One of the pressure transmitters is mounted in the control line for adjusting the motor
displacement (X-port) and is connected to the control system. The purpose of the transmitter is
to verify that the actual control pressure corresponds to the pressure calculated in the PLC. The
other pressure transmitter is mounted in the brake lines to monitor the brake pressure.

5.6 Manual Overload Protection System (MOPS)

The Main winch is fitted with MOPS. The purpose of this system is to reduce the risk of any
structural damage to the crane by giving the operator the possibility to release the winch brakes
and pay out wire if required. The system also works if a power failure should occur onboard the
vessel and it is for this reason that a UPS (re-chargeable battery package) is installed to provide
emergency power. By pushing a red button located on the left hand side of the operator’s chair,
this activates the system which includes the following main hydraulic components:

 Accumulators.
 3/2 way electrical operated pilot valve.
 A pressure relief valve.

Since the emergency release system works even if a power loss should occur the hydraulic
energy is taken from the 20 bladder accumulators mounted on the accumulator skid below the
Main Winch. The nominal volume of each accumulator is 50 litres and they are connected to the
“ACC1” and “ACC2” ports on the AHC valve block via flexible hoses.

The 3/2 way electric operated pilot valve is located on the AHC valve block and it is of poppet
valve design. In addition to change the configuration of some of the valves, it also ensures
sufficient oil flow to disengage the brakes on the main winch and to avoid cavitation on the
winch motors when the load is lowered.

The pressure relief valve is a direct operated pilot valve that is located inside the rotating crane
king. It is connected to the”MX” pilot port on each motor valve block which is the control port for
the pilot operated pressure relief valve in the motor valve block.

5.7 Automatic Overload Protection System (AOPS)

The AOPS is activated when a load is registered by the load cell exceeds a certain value
predefined according to AOPS load chart in the control system and the crane hook is outside a
defined sector of the shipside. The Winch Down electrically operated proportional valve is
energized in the main control valve (100% activation) which lowers the load at maximum speed
and stops when the load is below the rated platform lift capacity.

Page 15 of 18
Name: SP2582-1-L-MB-001, Number: 260675, Version: 0.3, State: RELEASED, Modifier: hollaan

Doc type: PROJECT DOCUMENT

Doc name: SP2582-1-L-MB-001 System Description

6 Whip Winch System

The crane is equipped with a Whip Winch (10T SWL) that is mounted on top of the Jib close to
the crane king. It contains a steel drum with two side plates and two gear-boxes. The main
components of the Winch are listed below.

6.1 Gearbox
There are two horizontally mounted gear boxes, one each side of the winch drum, equipped
with a fail-safe multi-disc brake and a sprag clutch. A fail-safe brake means that if no hydraulic
pressure is applied the brake is engaged, a result of this is the brakes will lock immediately if a
hose or pipe rupture should occur. The brake is dimensioned to take the full load plus any
additional dynamic forces acting on the winch and one brake is dimensioned to take full load
during personnel lift. Torque is transferred via a rotating flange on the gearbox

6.2 Hydraulic Motors

The gear boxes are hydraulically driven by fixed displacement hydraulic motors controlled by
means of a working section in the main control valve inside the crane king.

6.3 Winch Motor Valve Block

The hydraulic motors on the winch are equipped with valve blocks, flanged directly to the main
A and B ports on the motor. The valve block contains a pilot operated pressure relief valve and
a load control valve as well as cartridge valves which relate to Emergency Lowering. These
cartridge valves are inserted into cavities in the valve block.

The function of the pilot operated pressure relief valve is to limit the pressure drop or maximum
output torque across the hydraulic motor.

The load control valve is mounted between the “Winch UP” port on the motor and the A-port on
the working section in the main control valve. The functions of this valve are:

 Locking of the downstream flow or return flow if the pumps are stopped.

 Cavitation free load lowering controlled by means of the pilot pressure that is supplied in
the “Winch Down” line via the spools in the main control valve. This prevents the load
from accelerating downwards.

 Free upstream flow for load hoisting through the built-in check valve.

6.4 Hydraulic Valves

In addition to what is mentioned previously, the Winch system consists of the following main
hydraulic components:

 A main control valve (see chapter 1.8)

 Two 3/2 way electric operated directional valves
 A proportional pressure relief valve
 A fixed setting relief valve
 Two 4/2 way electric operated directional valves

Page 16 of 18
Name: SP2582-1-L-MB-001, Number: 260675, Version: 0.3, State: RELEASED, Modifier: hollaan

Doc type: PROJECT DOCUMENT

Doc name: SP2582-1-L-MB-001 System Description

 One pressure reducing valve

 Sequence valve

One of the 3/2 way electrically operated valves is used to enable Constant Tension (CT). When
the operator selects CT on the screen, this valve is energized and in turn opens a 2/2 valve in
the motor valve block. This enables the pilot pressure setting of the pilot operated pressure
relief valve in the motor block to be controlled by the proportional pressure relief valve in the
king via the MX port. This pressure is proportional to the tension in the wire set by the operator.

The other 3/2 way valve electrically operated valve is used when MOPS is selected. The valve
is energized and enables the pilot pressure setting of the pilot operated pressure relief valve in
the motor block to be controlled by the fixed setting relief valve in the king via the MX port. (For
a more detailed description of MOPS please see section 6.5)

The two 4/2 way electrically operated hydraulic pilot valves are housed in a cabinet along with
the sequence valve. The two 4/2 way valves separate the braking circuit when Personnel lift is
selected by the operator. One brake is dimensioned to take the full load when handling
personnel. The sequence valve ensures that 30 bar is present before the brakes are released.

6.5 Manual Overload Protection System (MOPS)

The whip winch is fitted with MOPS. The purpose of this system, like the one on the main winch
is to reduce the risk of any structural damage to the crane by giving the operator the possibility
to release the winch brakes and pay out wire if required. The system also works if a power
failure should occur onboard the vessel and it is for this reason that a UPS (re-chargeable
battery) is installed to provide emergency power. The system is activated by pushing the MOPS
button located near the operator’s chair. The system includes the following main components:

 2 Accumulators
 The MOPS/Emergency Pay Out Block
 Proportional Pressure Relief Valve

Since MOPS works even if a power loss should occur, the hydraulic energy is taken from two
bladder accumulators mounted close to the MOPS /Emergency Pay Out Block. The nominal
volume of each accumulator is 50 litres and they are connected to the ACC1, ACC2 ports on
the block.

The MOPS/Emergency Pay Out Block contains different valves which are connected by internal
drillings in the block. The main components included in the valve block are listed below:

 A 3/2 way electrically operated pilot valve

 A 2/2 way hydraulic operated directional valve
 One 3/2 way hydraulic operated pilot valve
 One 4/2 way hydraulic operated pilot valve
 Two pressure reducing valves
 Four check valves
 Shuttle valve

The 3/2 way electrically operated pilot valve is a directional poppet valve. The “P” port is
connected to the bladder accumulators mentioned above and the “T” port is routed to the
external drain port “CTD”. The “A” port is connected to the pilot valve on the 2/2 way pilot
operated directional valve and also the 4/2 hydraulic operated pilot valve.

The 2/2 way hydraulic operated directional valve is a cartridge valve and it consists of a main

Page 17 of 18
Name: SP2582-1-L-MB-001, Number: 260675, Version: 0.3, State: RELEASED, Modifier: hollaan

Doc type: PROJECT DOCUMENT

Doc name: SP2582-1-L-MB-001 System Description

stage including a valve cone, a bushing and a valve cover. On top of the cover there is a
hydraulic operated 3/2 way pilot spool valve with NG6 mounting pattern. The 2/2 way directional
valve is mounted in the same line as from the B ports on the winch motor block to the B port on
the on the main control valve inside the rotating crane king. The 2/2 way hydraulic operated
directional valve is used to close the connection between the “Lowering” port on the hydraulic
motor and the working section in the main control valve when the Emergency release system is
activated. In this mode the valve prevents oil to flow to the reservoir via the spool in the main
control valve (The A- and B ports are connected to the T port when the spool is in neutral
position). The 2/2 way valve is normally open i.e. when there is no pilot pressure available the
main cone is open.

When the MOPS button in the crane cabin is activated, the 3/2 way electric operated pilot valve
is activated and opens. The emergency release functions will now activate in the following
manner:

Oil from the two bladder accumulators will flow through a pressure reducing valve (40 bars) to
the 2/2 way hydraulic operated directional valve and it will close as described above. The
accumulators will also ensure sufficient oil flow to disengage the brakes on the winch and avoid
cavitation on the winch motor when the load is lowered.

In addition to this the 4/2 hydraulic operated pilot valve, also of NG6 design, will pressurize the
Pil2 port on the motor valve block on the winch and “dump” the pressure setting of the pilot
operated pressure relief valve mounted between the “Winch Up” port on the motor and the load
control valve in the motor valve block. The pressure setting of the valve is then determined via
the pilot port, MX. This line is routed to an electrically operated 3/2 valve which will be activated
to enable the tension to be set by a relief valve with a fixed setting. This will allow the winch to
pay out with a tension of 10% to 15% of the SWL.

6.6 Automatic Overload Protection System (AOPS)

The AOPS is activated when a load is registered by the load cell which exceeds a certain value
predefined according to AOPS load chart in the control system and the crane hook is outside a
defined sector of the shipside. The Winch Down electrically operated proportional valve is
energized in the main control valve (100% activation) which lowers the load at maximum speed
and stops when the load is below the rated platform lift capacity.

Page 18 of 18
 User Manual for Crane

4 Handling, Preservation & Installation

Table of Contents
1. Introduction ......................................................................................................................................1
2. Unloading and Handling ...................................................................................................................1
3. Crane Preservation ..........................................................................................................................1
4. Installation of Crane Unit ..................................................................................................................1
4.1. Crane installation .......................................................................................................................1
5. Initial Start-up ...................................................................................................................................1
6. Function and Load Tests..................................................................................................................2
7. Wire Handling Recommendation ......................................................................................................2
8. WI 58 Handling, storage and preservation procedures .....................................................................3

4 Handling, Preservation & Installation

MACGREGOR NORWAY AS
 User Manual for Crane

Blank page.

4 Handling, Preservation & Installation

MACGREGOR NORWAY AS
 User Manual for Crane

1. Introduction
The purpose of this procedure is to:

1. Ensure that all components are handled / lifted in a safe and correct way to avoid any injury or damage
to personnel or equipment.
2. Ensure up to 2 years’ storage with no deterioration in function and/or quality that could reduce the
working performance or service life of the unit.
3. Ensure that installation and initial start-up are performed in a safe and correct way.

2. Unloading and Handling

Crane components are provided with lifting lugs for safe lifting. See separate document: WI 58 Handling,
storage and preservation procedures page 3.

3. Crane Preservation
See separate document: WI 58 Handling, storage and preservation procedures page 3.

4. Installation of Crane Unit

Check the following:

 Deck structure must be free from cracks, rust, oil and other elements that could inhibit bolting/welding
of the pedestal to the sub-foundation.
 The crane is delivered as agreed.
 Be sure that no dust or other contaminants enter the hydraulic system.
 Be sure that the vessel’s foundation sub-structure is dimensioned to bear the weight of the specific
crane and the forces it will exert.

4.1. Crane installation

Crane delivered Ex Works, installed under MacGregor Norway AS supervision.

5. Initial Start-up
It is important to check that valves and controls are in the correct position before attempting to start the crane.

As a final check before starting, check the rotation of the electric motors. Motors must rotate in a clockwise
direction as seen from the motor’s fan end. If a motor rotates in the wrong direction, swap two phases and check
again for clockwise rotation.

The main HPU motors are bolted just below the slew bearing on the underside of the king bottom plate. Access
is through a door in the pedestal.

A hydraulic pump must not be allowed to run in the wrong direction for any length of time, as this will
reduce the service life of the pump.

4 Handling, Preservation & Installation

MACGREGOR NORWAY AS 1
 User Manual for Crane

Upon completion of the initial test run, check the oil level in the oil tank, and top up if necessary.

The first time the system is started there may be air in the system. Run the power pack for a couple of minutes at
low pressure. The winch and the slew will automatically vent air from the system when operated.

See Chapter 5 for details on crane start and operation.

6. Function and Load Tests

Do not put the crane into normal service until the Harbour Acceptance Test (HAT) and the Sea Acceptance Test
(SAT) have been performed.

7. Wire Handling Recommendation

Steel wire on a drum is a complex component in a winch system, and “training” a new wire will contribute to
optimum spooling

This is done by lowering and raising the full length of wire a minimum of three times while maintaining a
tension equivalent to 10%-20% SWL.

4 Handling, Preservation & Installation

2 MACGREGOR NORWAY AS
 User Manual for Crane

8. WI 58 Handling, storage and preservation procedures

(following pages)

4 Handling, Preservation & Installation

MACGREGOR NORWAY AS 3
 User Manual for Crane

Blank page.

4 Handling, Preservation & Installation

4 MACGREGOR NORWAY AS
Doc type WORK INSTRUCTION

Doc. ID WI 58 Handling, storage, preservation Marine

Business Area: Document owner: Document revision:

MacGregor Discipline lead Mechanical 1

Business Line: Document revised by:

OFS Advanced Load Handling 11.01.2013/ SRT

Handling, preservation & storage procedure -

Marine products

1 PURPOSE/ SCOPE
The purpose of this procedures is to ensure proper preservation, safe lifting, transport and storage of
MacGregor ship cranes, utility-winches and davits.

2 RESPONSIBILITIES
Discipline lead Mechanical is responsible for this instruction.
QC department is responsible for implementation and follow-up of this procedure.

3 GENERAL

3.1 Preservation
Preservation work in all stages of the project may involve usage of solvents that may be harmful to
people. Adequate protective measures must therefore be taken by personnel performing this type of work.
When purchasing preservatives, data sheet must be required as a part of the delivery. These sheets must
be received and correct action taken according to listing on data sheet before preservation is carried out.

3.2 Acceptance check of equipment

All equipment is initially preserved by MacGregor or subcontractors. Upon receipt, and prior to storage,
the equipment shall be checked. Areas where preservation is damaged, shall be repaired if found
necessary. Use the check record as a guide.(Ch 7.2.1)

3.3 Preservation of MacGregor equipment (fully assembled)

The hydraulic piping system on the equipment is flushed and sealed off by MacGregor/Subcontractor. All
open-end nozzles shall remain plugged or capped to protect from material that can contaminate the piping
and fluid in the piping. Non metallic plugs shall not be used. MacGregor deliver product drained and
without any cortex for storage under 3 months. For storage longer than 3 months ,the system must be
flushed through with cortex mixture and tank filled up over the suction nozzle (cortex mixing) to avoid

Page 1 of 25
Doc type WORK INSTRUCTION

Doc. ID WI 58 Handling, storage, preservation Marine

any corrosion to components.(refer to the preservation check records for details)

All yellow chromate materials are covered with Denso-tape to avoid corrosion.(refer to Denso-tape
procedure)
Shafts on unlocked rotating equipment mentioned in check record shall be rotated 1 ¼ turn in its rotation
direction to avoid brinelling in the bearing. Make sure that new shaft positions vary from one turn to the
other.
Connect heaters to all motors specified for heating. Check for an active space heater by using an Ampere
meter, or hand feel the temperature outside the motor.
MacGregor has topped up all gearboxes with gear oil. Vertical gear box with the pinion facing down, are
topped when they are in operation as well as during storage. These gearboxes are filled with oil and can
go right into operation provided that the storage time is limited. Horizontal gearboxes are also topped
with oil. Horizontal gearboxes must be drained to correct level prior to use of the boxes. However,
heavy-duty gearboxes have been drained for gear oil, and the gear oil is replaced with preservation
oil to specified level. See check record for correct oil and level. Gear boxes topped with oil shall be
marked with labels as shown in chapter 7.5.
All air bottles or accumulators are put under pressure using dried Nitrogen. The pressure is normally
between 2 and 3 bars. Inspect air bottles or accumulators for positive Nitrogen pressure. If the pressure is
below 1.5 bars, re-pressurize with Nitrogen with dew point -30°C or better.

All electric boxes or cabinets exposed to humidity shall be protected with desiccants inside. Place a
sticker on the outside of the cabinet with the starting date/ expiration date.
All non terminated cable ends shall be fitted with heat-shrink.
All heaters on motors, generators, panels etc. shall be energized for storage.
Evaluate if the King(internal) due to corrosion risk is to be put under heat with a external heater.
Lubrication points to be greased according to check record table in Ch 7
Exposed cylinder rod must be protected with applying grease onto rod and mechanical protected with a
thick rubber and wooden plank clamped around
Preservation shall be checked periodically. Any anomaly shall be rectified. The preservation period is
described in the check record.
If the storage area occasionally may be exposed to salt spray etc ,the equipment must be washed down
with freshwater periodically and protected with a tarpaulin

3.4 Preservation of MacGregor Equipment prior to transport(only steel)

All machined surfaces with surface roughness less than 12.5 to be protected by applying grease.
Machined surfaces with surface roughness 12.5 and above are to be primed only according to MacGregor
paint specification. Typical mounting flanges on platforms, brackets, etc are to be primed only.
All threads to and open flanges to be protected with grease.
Rethread and clean all welding sockets. Lubricate all threads with grease and spray tectyl onto the seal
face. No paint or damage must be visible on the face of the welding sockets. To seal off the socket,install
plugs which protect for dirt and water penetration

Page 2 of 25
Doc type WORK INSTRUCTION

Doc. ID WI 58 Handling, storage, preservation Marine

Gratings for platforms are to be hot dip galvanized or fiber glass suitable for offshore use. All hollow
sections, pipes and other closed areas to be sealed off, due to lack of corrosion protection inside or
between pipes
All fabricated bolts/washers and distance washer to be installed in respective places as a evidence for
correct trial assembly. Bolts/washer that can`t be installed for transport must be preserved with tectyl and
packed /secured with a protective packaging (bubble plastic) to avoid damage on bolt and other parts.
All open holes that are exposed for water/dust/contamination must be sealed off with a material that put
up with moisture for a periode over 3 months.
Manifolds to be clean and free of dirt. Apply a thin oil film into the manifold so all internal walls are
penetrated and then seal off inlet/outlet with steel plugs to protect against internal corrosion and unwanted
contamination inside manifold.
For longer preservation than 3 months preservation record “general check record for preservation of
steel” in chapter 8.2 to be used”

4 PRECEDING ACTIVITIES

4.1 Preparation
Prior to lifting and transport operations of MacGregor products the actions listed below shall be carried
out. A “Tilt Watch” may be placed on the items to check if the transport and lifting has been done in a
proper way.

4.1.1 Preparatory tasks

Reference is made to relevant transport drawing showing the equipment, lifting arrangement and transport
cradle etc.

 Wire rope to be fully spooled onto the drum with tension. The free end to be fastened properly.
 Wooden pads to be placed under the foundation feet of small parts with no transport cradle.
 Ensure that all movable parts are properly fastened to prevent them from any uncontrolled
movements.
 Area under influence of blade rubbing must be protected with thick rubber and secured properly
 Ensure that end of interface electric cables and hydraulic hoses are disconnected and their loose end
are fastened and protected properly. Make sure that all ends are marked properly to avoid any
problems during reconnection of the equipment.
 All temporary marking as gold money, labels etc.. must be secured with stainless steel wire
 The opened hydraulic connections to be protected against impurity with steel caps.
 Lifting and handling of the equipment to be prepared according to relevant lifting drawing.
 Length and capacity of loose lifting gear to be in accordance to relevant lifting drawing.
 Loose lifting gear to be inspected for defects.
 Loose lifting gear certificates to be present.

Page 3 of 25
Doc type WORK INSTRUCTION

Doc. ID WI 58 Handling, storage, preservation Marine

5 LIFTING

5.1 Safety Note

No operation shall commence before all safety measures are in place. Consult all relevant personnel
involved. Any safety hazard must be identified and the required safety measures explained.

 Always make sure that proper lifting equipment is used. The lifting equipment must have proper
strength related to the weight of parts to be lifted
 Always make sure that the shackles are properly fastened with shackle safety pins, with no twist on
the lifting wire before lifting.
 Always make sure that only certified lifting gear is used.

5.2 Lifting performance

The product has lifting lugs of required capacity, dimensioned for belonging shackles. The relevant lifting
drawing contains information about lifting lug locations and capacity. Total weight of the unit together
with weight in each sling is also specified. COG is indicated on the drawings and when correct lengths of
the lifting slings are used the lifted object should be in balance.

6 TRANSPORT
The equipment may be transported by sea or land to its final destination.
For detailed information on dimensions, weight and COG locations for each unit, refer to section 4 in this
document and/or corresponding GA drawing, transport drawing, and or relevant packing list.

6.1 Packing
Equipment belonging to the product may be packed in standard 20’ container,on deck of transport
vessel/truck. Preparations described in 3.1 shall be performed. Make sure no loose component remains in
the container or on deck of vessel/truck. All the modules shall be properly strapped . Smaller items may
be wrapped in VCI bags for transport

6.2 Receiving of goods

Check that equipment has not moved inside container, and there are no damages or elements missing
before unloading. When damages are found, take pictures when equipment still remains inside container
or on transport vessel/truck.
When a damaged have been discovered, the consignee and transport responsible must observe this and
make notice of this into the bill of lading. To be signed by both party
Carefully loosen the securing of each element.

Page 4 of 25
Doc type WORK INSTRUCTION

Doc. ID WI 58 Handling, storage, preservation Marine

6.3 Unpacking
The unpacking shall be done just prior to installation. If unpacked earlier, follow instruction given in
section 6.
Unpacking from open top container/vessel and open truck is done by using lifting sets/sling mounting on
the equipment. Follow lifting instructions given in section 4. Forklift is used for unpacking equipment
with no lifting sets.

6.4 Transport performance

Common recognized standard for stowing should be applied. The equipment can be transported on an
open platform/deck.
For loading/unloading process follow instructions given in section 4 and use the lifting aids mentioned
there.

7 STORAGE

7.1 Preparation
 If possible, indoor storage is preferable
 Prepare sufficient area for storing. The storage facilities shall protect the equipment from corrosive
and other harmful conditions over time so that it can be installed and taken into service with no
reduction in quality or expected lifetime.
 For outdoor storage of equipment, a sheltered place is recommended.
 All disconnected electrical and hydraulic interface joints are to be protected, no loose items left.
 Unpainted carbon steel surfaces to be preserved as described in attached tables of preservative.
 Touch up any damaged painting.
 If the equipment was exposed to salty air, dirt or particles, it shall be controlled and considered to be
cleaned/washed with fresh water prior to storage. If water isn`t properly, solvent according to table of
preservatives to be used(Ch 7.7)
 If outdoor storage is used, a tarpaulin must cover the product on the most critical exposed area of the
product. Use the check record for more information about each product(Ch 7)
 The product must not be stored close to painting or welding/steel grinding work.

7.2 Storage
The product and loose components is usually stored in its natural position. Wooden pads for rest should
be prepared to isolate the equipment from the ground. Unpainted/exposed steel shall rest on a rubber layer
with wooden pads below. The equipment cannot be stacked. The equipment is to be protected during
storing, and also after installation onboard against dust, damages, hot metal particles, grinding, humidity,
painting etc. (see chapter 6)

Note:
If the equipment is stored for more than three months, the standard periodic maintenance activities
(lubrication) are to be done according to the maintenance schedule. For details refer to corresponding
documents. Re-preservation is solely the responsibility of the buyer or the buyers appointed.

Page 5 of 25
Doc type WORK INSTRUCTION

Doc. ID WI 58 Handling, storage, preservation Marine

8 PRESERVATION CHECK RECORDS/TABELS

8.1 Preservation Check Record on Mechanic, Hydraulic, Electric, and Instrument

for assembled product

Page 6 of 25
Doc type WORK INSTRUCTION

Doc. ID WI 58 Handling, storage, preservation Marine

Preservation specification & record – davit, mechanical/hydraulic

Record No.: Tag No.: Description Record page:

Act. Intervals Date/Sign Date/Sign Date/Sign Date/Sign Date/Sign

Description of Preservation Activity Preservative
no Months Preserv. 1 Preserv. 2 Preserv. 3 Preserv. 4 Preserv. 5

Tectyl 506
1 3 All unpainted steel flanges to be coated with preservatives
Decordyn 350
General check for structural damage and corrosion. Particularly
2 3
pay attention to lifting equipment and wire

MacGregor
3 3 All painting to be undamaged. If not, repair painting
Technical Spec.
Tectyl506/
4 3 All parts which can be exposed to rust to be protected
CortecVpCI369
Tectyl506
5 3 Steel sign to be protected
Decordyn 350
Bolts acc. MGH
6 3 Open holes unused treaded opening in steel to be sealed off
Std /marine sealing
Check for functionality on lock on hook. If not sufficient, apply
7 3 Gleitmo spray 582
lubrication.
Check for preservation on wire clamp/internal in hook stop Tectyl 506
8 3
weight Decordyn 350

9 3 Check for installation of grease nipples and caps

Apply grease to all grease nipples(2-3 pump). Include bolts, wire

sheaves, cylinders, el motor ,winch bearing housing and docking
10 3 Texaco MultifakEP2
head(or other lubr. points exposed to water). Remove excess and
old grease

11 3 Inspect visible part of wire for securing and damage. If damaged ,

Page 7 of 25
Doc type WORK INSTRUCTION

Doc. ID WI 58 Handling, storage, preservation Marine

Preservation specification & record – davit, mechanical/hydraulic

Record No.: Tag No.: Description Record page:

Act. Intervals Date/Sign Date/Sign Date/Sign Date/Sign Date/Sign

Description of Preservation Activity Preservative
no Months Preserv. 1 Preserv. 2 Preserv. 3 Preserv. 4 Preserv. 5

contact professional personnel / QC.

Check for free rotation of wire sheaves. Visual check for damage,
12 3 wear, corrosion and crack. Repair/replace if necessary
Inspect accumulator for general condition. Check mounting
bracket(bolt/nuts)
Check nitrogen pressure value according to flow diagram. Use MacGregor manometer
13 3 MACGREGOR manometer fill/check instrument. To be fill/check instrument
performed by mechanic /trained personnel. Cap to be installed
and denso taped
Check condition of cylinder(paint, leak, corrosion)
14 3 No backslide of rod to be allowed. Contact mechanic if any
backslide
Extended cylinder rods(jib/shock damper etc) coated with Texaco Multifak EP2 &
15 3 preservative and protected with wood Wood
Winch motor/gear & consol must be controlled for overfill tag. If
16 3 not signed out or missing, oil level must be checked and new tag Overfill tag Ch 7.4
installed on winch/consol

Check D-fender for any loose parts(rubber plug) and general

17 3
condition.
Check connection ports on Davit leg and cabinet to be closed
18 3 Hydraulic steel caps
with steel caps and marked
Check that marking on hoses are unsullied and readable. Gold
19 3
coins installed on connection ports and secured

Page 8 of 25
Doc type WORK INSTRUCTION

Doc. ID WI 58 Handling, storage, preservation Marine

Preservation specification & record – davit, mechanical/hydraulic

Record No.: Tag No.: Description Record page:

Act. Intervals Date/Sign Date/Sign Date/Sign Date/Sign Date/Sign

Description of Preservation Activity Preservative
no Months Preserv. 1 Preserv. 2 Preserv. 3 Preserv. 4 Preserv. 5

20 3 All loose items/removed parts preserved, stored and marked.

Yellow chromate steel on hydraulic tubes and hoses denso taped

21 3 Densotape
and undamaged.
Check general condition on all hydraulic
22 3 components/valves(paint, leaks, corrosion) Apply lubrication to Gleitmo spray 582
the valve levers(rubber cap must be removed and replaced)

23 3 Check for proper grease in movable joint (hand pump) Gleitmo spray 582

Diesel motor options. Check for general condition, leak and all
24 3
connections is sealed

25 3 Check that tarpaulin is undamaged. Replace/repair if necessary

Check all signs for damage and in place(logo, maneuvering signs

26 3
etc..)
Comments:

Performed by Accepted by Specified Requirements:

Date/Signature: Date/Signature:  Norsok Standard Z-006.

Page 9 of 25
Doc type WORK INSTRUCTION

Doc. ID WI 58 Handling, storage, preservation Marine

Preservation specification & record – davit, Electrical

Record No.: Tag No.: Description Record page:

Act. Intervals Date/Sign Date/Sign Date/Sign Date/Sign Date/Sign

Description of Preservation Activity Preservative
no Months Preserv. 1 Preserv. 2 Preserv. 3 Preserv. 4 Preserv. 5

1 3 All sensitive instrumentation exposed to damage to be protected

Inspect starter cabinet for general condition. Check internals for

2 3 corrosion and moisture – if so, dry up and repair, add desiccant Cortex
and ensure tight sealing
Open nipples and glands in panels and junction boxes to be
3 3
sealed up

4 3 All non-terminated cable end fitted with heat-shrink

All spare cable entrances in panels and boxes plugged. If not

5 3
vertical installed with drain plug down – seal drain plug

6 3 All non-terminated cable end fitted with heat-shrink

Gasket in panels or junction box to be protected with

7 3 Silicon grease
preservatives, if stored outdoors
Check electric motor for gen condition . Pay particular attention
8 3
to closeness on connections points(plugs in terminal box)

9 3 Check for physical damages to cable trays etc..

Comments:

Performed by Accepted by Specified Requirements:

Date/Signature: Date/Signature:  Norsok Standard Z-006.

Page 10 of 25
Doc type WORK INSTRUCTION

Doc. ID WI 58 Handling, storage, preservation Marine

Preservation specification & record – Crane, Mechanical

Record No.: Tag No.: Description Record page:

Act. Intervals Date/Sign Date/Sign Date/Sign Date/Sign Date/Sign

Description of Preservation Activity Preservative
no Months Preserv. 1 Preserv. 2 Preserv. 3 Preserv. 4 Preserv. 5

1 3 Check for structural damage, corrosion and paint condition.

MACGREGOR
2 3 All painting to be undamaged. If not, repair painting
Technical Specification
Tectyl506
3 3 Fabrication steel sign to be protected(sign welded to steel)
Decordyn 350
Open holes unused treaded opening in carbon steel to be sealed Bolts acc MGH
4 3
up sandard /marine sealing
Texaco
5 3 Door / Hatch hinges checked for grease
Multifak EP2
6 3 Gasket in door and hatches to be checked and greased if dry Silicon grease

7 3 All drain holes to be checked for function

Yellow chromate steel on hydraulic tubes and hoses densotaped

8 3 Densotape
and undamaged.

9 3 Check for installation of grease nipples and caps

Apply grease to all grease nipples(2-3 pump). Include bolts, wire

10 3 sheaves, cylinders, el motor and winch bearing housing (or other Texaco MultifakEP2
lubr. points exposed to water). Remove excess and old grease

11 3 Check grease internal on cog wheel. Apply grease if insufficient CRC SP400

Check for free rotation of wire sheaves. Visual check for damage,
12 3
wear, corrosion and crack. Repair/replace if necessary

13 3 Evaluate external heater to the King to avoid condense External heater

Page 11 of 25
Doc type WORK INSTRUCTION

Doc. ID WI 58 Handling, storage, preservation Marine

Preservation specification & record – Crane, Mechanical

Record No.: Tag No.: Description Record page:

Act. Intervals Date/Sign Date/Sign Date/Sign Date/Sign Date/Sign

Description of Preservation Activity Preservative
no Months Preserv. 1 Preserv. 2 Preserv. 3 Preserv. 4 Preserv. 5

14 3 Check condition on Nylatron pads if installed(tears, damages)

15 3 Check that protection structure (grid, grating) is undamaged

16 3 Chain linkage which can be exposed to rust to be protected Clearlube

Inspect visible part of wire for securing and damage. If damaged ,

17 3
contact professional personnel / QC.
Check for functionality on lock on hook. If not sufficient , apply
18 3 Gleitmo spray
lubrication
Check for preservation on wire clamp/internal in hook stop Tectyl 506
19 3
weight Decordyn 350
Check all signs for damage and in place(logo, maneuvering signs
20 3
etc..)
Check for wear and proper grease on winch slew gear ring and
21 3 Kluber Grafslocon
drive pinion
Comments:

Performed by Accepted by Specified Requirements:

Date/Signature: Date/Signature:  Norsok Standard Z-006.

Page 12 of 25
Doc type WORK INSTRUCTION

Doc. ID WI 58 Handling, storage, preservation Marine

Preservation specification & record – Crane, Hydraulic

Record No.: Tag No.: Description Record page:

Act. Intervals Date/Sign Date/Sign Date/Sign Date/Sign Date/Sign

Description of Preservation Activity Preservative
no Months Preserv. 1 Preserv. 2 Preserv. 3 Preserv. 4 Preserv. 5

Hydraulic tank initially filled up (cover suction nozzle)with Rando oil HD46/
1 3 specified oil and 2% cortec Cortec
Inspect accumulator for general condition. Check mounting
bracket(bolt/nuts)
MacGregor manometer
2 3 Check nitrogen pressure value according to flow diagram. Use fill/check instrument
MacGregor manometer fill/check instrument. To be performed by
mechanic /trained personnel. Cap to be installed and denso taped
Winch/Slew motor and gear + consol must be controlled for
3 3 overfill tag. If not signed out or missing, oil level must be Overfill tag Ch 7.5
checked and new tag installed on winch/consol
Check connection ports (hyd. interfaces) to be closed with steel Tectyl 506
4 3 caps and marked. Nozzle faces coated with preservatives Decordyn 350
Check condition of cylinder(paint, leak, corrosion)
5 3 No backslide of rod to be allowed. Contact professional
personnel if any backslide
Extended cylinder rods(jib/shock damper etc) coated with Texaco Multifak EP2,
6 3 preservative and protected with wood rubber & Wood

7 3 All loose items/removed parts preserved, stored and marked

Check all valves inside king (technical room) for corrosion Tectyl 506
8 3 protection Decordyn 350
Check that marking on hoses are unsullied and readable. Gold
10 3 coins installed on connection ports and secured

Page 13 of 25
Doc type WORK INSTRUCTION

Doc. ID WI 58 Handling, storage, preservation Marine

Preservation specification & record – Crane, Hydraulic

Record No.: Tag No.: Description Record page:

Act. Intervals Date/Sign Date/Sign Date/Sign Date/Sign Date/Sign

Description of Preservation Activity Preservative
no Months Preserv. 1 Preserv. 2 Preserv. 3 Preserv. 4 Preserv. 5

Check general condition on all hydraulic

11 3 components/valves(paint, leaks, corrosion) Apply lubrication to Gleitmo spray 582
the valve levers(rubber cap must be removed and replaced)
Check general condition of hydraulic remote control(damage,
12 3 preservation, signs etc..)
Yellow chromate steel on hydraulic tubes and hoses densotaped
13 3 and undamaged. Densotape

Comments:

Performed by Accepted by Specified Requirements:

Date/Signature: Date/Signature:  Norsok Standard Z-006.

Page 14 of 25
Doc type WORK INSTRUCTION

Doc. ID WI 58 Handling, storage, preservation Marine

Preservation specification & record – Crane, electrical and instrument

Record No.: Tag No.: Description Record page:

Act. Intervals Date/Sign Date/Sign Date/Sign Date/Sign Date/Sign

Description of Preservation Activity Preservative
no Months Preserv. 1 Preserv. 2 Preserv. 3 Preserv. 4 Preserv. 5

1 3 All sensitive instrumentation exposed to damage to be protected

Inspect starter cabinet for general condition. Check internals for

2 3 corrosion and moisture – if so, dry up and repair, add desiccant if
missing and ensure tight sealing
Open nipples and glands in panels and junction boxes to be
3 3 sealed up

4 3 All non-terminated cable end fitted with heat-shrink

All spare cable entrances in panels and boxes plugged. If not

5 3 vertical installed with drain plug down – seal drain plug

6 3 All non-terminated cable end fitted with heat-shrink

Gasket in panels or junction box to be protected with

7 3 preservatives, if stored outdoors
Check electric motor for general condition . Pay particular
8 3 attention to closeness on connections points (plugs in terminal
box)

9 3 All sensitive instrumentation exposed to damage to be protected

10 3 Solenoid valves protected against corrosion

Batteries for PLC and CPU fully charged and isolated from
11 3 consumer

13 3 Cabin to be heated

Page 15 of 25
Doc type WORK INSTRUCTION

Doc. ID WI 58 Handling, storage, preservation Marine

Preservation specification & record – Crane, electrical and instrument

Record No.: Tag No.: Description Record page:

Act. Intervals Date/Sign Date/Sign Date/Sign Date/Sign Date/Sign

Description of Preservation Activity Preservative
no Months Preserv. 1 Preserv. 2 Preserv. 3 Preserv. 4 Preserv. 5

14 3 Cabin AC Unit to be protected by a tarpaulin

Comments:

Performed by Accepted by Specified Requirements:

Date/Signature: Date/Signature:  Norsok Standard Z-006.

Page 16 of 25
Doc type WORK INSTRUCTION

Doc. ID WI 58 Handling, storage, preservation Marine

8.2 GENERAL CHECK RECORD FOR PRESERVATION OF STEEL (storage exceeding 3 months)

General check record for preservation of steel (storage exceeding 3 months)

Record No.: Tag No.: Description Record page:

Act. Intervals Date/Sign Date/Sign Date/Sign Date/Sign Date/Sign

Description of Preservation Activity Preservative
no Months Preserv. 1 Preserv. 2 Preserv. 3 Preserv. 4 Preserv. 5

1 3 Inspect machined surfaces for general condition and if

1.Feryl 101
preservation applied before is still durable. If damaged or
2.VpCI 369
insufficient, add necessary preservation for protection
2 3 Other unpainted steel surfaces : Check for general condition,
1.Feryl 101
damaged and insufficient preservation. Add new preservation of
2.VpCI 369
necessary
3 3 Threaded bolt holes: Check for general condition, damaged and 1.Feryl 101
insufficient preservation. Add new preservation of necessary 2. VpCI 369
4 3 Weld Sockets: Check for proper applied preservation and
installed plugs to protect from water/dirt. Apply preservation into VpCI 369
threads if necessary and install plugs that protect properly against & plug
water/dirt
5 3 Bolts (installed into bolt holes).Check conditions for already
VpCI 369 and plastic
applied preservation. If damaged and insufficient preservation
add new preservation if necessary
6 3 Open holes: If any open holes are found that affect quality on
product, holes must be covered with blind covers and sealed off Blind covers
properly so no rain and dirt enter
7 3 Loose parts: All loose parts must be checked for general
condition and proper preservation .
Outdoor: items properly attached /secured to structure and Outdoor:
marked. Verify already applied preservation and apply new if VpCI 369
necessary

Page 17 of 25
Doc type WORK INSTRUCTION

Doc. ID WI 58 Handling, storage, preservation Marine

General check record for preservation of steel (storage exceeding 3 months)

Record No.: Tag No.: Description Record page:

Act. Intervals Date/Sign Date/Sign Date/Sign Date/Sign Date/Sign

Description of Preservation Activity Preservative
no Months Preserv. 1 Preserv. 2 Preserv. 3 Preserv. 4 Preserv. 5

Indoor: Verify condition and already applied preservation. Apply Indoor:

new if necessary Pro Super
8 3 All manifolds to be checked internal for applied Internal surface:
preservation(hydraulic oil). Check that all plugs are installed and Hydraulic Oil(LSS05)
sealed properly
For preservation on outer structure of manifold , paint condition Outer surface:
must be checked . If not surface treated, check and confirm if Tech Spec
there is a preservation film applied. Pro Super

Comments:

Performed by Accepted by Specified Requirements:

Date/Signature: Date/Signature:  Norsok Standard Z-006.

Page 18 of 25
Doc type WORK INSTRUCTION

Doc. ID WI 58 Handling, storage, preservation Marine

8.3 Preservation Label

REAR OF LABEL FRONT OF LABEL

MAINTENANCE

Signature Date

PRESERVATION
CARRIED OUT

HM PROJECT №: ____________

SERIAL №:__________________

INTERVALS:__________________

DATE_________ SIGN_________

Page 19 of 25
Doc type WORK INSTRUCTION

Doc. ID WI 58 Handling, storage, preservation Marine

8.4 Topped Gearbox

WARNING

THIS GEARBOX
HAS BEEN
OVERFILLED WITH
PRESERVATION OIL

THE OIL MUST BE DRAINED

FILL NEW OIL TO CORRECT
LEVEL ACCORDING TO THE
ACTUAL LUBRICATION CHART

Date_________ Sign._________

Page 20 of 25
Doc type WORK INSTRUCTION

Doc. ID WI 58 Handling, storage, preservation Marine

8.5 Table of Preservatives

Part Recommended preservatives

Wheels Decordyn 350

Densotape on roller surface if needed
Tectyl 506 in creviced areas

Bondura bolts Decordyn 350

Clevis pins Tectyl 122A with overlap towards painted surfaces
Tectyl 506 in creviced areas
Other accepted products:
Cortec VpCI 368 and Cortec VpCI 368HB
Exposed/machined carbon steel Decordyn 350
Tectyl 122A with overlap towards painted surfaces
Other accepted products: Cortec VpCI 368HB

Wire Bridon Brilube 70

Feryl 101
Cortec VpCI368 on dry wire
Wire grease outside
Wires are pre-greased
Wire sheave Decordyn 350
Tectyl 122A
Tectyl 506 in creviced areas and inside wire cone.
Other accepted products:
Cortec VpCI368 and Cortec VpCI 368HB
Drive rack equipment Decordyn 350
Tectyl 122A with overlap towards painted surfaces
Other accepted products: Cortec VpCI368HB

Pinion Equipment Decordyn 350

Tectyl 122A
Other acceptable products:
Cortec VpCI368HB
Slew pinion teeth on cranes. Kluber Grafslocon Ca 902 (first layer)
Open gear on slew pinion rack and pinion drive Kluber Grafslocon A G1 (second layer)
Dry and clean pinion can be preserved by means of
Tectyl 122A or 121B, Cortec VpCI368HB

Page 21 of 25
Doc type WORK INSTRUCTION

Doc. ID WI 58 Handling, storage, preservation Marine

Part Recommended preservatives

Yellow chromed fittings Densotape

Decordyn 350
Tectyl 506
Cortec VpCI368
Chains Gleitmo 582 spray
CRC SP400

Open holes To be plugged with plastic or metallic plug

Open Holes with threads Feryl 101 into threads and on plug
VpCI 369 onto threads and on plug

Pneumatic cylinders Cortec VpCI369 on exposed cylinder rods and

covered with plastic film
It is not a part of standard to preserve pneumatic
cylinders, but recommended for long time storage

Hydraulic cylinders Cortec VpCI 369 and cover with plastic film and
wood board

Preservation of Junction Boxes and cabinets Insert Cortec VpCI emitter dimensioned for
cabinet size (Lifetime 2 years)
Spray cabinet with Cortec VpCI238, when
inspection and close.
If there are open cable glands in the cabinet, plug
with plastic plug and change emitter in cabinet

Preservation of electrical interface contacts Spray with Cortec VpCI238

Cabin AC unit Protect outside unit from rain and dust with a
tarpaulin

Hooks and blocks Bearings to be greased with Texaco EP 2

Texaco Novatex Heavy EP2

Telescopic jib with Nylatron sliding pads

Texaco Multifak EP2
(Sliding surface only)

Page 22 of 25
Doc type WORK INSTRUCTION

Doc. ID WI 58 Handling, storage, preservation Marine

Part Recommended preservatives

Motor shaft, spline sleeve Kluber Kluberpaste 46MR401

Treads on pipe and hose fittings Gleitmo 582 spray

Lubrication for assembly and corrosion Kluber Kluberpaste 46MR401

protection of pins, bearing surface and
spherical bearings Texaco Multifak EP2 (if grease nipple)

Valve lever housing, Spring housing, internally Kluber Kluberpaste 46MR401

1.Gleitmo 582 spray

Pins/bolts in shackles
2.Kluber Kluberpaste 46MR401

Threads on bolt, studs Kluber Staburags NBU30K

1. Gelitmo 582 spray

Dead weight on wire rope incl. timble
2. Kluber Kluberpaste 46MR401

Spherical bearings in knuckle jib,

Texaco Novatec Heavy EP2
bearing/cylinder.
Kluber Staburags NBU 12K
Jib bearing hydraulic cylinder

8.6 De- preservation

Effort has been made to minimize the need of de-preservation. Preservatives may be left on the products
when going into operation provided that these will contribute to extended life of the product and not being
harmful to the product in any way.
A certain extent of de-preservation is required. Technical data sheets for each preservative provides
information regarding which type of solvent, de-greaser or washing agent needed for its removal. Product
data sheets for de-greaser and preservative should be reviewed prior to removal of preservatives.

De-preservation must be done before commissioning start-up. The commissioning activities comprise
preparation checking, functional activities and operational activities.
The preparation checking and functional activities must be performed in the same phase, but the
operational activities may be performed in a later phase than the functional activities depending on
installation completion.
If commissioning is performed during multiples phases, the equipment shall be preserved when functional
activities are completed. Subsequently, de-preservation must be performed prior to commissioning
operational activities.
Normally, handover to operation or client is accomplished short after commissioning. Preservation is
normally not repeated in this phase.

Page 23 of 25
Doc type WORK INSTRUCTION

Doc. ID WI 58 Handling, storage, preservation Marine

De-preservation (equipment specific) comprises the following activities:

 Remove all protection structure and protective cloths.
 All protection of cylinder rod(rubber/ wood/ denso tape/ plastic) must be removed before start
up/moving of cylinder.
 Extended cylinder rods(remove preservative as Cortec VpCI 369) to be washed dissolving agent to
remove preservation.
 Drain gear oil in gearboxes to correct level in accordance to user manual guidance
 Reconnect PLC and CPU batteries.
 If re-preservation shall not be performed after functional activities, remove all desiccants inside
cabinets, panels and boxes.
 Remove plugs or caps for all open-end nozzles meant to be available during operation.
 Connect heaters to permanent power source.
 Sealed drain plugs in panels or boxes to be unsealed if correct installed vertical down.
On products stored for more than 3 months, oil must be drained from tank to remove collected moisture
and cortex remnants. New oil must be filled into tank before start up.

8.7 Project cycle for preservation at delivery

Production with Transport Acceptance check on

receipt
Preservation

Maintenance Storage indoors/outdoors Periodic preservation

Preservation/repair Maintenance preserve
preservation by 3 months interval

Assembly and Periodic preservation De-preservation where

installation Maintenance preserve required in procedure
by 3 months interval

Page 24 of 25
Doc type WORK INSTRUCTION

Doc. ID WI 58 Handling, storage, preservation Marine

8.8 Project cycle for preservation after use

Preservation/repair Storage Periodic preservation

preservation Maintenance preserve
by 3 months interval

De-preservation where
required in procedure

Page 25 of 25
 User Manual for Crane

5 Operation
Table of Contents
1. Safety ..............................................................................................................................................1
1.1. Safety Features .........................................................................................................................1
1.2. Safety Instructions .....................................................................................................................3
1.3. General Handling Considerations ..............................................................................................4
1.3.1. Weather and Sea State .......................................................................................................4
1.3.2. Derating ..............................................................................................................................4
1.3.3. Parking................................................................................................................................4
1.3.4. Tugger Winch Parking .....................................................................................................4
1.3.5. Welding ...............................................................................................................................4
2. Modes of Operation .........................................................................................................................5
2.1. Normal.......................................................................................................................................5
2.2. Active Heave Compensation (AHC) / Auto Tension (AT) ...........................................................5
2.3. Constant Tension (CT) ..............................................................................................................5
2.4. Personnel Lift .........................................................................................................................5
3. Crane Controls Overview .................................................................................................................6
3.1. General .....................................................................................................................................6
3.2. Cabin Equipment .......................................................................................................................6
3.3. Operating Panel OP-105 (On Wall) ...........................................................................................7
3.4. Chair Left Operating Panel (OP-103) .........................................................................................7
3.5. Controls Layout .........................................................................................................................8
3.6. Chair Right Operating Panel (OP-104) ....................................................................................10
3.7. Control Cabinet CC-100 ..........................................................................................................11
3.8. Control Screen (HMI) HB001 ...................................................................................................12
3.8.1. General .............................................................................................................................12
3.8.2. General Screen Elements and Layout ...............................................................................12
4. Crane System Start and Stop.........................................................................................................19
4.1. Pre-Start Preparations .............................................................................................................19
4.2. Normal Start – From Operator’s Control Screen in Cabin ........................................................20
4.3. Normal Shutdown ....................................................................................................................21
5. HPU Control...................................................................................................................................22
5.1. General ...................................................................................................................................22
5.2. HPU Operator Screens ............................................................................................................23
5.2.1. General .............................................................................................................................23
5.2.2. Reservoir Surveillance ......................................................................................................25

5 Operation
CARGOTEC NORWAY AS
 User Manual for Crane

6. Normal Crane Operations (Normal Mode) ..................................................................................... 27

6.1. General ................................................................................................................................... 27
6.2. Load Parameters .................................................................................................................... 28
6.3. Crane Ratings ......................................................................................................................... 30
6.4. Main Winch ............................................................................................................................. 31
6.4.1. General ............................................................................................................................ 31
6.4.2. MW Control Screens ........................................................................................................ 31
6.5. Whip Winch ............................................................................................................................. 34
6.5.1. General ............................................................................................................................ 34
6.5.2. WW Control Screens ........................................................................................................ 34
6.5.3. Whip Winch Constant Tension.......................................................................................... 36
6.5.4. Personnel Lift.................................................................................................................. 38
6.6. Slew ........................................................................................................................................ 38
6.7. Main Jib .................................................................................................................................. 39
6.8. Knuckle Jib ............................................................................................................................. 40
6.9. Tugger Winches .................................................................................................................... 41
7. AHC and Auto Tension (AT) Operating Modes .............................................................................. 43
7.1. Overview ................................................................................................................................. 43
7.2. AHC / AT Restrictions ............................................................................................................. 44
7.3. AHC and AT Mode Operating Instructions .............................................................................. 45
8. Derating ......................................................................................................................................... 49
8.1. Derating Overview .................................................................................................................. 49
8.2. Load Radius Diagrams / Work Area ........................................................................................ 51
9. Emergency Procedures ................................................................................................................. 53
9.1. Emergency Stop ..................................................................................................................... 53
9.2. Restart After an Emergency Stop ............................................................................................ 53
9.3. Emergency Release Functions (AOPS – MOPS) (MW and WW) ............................................ 53
9.3.1. Automatic Overload Protection System (AOPS) ............................................................... 53
9.3.2. Manual Overload Protection System (MOPS) ................................................................... 53
9.4. Emergency HPU Operation ..................................................................................................... 54
9.4.1. Emergency Operation Procedures .................................................................................... 54
10. Alarms ......................................................................................................................................... 55
10.1. General ................................................................................................................................. 55
10.2. Alarm Description .................................................................................................................. 59
10.2.1. Alarm List ....................................................................................................................... 60
11. Trend Display Screen .................................................................................................................. 99
12. Misc Screen............................................................................................................................... 101
13. Network Status Screen .............................................................................................................. 102

5 Operation
CARGOTEC NORWAY AS
 User Manual for Crane

14. Setup Screen ............................................................................................................................. 103

15. Joystick Setup Screen................................................................................................................ 105
16. Troubleshooting ......................................................................................................................... 106
17. Crane Setup ............................................................................................................................... 107
17.1. General ............................................................................................................................... 107
17.2. Crane Slew Initialisation ...................................................................................................... 107
17.3. Winch Initialisation ............................................................................................................... 107
17.4. Main Jib Angle Sensor Initialisation / Replacement.............................................................. 108
17.5. Knuckle Jib Angle Sensor Initialisation / Replacement ......................................................... 108
18. SIEMENS PLC CONTROL SYSTEM – SIMATIC S7 300 ........................................................... 109
18.1. General ............................................................................................................................... 109
18.2. PLC System LEDs ............................................................................................................... 109
18.3. Power Supply Module LEDs ................................................................................................ 109
18.4. S7 300 CPU LEDs ............................................................................................................... 110
18.5. DP Interface LEDs ............................................................................................................... 111
18.6. Ethernet (PN) Interface LEDs .............................................................................................. 112
18.7. Interface Module IM 360 LED .............................................................................................. 113
18.8. Interface Module IM 361 LEDs ............................................................................................ 113
18.9. Digital Input / Output Modules.............................................................................................. 113
18.10. Analogue Input / Output Modules ...................................................................................... 114
19. REPLACING SIEMENS S7 COMPONENTS .............................................................................. 115
19.1. General ............................................................................................................................... 115
19.2. PLC Modules ....................................................................................................................... 115
19.3. Power supply ....................................................................................................................... 115
19.4. PLCs ................................................................................................................................... 116
19.5. Digital or Analogue Modules ................................................................................................ 117
20. End Notes .................................................................................................................................. 118

Annex A - Load Calculator...................................................................................................................A1

Annex B - Wire life-cycle calculator......................................................................................................B1

Annex C - Emergency Operation Procedures......................................................................................C1

5 Operation
CARGOTEC NORWAY AS
 User Manual for Crane

1. Safety
1.1. Safety Features
General The equipment delivered by Cargotec Norway AS under this contract has been
designed in accordance with current HSE regulations and standards.

In order to operate safely, prevent injuries to personnel and avoid damage to

equipment it is of utmost importance that both the owner and the user of the
equipment thoroughly study the contents of this manual before operating the machine
or any device controlled by equipment delivered by Cargotec Norway AS.

Emergency stop An emergency stop button is located on the right-hand operating panel on the
operator’s seat inside the cabin. Pressing this button cuts off the crane’s hydraulic
pressure. At least one emergency stop button is also located inside the king.

Spring-centred control All control levers, both two-way and joystick type, are spring-centred. When released,
levers they all return to centre, and whatever motion is active stops.

Overload protection All crane motions are protected against overload by hydraulic relief valves and by the
control system. If a particular motion is attempted which exceeds the crane’s design
capabilities, the relevant relief valve for the particular motion will feed the hydraulic
oil back into the hydraulic oil tank, preventing the motion.

Hook stop systems There are two hook stop systems. The software hook stop is based on wire payout
information from rotational encoders on the winch drums and implemented by the
PLC software. The hardware hook stop is based on a switching device suspended
from the tip of the knuckle jib. When the hook touches this device, twin switches send
a double signal to the control system, which stops the winch before the hook is pulled
into the sheave.

Luffing cylinder The jib luffing cylinders are fitted with mechanical stroke limiters which allow luffing
limitation to take place at full speed.

Load holding valves The main jib luffing cylinders are fitted with pilot-operated load-holding valves.
These valves are connected directly to the cylinder ports and have a dual function:

 Maintaining constant luffing speed independent of the load.

 Blocking cylinder motion in case of hydraulic pressure loss. This will
immobilise the cylinders in case of hose or pipe failure.

Failsafe brakes The winch and slew gearboxes all have failsafe, oil-bath, multidisc hydraulic brakes.
In case of hydraulic pressure loss due to hose/pipe failure, the brake actuates
automatically and halts further motion.

Aircraft warning Red aircraft warning lights are mounted atop the main winch and the main jib outer
lights end to mark the crane during conditions of darkness.

Emergency power If the main system power should fail, the winch and other crane functions may be
supplied by the emergency power system which provides a direct connection to the
ship’s power supply. The AHC system will not be available for operation in
emergency mode, however.

5 Operation
CARGOTEC NORWAY AS 1
 User Manual for Crane

Load / Radius control A jib angle sensor system provides data to the control system for calculating the
system working radius. Load cells in sheave hubs on the knuckle jib register the actual load
suspended from the crane. When a lift is close to the allowable radius/capacity, a
warning is displayed on the operator screen. When the maximum permissible radius is
exceeded, the control system halts jib out movement. The only manoeuvre then
allowed by the control system is movement towards a shorter radius.

Tugger Winches The crane operator must ensure that ANY and ALL operations in which a tugger
winch physically holds the main hook away from the whip winch working area are
under precise control. The tugger winch must always be in constant tension mode.
This will allow the tugger winch to pay out wire if the load on the main hook
increases. This may be due to movement of the crane or accidental movement of the
main winch. If there is a power failure or the crane has been switched off, the tugger
winch must be reset to constant tension mode. Cargotec Norway AS also recommends
the use of a “weak-link” connecting sling equivalent to the tugger winch SWL with an
extra safety sling instead of connecting the tugger hook directly to the main hook.

Emergency release Automatic Overload Protection System (AOPS)

systems
The Automatic Overload Protection System protects the crane against the effect of a
gross overload during operation by releasing the wire in a controlled payout before the
crane sustains significant damage. When the system is activated the winch will
automatically pay out wire. As long as AOPS is activated, the winch will maintain a
retaining force corresponding to the relevant SWL.

AOPS is inaccessible when the jib tip is over deck, and is automatically made
accessible when the jib tip is over water.

Manual Overload Protection System (MOPS)

If the wire is caught on another vessel or the seabed and the crane and/or vessel is
disabled, there is a risk of exposing the crane to higher loads than it is designed for as
the vessel drifts. Should this occur, the operator can activate the MOPS by pressing
the yellow button for the appropriate winch on operating panel OP-104 (next to right
joystick). The system will then pay out wire while maintaining a retaining force of
approx. 10-20% of maximum rated winch capacity.

Both emergency release functions are inaccessible to winches operating in personnel-lift mode.

5 Operation

2 CARGOTEC NORWAY AS
 User Manual for Crane

1.2. Safety Instructions

Never handle loads The jib system is able to lift heavier loads at reduced radius. When lifting heavy loads,
heavier than the always check that the winch are able to lift the load before any further operation.
winch can lift

Risk of collision Pay attention to the risk of collision with the superstructure when slewing and jibbing.

Auto Tension with Never activate Auto Tension Mode while a load is hanging from the hook. This can put
load in the hook the load into free fall and cause major damage to vessel or other structure.

Lifting gear Never use lifting gear with cracks deformations etc. that can reduce the original
strength. All lifting gear must also have the required lifting capacity for the actual load.

Always pay Respect the alarms and information given on the screen.
attention to the
crane control system

Override Mode Do not operate the crane in override mode unless the situation requires this. Override
mode supersedes all interlocks of crane

Operator To operate the crane, the operator must be familiar with the crane and crane user
manual. The crane operator must also fulfil the requirements given by the vessels flag
authorities.

Single wire parts The crane must never be operated if the information on the screen is not correct
compared to actual block in use.

Wire tension – Operational restriction on main winch, please refer to Annex B - "Safety Bulletin 2010-
retrieval operations SB03".

5 Operation
CARGOTEC NORWAY AS 3
 User Manual for Crane

1.3. General Handling Considerations

1.3.1. Weather and Sea State
A ship and crane’s surroundings have a significant impact on what a crane can do and how; thus, wind and sea
must always be taken into account when planning and performing a lifting operation. The situation must be
reassessed if conditions change appreciably in the course of an operation.

A crane can operate under a wide range of conditions, but a few key parameters are critical to operational
planning. These include wind speed and direction, heave (wave height and period), list and trim conditions,
offlead angles and the type of lift (i.e. internal, external or ship-to-ship – also treated as an environmental
factor).

Obviously, where relative movements are concerned (external and ship-to-ship lifts), sea state and
weather are important factors that must be taken into account in all planning and operations.

1.3.2. Derating
Operators and users of MacGregor offshore cranes need to understand the basics of crane load limitations under
varying conditions and different operating modes to avoid putting excessive strain on the crane. Incorrect crane
operation can lead to dangerous situations, damage to equipment and vessel, serious personal injury or worse.

A crane always has its own individual ratings, which describe exactly what capacity the crane can lift at a given
radius under given conditions. As the radius increases or as conditions deteriorate, the allowed rating decreases;
this is referred to as derating. Load diagrams apply to internal, subsea (external) and ship-to-ship lifting
situations.

1.3.3. Parking
The crane must be properly parked after use: knuckle jib folded in, main jib down, slew angle at park and both
knuckle jib and hook(s) in their cradles, if present. This achieves three important purposes:

1. With the cylinder rods fully retracted, their bare metal surfaces are protected from the corrosive marine
environment.
2. Releasing system pressure eliminates strain on system components and extends the life of seals on
cylinders, valves and connections.
3. Securing idle equipment is an important safety measure on board a ship.

1.3.4. Tugger Winch Parking

When the crane is parked, the tugger winches should also be parked – i.e. both tugger winch cylinders should
be retracted completely to protect the cylinders and minimize cylinder rod corrosion.

1.3.5. Welding
Sensitive electronic components are easily damaged by the stray electrical charges that welding currents can
produce. Therefore, if any electric welding is to be done on the crane, the control system must first be isolated
by removing the main control system fuse, -F15, located in ES400 in the king.

5 Operation

4 CARGOTEC NORWAY AS
 User Manual for Crane

2. Modes of Operation
2.1. Normal
Normal crane operation allows the crane operator to carry out most lifting operations with the crane such as
slewing, luffing, ordinary lifting and lowering with any winch, and parking.

2.2. Active Heave Compensation (AHC) / Auto Tension (AT)

Active Heave Compensation mode allows the operator to perform all normal functions with the added benefit of
automatic compensation for vessel/crane movement. Simple AHC maintains position control to keep the hook
steady; Auto Tension is a sub-mode that additionally keeps the pull on the load steady. Found only on main
winch and/or whip winch.

2.3. Constant Tension (CT)

In this mode, the control system keeps wire tension at a constant, adjustable value based on load deviations
registered by the load cell. For reasons of safety, it is impossible to switch between main winch and whip winch
while constant tension is enabled, meaning that these buttons are inhibited.

2.4. Personnel Lift

Main or whip winches can be equipped with a personnel lift mode which imposes added restrictions to ensure a
very high margin of safety. The emergency release systems (MOPS/AOPS) are disabled in this mode.

5 Operation
CARGOTEC NORWAY AS 5
 User Manual for Crane

3. Crane Controls Overview

3.1. General
Equipment located in the cabin is briefly presented in this section, and operation is described in subsequent
sections.

 Left and right control consoles on operator’s seat

 Operating panel on side wall
 LCD operator’s screen with graphic control interface
 One video monitor for winches
 UHF / VHF radios, plus microphone
 Switches for window wipers and washers
 Cabin heating, ventilation and air conditioning
 Radio with CD player
 One folding chair

3.2. Cabin Equipment

Window wiper and The front window, roof window and both side windows are all equipped with wipers
washer and washers, with control switches and buttons on the wall panel. The front window
wiper and washer can be operated both from buttons on the left joystick and from the
wall panel.

Cabin climate control The cabin is equipped with a heater and air conditioner. Temperature is thermostat-
controlled.

Radio/CD player Stereo system mounted on wall panel, speakers on left and right walls.

VHF/UHF radio A VHF radio and a UHF radio for communication, mounted on the wall panel.
Microphone on gooseneck, push-to-talk (PTT) foot switch on floor and equivalent
PTT button on right joystick (black front switch).

Signal Horn Outside cabin, with a horn button on the left joystick (red top-switch).

5 Operation

6 CARGOTEC NORWAY AS
 User Manual for Crane

3.3. Operating Panel OP-105 (On Wall)

General Operating panel OP-105 on the cabin’s left-hand wall has switches for the cabin lights,
window wipers and washers and defrosting fan, as well as a system buzzer.

Cabin light switch For turning cabin lights on and off.

Defrosting Fan For turning window defroster on and off.

Window wipers and Front, roof and both side windows are all equipped with washers and wipers.
washers

3.4. Chair Left Operating Panel (OP-103)

General OP-103 is located in the operator chair left console, and includes:

 A four-way joystick with several top and front switches

 MOPS buttons and other buttons
 Tugger winch controls

Left joystick This is a four-way spring-centred joystick that controls main jib and slew manoeuvres.
Has buttons for blowing the horn, acknowledging alarms and operating front washer
and wiper, a thumbwheel for controlling the left tugger winch, and a trigger-like dead
man's switch on the front that must be pressed and held while working the joystick.

MOPS (Manual There are two MOPS buttons, one for the main winch and one for the whip winch,
Overload protection which are covered to prevent inadvertent MOPS activation. Lift the cover to press the
system) button. More information in the sections on the main and whip winches.

Tugger Winch This button is for activating/deactivating the tugger winches (both 1 and 2). More
On/Off information about the tugger winches is found later in this chapter.

Tugger winch 1 and 2 These two buttons activate/deactivate constant tension mode separately for each
CT On/Off tugger winch.

Tugger winch swivel These two spring-centred levers swivel the tugger winch turntables.
levers 1 and 2

5 Operation
CARGOTEC NORWAY AS 7
 User Manual for Crane

3.5. Controls Layout

Emergency Stop Personnel Lift

Activate
AHC/CT/AT

Wall Panel with Emergency Stop

Right Joystick Left Joystick Control Joystick

Panel Panel Enable

5 Operation

8 CARGOTEC NORWAY AS
 User Manual for Crane

Left joystick This four-way joystick controls crane slew and main jib up/down. Front/top
switches, deadman’s switch and thumbwheel for left tugger up/down and
tension.

FUNCTION COMMENTS

Joystick X-positive Crane swing Clock Wise (CW)

Crane swing Counter Clock
Joystick X-negative
Wise (CCW).
Joystick Y-positive Main jib down
Joystick Y-negative Main jib up
Red Push Button Test
Green Push Button Alarm Acknowledge
Blue Push Button Front Washer
Black Push Button Front Wiper
Tugger Winch 1 in/out + Step
Thumb Wheel
Tension

Right joystick Right Joystick Manoeuvres (MW/WW Up and Down, Knuckle Jib)

FUNCTION COMMENTS

Joystick X-positive Crane knuckle jib out

Joystick X-negative Crane knuckle jib in
Joystick Y-positive Winch down
Joystick Y-negative Winch up
Red push button Bullhorn
Green push button Initialize parameters
Blue push button Main/whip winch selection
Black push button PTT (UHF/VHF)
Thumbwheel Tugger 1 in/out, tension +/-

5 Operation
CARGOTEC NORWAY AS 9
 User Manual for Crane

3.6. Chair Right Operating Panel (OP-104)

General OP-104 is located in the operator chair right console, and includes:

 A four-way joystick with several top and front switches

 A switch to activate/deactivate the joysticks (Ctrl Enable)
 An Emergency Stop (ES) button
 A button to activate AHC/AT modes
 A personnel lift mode key switch and indicator lamp

Right joystick This is a four-way spring-centred joystick that controls knuckle jib and mw/ww
manoeuvres. Has buttons for selecting mw or ww, push-to-talk function (UHF/VHF
radios), a thumbwheel for controlling the right tugger winch, and a trigger-like
deadman’s switch on the front that must be pressed and held while working the
joystick.

Control enable on/off Turning this switch On enables the joysticks.

Note: To prevent accidents, always set in ‘Off’ position when leaving the operator
chair or when the crane is not being operated!

AHC/AT activate Blue button activates AHC or AT mode depending on which mode is selected on the
operator’s screen.

Emergency stop The large, red ES button locks in stop position when activated. To release turn the
button button counter clockwise.

Personnel lift  This key switch activates or deactivates personnel lift mode on the whip winch. The
enable/disable key can only be removed in normal mode. More info in the whip winch section.

Personnel lift This lamp lights when personnel lift mode is activated.
indicator lamp

Emergency Stop

AHC/CT/AT Personnel Lift

5 Operation

10 CARGOTEC NORWAY AS
 User Manual for Crane

3.7. Control Cabinet CC-100

General CC-100 is located behind the operator’s chair and contains the PLC, the
computer (PC) and other electric/electronic components presented in Chapter
3. The on/off key-switch for the entire control system is also located here.

Control system key- When this switch is turned Off, the emergency stop loop is de-energized,
switch meaning that no pumps or crane functions can be activated. This switch is
always turned off to ensure that the crane cannot be operated while service is
being performed. System off is also indicated by an alarm on the control
screen. This switch may be locked in the Off position.

Warning: This switch will stop the crane in any mode, including AHC/AT.

5 Operation
CARGOTEC NORWAY AS 11
 User Manual for Crane

3.8. Control Screen (HMI) HB001

3.8.1. General
Control screen HB001 is a 17” LCD touch screen with a graphic HMI (Human Machine Interface) used for
operating and monitoring crane functions. The HMI application runs on a Windows XP® PC, also in the CC-
100 cabinet, with an Ethernet connection to the control system PLC.

3.8.2. General Screen Elements and Layout

The control interface on the screen is designed to display the most vital data in an intuitive presentation.

Main functions 1. Alarm Banner (always on top) displays the last incoming alarm. This alarm is acknowledged on
the alarm screen or by pressing the yellow top switch on the left joystick. Described in further
detail in the alarm section.
2. Alarm Status Banner (always on top) displays the alarm status for different groups. Described in
further detail in alarm section.
3. Equipment and Functions Status Banner (always on top) displays the status of equipment and
functions by using different colours. Described in more detail below.
4. Field displaying the name of the active screen
5. Time and date field
6. Buttons for selecting either the Main- or Whip Winch (illus. next page).
7. Load indicator:
Green area: Load range for the selected crane derating. This range can change according to
mode, wave-height and dynamic factor.
Yellow area: Dynamic forces are acceptable. This range can change according to mode, wave-
height and dynamic factor.
Red area: Load exceeds 100% of maximum SWL for Internal Hs=0 in current mode
8. Menu button (menu presented next page).
9. Relative Knuckle Jib Angle Information. Press Rel. Knuckle Jib button for pop-up dialog box
(illustration next page).

1
5
4
2 3

5 Operation

12 CARGOTEC NORWAY AS
 User Manual for Crane

Bringing up displays

The following screens are defined and can be selected by touching the MENU button at the bottom
and selecting the desired screen from the menu (shown at right):

 Previous
 Setup
 Alarm
 Misc
 Tugger winches
 MW Lineup
 HPU
 Trend
 Main

The menu also has a Previous button at the top which will return the previous screen.

Choosing an item in this menu will not start any process.

Relative Knuckle Jib Angle dialog pop-up (9)

5 Operation
CARGOTEC NORWAY AS 13
 User Manual for Crane

Equipment/status The items in the Equipment and Function Status Banner are presented here:
indication
STATUS LINE FUNCTION
TEXT

Main AOPS 1. Grey: AOPS not enabled

2. Green: AOPS is enabled but not active
3. Flashing red: AOPS activated
Main MOPS 1. Grey: MOPS disabled
2. Green: MOPS is enabled but not active
3. Flashing red: MOPS activated
Main 2 part 1. Grey: Main winch double part disabled
2. Green: Main winch double part enabled
Whip AOPS 1. Grey: AOPS not enabled
2. Green: AOPS is enabled but not active
3. Flashing red: AOPS activated
Whip MOPS 1. Grey: MOPS disabled
2. Green: MOPS is enabled but not active
3. Flashing red: MOPS activated
IntLock Override 1. Grey: Interlocks are active
2. Orange: Operator has activated interlock
override

WARNING:

When interlock override is active, all safety

features in the crane control system are
deactivated. We recommend that a report is filled
out with the reason for activating this function each
time it is used.

Personnel lift 1. Grey: Whip Winch Personnel lift is

Active disabled.
2. Blue: Whip Winch Personnel lift is
enabled.
Control Enabled 3. Grey: Joysticks and foot pedals are
disabled.
4. Blue: Joysticks and foot pedals are enabled.

5 Operation

14 CARGOTEC NORWAY AS
 User Manual for Crane

General screen objects

General Screen objects are basically objects with a certain functionality attached to them.

Examples of screen objects are ‘bar graphs’. All bar graphs in the front screen
application have the same design and share the same basic functionality. Other
examples are numeric output fields etc.

Common functionality improves recognition, accelerates the learning curve and

simplifies the application. It is very important that the user is familiar with the
different properties of the screen objects.

General buttons Buttons in the HMI screen application are activated by touching them on the touch
screen. Some buttons, when touched, will produce a pop-up dialogue that prompts the
user for input. The various pop-up dialogues will now be presented in brief.

FUNCTION : DESCRIPTION

Grey Background : The function is not activated

Yellow Background : The function is activated

Grey Text on Button : The button is inhibited – cannot be operated

Background is : The associated function is active (the Main

Blinking Winch mode-selection buttons are typical
examples). After pressing Confirm, but before
AHC is ready, the button blinks.

S and R (Set/Reset) In some displays have an S or R button. These

buttons are places where specific settings are entered.
In all cases touching the button brings up a
dialogue to enter a new value or confirm a new
setting.

Bar Graphs Bar graphs are a vital part of the front screen application. These are used to show
system parameters both in analogue and numeric format.

The bar graphs used in the HMI screen application have a set of features associated
with them.

Bar graph scaling enables the operator to adjust the scale to suit the values expected in
the coming operation, or to zoom in to specific signal ranges. Touch the bar graph that
is to be adjusted. A pop-up dialogue with several options is displayed on the screen.
Use the selections to set a new maximum or minimum, for example, and then close the

5 Operation
CARGOTEC NORWAY AS 15
 User Manual for Crane

pop-up. The bar graph will now show the new settings.

A max/min marker function is included to help visualise the range of

a signal. When this function is active, two light blue lines are used to
continuously show the lowest and highest value shown by the bar
graph. For example, if this mode is active and the highest value ever
shown is 7.0, the “high” marker is next to the 7.0 point on the scale. If
the bar graph value exceeds this value, for example to 8.0, the “high”
marker is pushed up to the 8.0 point. Note that the low/high markers
for all bar graphs can be reset by touching the Set Markers button on
the bar graph pop-up that appears when the bar graph is touched.

A reference marker function is included as a help to the user. When

this function is active, a yellow line is “frozen” on the screen to
display a reference that the user can adjust as needed. This feature is
useful for observing variations.

Numeric output fields Numeric output fields are used to display

any real time value.

The output field states the name of the signal and the unit of measure.

All output fields have a light grey background and black numbers.

Touch the unit of measure to change the unit of the signal.

Input fields Numeric input fields are used to enter new values. The input field consists of the name
of the signal, and the unit of measure, if relevant.

All input fields have a white background and black text/numbers. After touching the
white area, a pop-up dialogue appears in which the user enters the appropriate input.

Status indicators Status indicators display the state of a

signal or a system. The lamps are grey by
default, and go red or green depending on the value of the signal.

Radio buttons Radio buttons are used to choose among different

choices.

Click inside the circle beside the item to be selected. If

the selection is approved by the control system, a black
dot is showed inside the circle indicating that the
selection has been carried out.

5 Operation

16 CARGOTEC NORWAY AS
 User Manual for Crane

Valve objects Two types of valves are used in the HMI screen application: valves which the operator
can open/close directly, and valves which the operator cannot open/close (operated by
the control system).

When the operator touches a valve object with direct control capabilities, a pop-up
dialogue will appear prompting to confirm a start or stop command.

The colour coding below is used to show the various modes of operation for all valve
objects with direct control functionality.

SYMBOL OBJECT FUNCTION

Steady grey fill No feedback and no

command signals are
attached to the object

The valve has been

Steady white fill
closed by the PLC

Flashes while the valve is

Flashing white and green
closing or opening

The valve has been

Steady green fill
opened by the PLC

5 Operation
CARGOTEC NORWAY AS 17
 User Manual for Crane

Pump objects The pumps are presented with colour codes indicating pump status.

SYMBOL OBJECT DESCRIPTION

Grey frame, white fill A grey frame indicates that the

pump is in remote mode, white
fill that it is ready

A yellow frame indicates that

Yellow frame, white fill the pump is in local mode,
white fill that it is ready to be
started

Grey fill Pump is not ready

Green fill Pump is running

Pump has stopped (tripped by

Red fill
system fault)

Pump is not available, for

Red X over pump instance when emergency
button is activated.

Filter objects The various filters are presented on the front screen with colour coding
indicating filter status.

SYMBOL OBJECT DESCRIPTION

Grey fill Grey fill indicates that the filter

is ok.

Red fill Red fill indicates that the filter

is clogged and needs servicing.

5 Operation

18 CARGOTEC NORWAY AS
 User Manual for Crane

4. Crane System Start and Stop

4.1. Pre-Start Preparations
Planning All operating factors must be considered by the operator before the crane is started.
The following conditions must be checked but are not limited to:

 Weight, COG and shape / added mass of the load(s) to be lifted

 Weather / environmental conditions
 An assessment of the actual lift job is to be performed on the basis of the first
two items. Lift mode and derating to be determined, limits identified, lifting
gear selected.
 A plan must be made for safe execution of the lifting operation. Deck area for
pick-up and landing of loads and the routing between are to be visually
checked for obstructions, clear view and maximum loading imposed on deck.

Equipment check The operator must first check the crane and all its systems and equipment:

 Check that lifting gear / loose gear is in good order and approved for the
purpose by a visual inspection of equipment and certificates.
 Visually inspect crane, wires, wire sheaves, machine room with pumps, hoses,
oil tank level and valves (visible leaks/defects).
 Check that emergency stop buttons in king are not activated.
 Check that the crane is fit for the operation and rigged for the job in question:
winch selection, reeving, hook height above deck, working radius etc.
 Communication with bridge

Control system Check that the Control System on/off switch (also called the service mode switch)
on/off switch located in control cabinet (CC-100), is ON (1).

Warning: If the key is in OFF position, always check whether any service
operations are being performed on the crane before switching ON and starting
up.

System checks Check that the emergency stop button in the cabin is not activated. If one or more
(in/from cabin) emergency buttons are activated an alarm will be displayed on the alarm screen and it
will not be possible to start any pumps.

Review alarm status to get an overview of the situation. Use the Alarm Status Banner
buttons to check unacknowledged alarms.
Check all active alarms and take the whatever steps are necessary to prepare for crane
operation.

Check HPU Status Choose the HPU screen from the menu. Check that the tank oil levels are acceptable
and that the temperature in the oil reservoir is ok.

Check that the Ctrl Enable switch on OP-104 (right operating panel) is Off.

5 Operation
CARGOTEC NORWAY AS 19
 User Manual for Crane

4.2. Normal Start – From Operator’s Control Screen in Cabin

Motor start-up (The HPU screen is still open from the HPU status check):

1. Starts each main pump by touching its motor symbol.

2. If the circulation motor is set to “Auto”, the circulation pump will automatically
start when a main pump is started. In “Manual” mode, the operator must start/stop
the circulation pump separately.
3. The CJC pump must be started manually, but it should normally be running, even
when the crane is not in use.

Cold weather If the oil temperature is under 0°C, close the shutoff valve downstream from the
start circulation/cooling pump. This will help the system warm up faster. Open the valve once
the oil temperature has reached 0°C.

After start Note: Motor symbols will flash until the start-up procedure is completed. Do not operate
the controls before these symbols have a steady green light.

 Check that oil level and temperature are acceptable, that all colour codes on the
HPU screen are normal (green motors, grey filters), and there are no critical
alarms on the alarm banner.
 Pay attention to the crane control system and respect the warnings and alarms it
gives.
 Is communication with the slinger / banksman satisfactory?
 Is communication with the bridge in order?

Once the HPU has started and system checks are complete, the crane is ready for
operation.

5 Operation

20 CARGOTEC NORWAY AS
 User Manual for Crane

The Ctrl Enable switch on OP-103 (left operating panel) remains Off if any mode is to be
selected or derating performed. Always turn this switch off before leaving (or entering)
the operator’s seat.

Details on how to operate the crane are described in later chapters.

4.3. Normal Shutdown

Turn off AHC/AT Check that AHC/ AT mode and constant tension (CT) modes are deactivated on
and CT modes whatever winches have them.

Park crane Park crane before initiating shutdown: knuckle jib folded in, main jib down, slew angle
at park and both knuckle jib and hook(s) in their cradles, if present.

Controls on/off Check that the Ctrl On/Off switch on operating panel OP-104 (right) is turned OFF.

Shut down The main pumps can now be stopped by touching the motor symbols on the HPU
screen to select them, and then touching the Stop button in the motor pop-up to stop
them.

The circulation pump will continue to run 5 minutes after the last main pump has
stopped. The circulation pump will stop automatically if it is set in “Auto” mode. The
CJC filter pump is left to run continually, even when the crane is not in use.

5 Operation
CARGOTEC NORWAY AS 21
 User Manual for Crane

5. HPU Control
5.1. General
Pumps The HPU consists of two single main pumps, one circulation pump, one CJC filter
pump and three oil coolers.

Local/remote pump For service purposes all pumps can be started and stopped locally at the starter panels.
control Set local/remote switches to Local.

To return pump control to the control system, the local/remote switches on the starter
panel in the king must be set to Remote, indicated in the control system by a grey
frame around the motor symbols.

Sensors Level and temperature sensors and switches on the oil reservoir send information to
the control system.

Pressure sensor switches on all system filters send signals to the control system when
clogged.

Analogue indications are given in the king (thermometer, sight glass, warning lights).

5 Operation

22 CARGOTEC NORWAY AS
 User Manual for Crane

5.2. HPU Operator Screens

5.2.1. General
The HPU screen shown below is opened by choosing HPU in the menu. The table underneath lists the main
functions on this screen.

6 8
5

2 10

Item no Description
1 Main pump status (1-2)
2 Circulation pump status
3 Filter symbol (red when clogged)
4 Pressure reading main pressure
5 Oil Temperature
6 Oil Tank Level in %
7 High temp alarm lamp
8 High and low level indication lamps and bar graph
9 Buttons for choosing the HPU or main winch lineup screens
10 CJC filter pump status

5 Operation
CARGOTEC NORWAY AS 23
 User Manual for Crane

Main Winch lineup This screen displays information about the valves in the hydraulic control system as
screen well as various pressure readings. It also provides oil cooler fan motor control.

The buttons along the bottom right provide easy access between the two HPU system
screens.

5 Operation

24 CARGOTEC NORWAY AS
 User Manual for Crane

5.2.2. Reservoir Surveillance

Feedback to the control system from the tank sensors and switches affects HPU start and stop, generates alarms
on the operator’s terminal and provides operating parameters for oil cooler control.

Analogue sensors SENSOR PARAMETER FUNCTION / RESPONSE

Temperature  Temp. reading on HMI display

Oil temperature
sensor  Alarm issued to operator
 HPU stop

Level/pressure SWITCH ALARM SYSTEM / RESPONSE

switches
Reservoir Reservoir Low level  Alarm indication on HPU screen
Low level alarm on HMI display
switch

Resevoir Reservoir LowLow  All pumps are stopped if they are

LowLow level alarm running.
level switch  Blocks pump start.
 Alarm indication on HPU screen
on HMI display

Resevoir Reservoir high level  Alarm indication on HPU screen
High level alarm on HMI display

Resevoir Reservoir HighHigh  Alarm indication on HPU screen

HighHigh level alarm on HMI display
level

Reservoir Reservoir High  Alarm indication on HPU screen

High temperature alarm on HMI display
temperature
switch

Reservoir Reservoir HighHigh  Alarm indication on HPU screen

HighHigh temperature alarm on HMI display
temperature
switch

5 Operation
CARGOTEC NORWAY AS 25
 User Manual for Crane

Filter status All hydraulic system filters have built-in pressure switches that signal the PLC when
the filter is clogged. When a pressure switch is activated, an alarm is generated in the
control system and displayed on the HMI screen, as described in earlier chapters.

Oil cooler The crane is equipped with seven forced-air oil coolers that can be set for manual or
manual/automatic automatic operation:
operation
MODE DESCRIPITON

Manual Manual mode is set by touching MAN in the Oil cooler motor
operation pop-up. This must be done for each cooler. Each cooler can
then be started and stopped by touching the OFF and ON buttons.

Note: The oil cooler will not start automatically when in manual
mode, which may lead to overheating, especially during AHC
operations.

Automatic Automatic mode is set by touching AUTO in the Oil cooler motor
(recommend operation pop-up. When automatic mode is selected, the coolers start
ed) at the following temperatures:

 Cooler 1: > 45 degrees C

 Cooler 2: > 50 degrees C
 Cooler 3: > 55 degrees C
 Cooler 4: < 59 degrees C

When automatic mode is selected, the coolers stop at following

temperatures:

 Cooler 1: < 44 degrees C

 Cooler 2: < 49 degrees C
 Cooler 3: < 54 degrees C
 Cooler 4: < 59 degrees C

5 Operation

26 CARGOTEC NORWAY AS
 User Manual for Crane

6. Normal Crane Operations (Normal Mode)

6.1. General
Normal crane operations consist of the following:

 Starting the pumps

 Rating/derating
 Main winch functions
 Whip winch functions
 Slew functions
 Main jib functions
 Knuckle jib functions
 Tugger winch functions

Starting the pumps All motor/pump units are started from the operator’s touch-screen in the cabin. Check
that the HPU is running at an idle pressure of approx. 40 bar. Check that the
circulation pump has started automatically. Make sure that the oil coolers are set Auto
to maintain proper temperature control during operation.

IMPORTANT! When planning to operate more than one crane function at a time, ALL pumps must be
running.

Loads are always lifted off the deck by using the winch. Any of the main jib,
knuckle jib and slew functions may then be used once the crane is carrying the
load.

Sections on Main and During crane operations, relevant information and controls are found in the Main and
Whip winches Whip screens on the operator’s terminal. All items on these screens will be briefly
presented in the sections on the two winches. The details on pop-ups and so on will be
presented in subsequent sections as their functions are presented.

5 Operation
CARGOTEC NORWAY AS 27
 User Manual for Crane

6.2. Load Parameters

Hook position and hook A rotational encoder is installed on the main winch for keeping track of hook
stops position and wire payout. The encoder registers nothing but the length of wire paid
out. Since the hook position follows the jib tip, and the jib tip’s position varies with
the main and knuckle jib angles without affecting wire payout, the control system
PLC must continuously use real-time crane geometry parameters to calculate the
hook’s true position.

The main winch has two upper hook stops and one lower hook stop

 Upper hook stop (calculated from encoder signals )

 Upper hook stop (signal from the hook stop proximity switches)
 Lower/end hook stop (calculated from encoder signals)

The upper (software) hook stop is activated by the control system when the
calculated hook position is less than the initialized zero meters. When upper hook
stop is reached, the knuckle jib in and main jib down movements stop.

The lower hook stop (end stop) is activated by the control system when three turns
are left on the winch drum. Payout stops, preventing the entire length of wire from
being run out. An alarm is given when the calculated wire payout is less than 50
metres from the end stop.

CAUTION! Wire stretch may cause inaccuracy in this function.

It is recommended that a verification of this function is included in the crane

operator’s daily check list.

Hook load sensor A dual bridge load cell fitted to the upper sheave hub on the knuckle jib measures the
main winch load. The load can be monitored on the HMI display in the cabin. Refer
to Cargotec Norway AS load charts for an overview of crane derating according to
radius and sea state.

Maximum load The maximum permissible load for the current crane derating and radius is displayed
inside the dial on the main screen.

An alarm is generated on the control screen and the cabin buzzer is activated when
90 % of max load is reached. At 110 % of maximum load the horn outside the cabin
will sound and an alarm will be generated on the operator display.

When the load reaches 110% of allowed maximum load, the main- and knuckle
jib will only be allowed to move to a smaller radius.

Crane Radius The radius is the calculated distance from jib tip to centre of crane king.

Crane radius is calculated from the main jib angle and knuckle jib angle registered
by the jib angle encoders.

5 Operation

28 CARGOTEC NORWAY AS
 User Manual for Crane

Interlocks The following states will halt winch up movement in normal mode:

 Upper hook stop

 Hook load > 130% of max load for Hs=0 (Dynamic overload)
 Main winch encoder error

The following will halt winch down movement in normal mode:

 Lower hook stop

 Main winch encoder error

Derating Derating comprises a range of parameters in specific situations, and is dealt with in
the following section.

5 Operation
CARGOTEC NORWAY AS 29
 User Manual for Crane

6.3. Crane Ratings

General The current crane rating is displayed in the upper right-hand corner of the current
winch screen (sections 5.7.3.1 (MW) and 5.7.4.1 (WW)). Touching the S button next
to the rating field opens one of the Crane Rating pop-ups shown below. The rating set
here will affect the maximum permissible hook load according to mode, sea state and
radius.

Modes The available modes are:

 Offshore Lift
 Ship to Ship Lift
 Engineered Subsea Lift
 Shipboard Lift

Derating maximum lift The control system computes the maximum permissible hook load relative to the crane
radius, based on mode selection and Dynamic Factor or Significant Wave Height input
in the Crane Rating dialog box.

This is the process called derating, which implements a reduction in crane capacity
reflecting the higher dynamic forces acting on the crane and load under certain
conditions

Significant wave heigth The Significant Wave Height input box is used in Offshore and Ship to Ship modes
for derating the crane according to the sea state.

Dynamic factor In Engineered Subsea Lift mode, a hydrodynamic analysis based on the specific
geometry of a load must be performed to obtain the dynamic factor for each specific
subsea lift.

See also section 5.9 Derating.

5 Operation

30 CARGOTEC NORWAY AS
 User Manual for Crane

6.4. Main Winch

6.4.1. General
The main winch is selected by touching the MW On button on the menu banner to the left of the main screen.
The winch is controlled by the right joystick y-axis: y-positive (pushing joystick) pays out, and y-negative
(pulling joystick) hauls in the wire.

6.4.2. MW Control Screens

When the main winch has been selected on the operator’s control terminal, the Main Winch Screen appears on
the display:

Main Winch screen

4 2 1
3

12

14
13
7 15

16

11

8 9

10

Screen items 1. Indicator showing currently selected Crane Rating

description 2. Button for opening dialogue for setting Crane Rating
3. Indicator showing currently selected Main Winch mode
4. Button for opening dialogue for selecting Main Winch mode.
5. Indication field showing whether the selected Main Winch mode is activated
or not.
6. Button for resetting the hook reference position.
7. Buttons for increasing/decreasing constant tension force
8. Button for resetting the main winch trip meter
9. Button for resetting the whip winch trip meter
10. Fields showing “relative” hook position (trip meter)
11. Fields showing hook position (measured from upper hook stop)
12. Radio buttons for selecting crane load range
13. Button for redefining the current crane load range
14. Button for opening crane systems information pop-up
15. Button for opening slew slow speed
16. Button for opening pop-up for selecting speed limits
5 Operation
CARGOTEC NORWAY AS 31
 User Manual for Crane

MW mode selection
pop-up

Main winch This pop-up gives the operator

information pop-up information on various pressure
readings and status items relevant
to the main winch.

5 Operation

32 CARGOTEC NORWAY AS
 User Manual for Crane

Crane information This pop-up gives the operator information on various pressure measurements
pop-up and status items relevant to other crane functions.

5 Operation
CARGOTEC NORWAY AS 33
 User Manual for Crane

6.5. Whip Winch

6.5.1. General
The whip winch is selected by touching the WW On button on the menu banner to the left of the main screen.
The winch is controlled by the right joystick y-axis: y-positive (pushing joystick) pays out, and y-negative
(pulling joystick) hauls in the wire.

6.5.2. WW Control Screens

When the whip winch has been selected on the operator’s control terminal, the Whip Winch Screen appears on
the display:

WW screen 4 1
3 2

6
9
14
8 15
7
16

10

11 12

13

Screen items 1. Indicator showing current Crane Rating

description 2. Button for opening Crane Rating dialogue
3. Indicator showing current Whip Winch mode
4. Button for opening dialogue for selecting Whip Winch mode
5. Indicator showing whether the selected Whip Winch mode is activated or not
6. Button for redefining the current crane load range
7. Radio buttons for selecting crane load range
8. Fields showing the hook position, (measured from upper hook stop)
9. Button for resetting the main winch trip meter
10. Button for resetting the whip winch trip meter
11. Fields showing “relative” hook position (trip meter)
12. Button for opening crane systems information pop-up
13. Button for opening slew slow speed
14. Button for opening pop-up for selecting speed limits

5 Operation

34 CARGOTEC NORWAY AS
 User Manual for Crane

Whip winch This pop-up gives the operator

information pop-up information on various pressure
readings and status items relevant to
the whip winch.

Crane information This pop-up gives the user information on various pressure readings and status items
pop-up relevant to other crane functions.

5 Operation
CARGOTEC NORWAY AS 35
 User Manual for Crane

6.5.3. Whip Winch Constant Tension

The constant tension has to be chosen from the whip winch mode select
menu which is opened by pressing the “S” next to the whip winch mode in
the upper left corner in the whip winch screen.

5 Operation

36 CARGOTEC NORWAY AS
 User Manual for Crane

Constant tension status

The different status for constant tension is presented below:

CT NOT ENABLED CT ENABLED, NOT CT ACTIVE

ACTIVE

Activating constant tension

1. Start main pumps

2. Open whip winch mode select menu and press constant tension mode and confirm.
3. The upper status field should change from “Normal” to “Constant tension” and the lower status field
should change from “Not Active” to “Ready”. Note that tension is not activated yet.
4. When the ready state is on, turn the CTRL ENABLE switch on the right control panel ON and then
press the blue AHC/AT/CT ACTIVATE button on the same panel.
5. The lower status field will now change from “Ready” to “Active” and to blue background with white
text.
6. The winch is now in constant tension, but the wire will only be pulled out if tension in wire is greater
than the tension set point. To pull in wire when tension in wire is less than set point, use the winch
joystick. Normally the joystick should be continuously activated in pull in direction.

Deactivating constant tension/lift off

1. When ready to lift off from the ship, pull winch joystick 100% in lifting direction.
2. Deactivate CT by pushing the AHC/AT/CT ACTIVATE button. When CT mode is not needed any
more, press the “Normal”-button to disable constant tension. The status text will change to “Normal”.

5 Operation
CARGOTEC NORWAY AS 37
 User Manual for Crane

6.5.4. Personnel Lift

General The whip and main winches are rated for a personnel lift mode. The indicator in the
status field shows if personnel lift is activated. The load indicator on the whip winch
screen is automatically scaled to fit the personnel lift load range. The winch gear
brakes engage when the joystick is centred or if an emergency stop or power failure
should occur.

Activating personnel This mode is activated by turning on the key switch on the right control panel (OP-
lift mode 104). If the hook load exceeds 1 ton, the mode is not activated until the load is less
than 1 ton. A load increase raising the hook load above 1 tonne will not deactivate
personnel lift mode, however but it will trigger an alarm.

Deactivating Turn off the personnel lift key switch on the left control panel (OP-104).
personnel lift mode

Personnel lift  Crane load is 130 % of max allowed load in personnel lift mode, winch up
interlocks movement is stopped.
 Whip Winch AOPS is disabled (status field becomes grey)
 Whip Winch MOPS is disabled (status field becomes grey)
 AHC/AT is disabled status field becomes grey)

Other operating  Mean wind velocity <10 m/s

prerequisites (except
 Significant wave height <2m
for emergency
operations)  Visibility Daylight
 The crane operator shall have a means of direct communication with the
personnel being lifted or with a banksman who has a direct view of the
personnel being lifted.
 Lifting of personnel shall only be performed using equipment specially
designed for the purpose, i.e. baskets conforming to EN14502-1.

6.6. Slew
Control The left joystick’s x-axis (left control panel OP-103) controls crane slew. Pushing the
joystick left slews the crane to the left (counter clockwise), and pushing the joystick
right slews the crane to the right (clockwise).

Centring the joystick as the crane is slewing will cause the control system to ramp
down the slew speed to zero, bringing crane slew to a smooth, controlled stop.

The displayed slew angle range is from zero to 360 degrees, where zero indicates the
crane pointing straight forward relative to the vessel. Angle value increases in right
(clockwise) direction. Crane slew is unlimited in both directions.

Interlocks The following will halt slew movement:

 Slew position encoder error

5 Operation

38 CARGOTEC NORWAY AS
 User Manual for Crane

6.7. Main Jib

Control The left joystick y-axis (operating panel OP-103) controls main jib movement.
Pushing the joystick forward lowers the main jib and pulling the joystick back raises
the main jib.

The position of the main jib is measured by an angle sensor, with the angle increasing
as the jib moves up. Zero degrees is when the main jib is at its lower end stop. Main
jib angle is displayed on the operator’s terminal.

Jib speed is reduced as it approaches its end-points to provide a smooth stop.

Main jib down movement is stopped if the active winch’s hook stop is reached
(indicated by alarms). The active winch’s wire must then be paid out in order to
continue the main jib’s down movement.

Interlocks The following will stop main jib up movement:

 End stop reached.

 Main jib angle encoder error.
 Main jib moving in wrong direction – alarm
 Main winch Hook load > 110% of max allowed load and increasing radius

The following will stop main jib down movement:

 End stop reached

 Whip winch hook stop
 Main winch hook stop
 Main winch Hook load > 110% of max allowed load and increasing radius
 Main jib moving in wrong direction - alarm.
 Main jib angle encoder error.

5 Operation
CARGOTEC NORWAY AS 39
 User Manual for Crane

6.8. Knuckle Jib

Control The right joystick x-axis (operating panel OP-104) controls knuckle jib movement.
Pressing the joystick right swings the knuckle jib out and pressing the joystick left
swings the knuckle jib in.

The position of the knuckle jib is measured by an angle sensor, with the angle
increasing as the jib swings out. The angle of the knuckle jib is relative to the main jib.
Zero degree is when the knuckle jib is perpendicular to the main jib. Knuckle jib angle
is displayed on the operator’s terminal.

Jib speed is reduced as it approaches its end-points to provide a smooth stop.

Knuckle jib in movement is stopped if the active winch’s hook stop is reached
(indicated by alarms). The active winch’s wire must then be paid out in order to
continue the knuckle jib’s in movement.

Knuckle jib out movement is stopped if the maximum hook load is exceeded.

Interlocks The following will stop knuckle jib out movement:

 Main winch Hook load > 110% of max allowed load and increasing radius
 End stop reached
 Knuckle jib angle encoder error.

The following will stop knuckle jib in movement:

 End stop reached

 Whip winch hook stop
 Main winch hook stop
 Knuckle jib angle encoder error
 Main winch Hook load > 110% of max allowed load and increasing radius

5 Operation

40 CARGOTEC NORWAY AS
 User Manual for Crane

6.9. Tugger Winches

General The following steps must be completed before running the tugger winch:

1. Ensure that at least one main pump is running.

2. Press the tugger winch enable button (TUGGER ON/OFF) on the left control
panel (OP-103).

The tugger winch is controlled with the left joystick thumb wheel

Caution There is no load or position monitoring on the tugger winch system. Use great caution
when operating the tugger winches!

Tugger Winch screen

1
4
2

Screen items 1. Field showing constant tension status for the tugger winch. Field becomes
description blue with white text when constant tension is activated. More details on
tugger winch constant tension later in this section.
2. Button for increasing constant tension force. Tension setting increases 5%
each time pushed.
3. Field showing constant tension reset force – the tension force that will be
applied when the R button next to this field is touched and confirmed in the
pop-up.
4. Bar graph showing actual constant tension force.
5. Button for decreasing constant tension force. Tension decreases 5% per push.

5 Operation
CARGOTEC NORWAY AS 41
 User Manual for Crane

Turntables The turntable is operated using the Tugger Turntable joystick in the left control panel
(OP-103).

Constant tension To operate the Tugger winch in constant tension mode, first press the tugger winch
enable (TUGGER ON/OFF) button. Constant Tension can then be activated by pressing
the Tugger CT on/off button in the left control panel (OP-103

). The button lights to indicate that CT mode is activate.

When CT mode is activated for the tugger winch, the joystick thumbwheel function
changes from up/down to higher/lower tension. Tension force changes in increments
of 5% of maximum winch capacity.

To deactivate tugger winch CT, press the Tugger CT on/off button. The button light
will turn off.

Caution If tugger winch CT function is activated with no load on the winch, the wire can
be pulled in rapidly, causing damage and/or personal injury.

5 Operation

42 CARGOTEC NORWAY AS
 User Manual for Crane

7. AHC and Auto Tension (AT) Operating Modes

7.1. Overview
Before activating these modes, it is important that the crane is in good operational condition (i.e. not in need of
service). It is also important that the circulation pump and the coolers are set to “Auto” to maintain proper
temperature control, as these modes generate a great deal of heat.

A preliminary test of AHC function at 50 m below the sea surface (suggested depth) is strongly recommended
to ensure that it is functioning properly before proceeding to working depth.

The AHC mode is normally activated when the load has been lowered to a suitable position above the seabed.
The crane should be positioned so that the wire is as close to the ship’s C.O.G. as practically possible to reduce
the effect of roll and pitch.

When AHC is activated and the distance between the hook and the seabed is satisfactory, the load can be
carefully lowered by means of the winch down joystick. When the load has been successfully landed, the hook
can be released.

Auto Tension mode is normally selected when picking up a load from the seabed where it is necessary to
overcome suction forces. When the crane is in AT mode the operator can increase the tension forces to pull the
load loose from the seabed. The winch will continue to hoist until the operator decreases the tension force
setting and achieves a steady, balanced lift.

Auto Tension mode uses a combination of position and force control. Another use for AT mode is to maintain
tension in the lifting slings to prevent lifting equipment from getting entangled with other equipment on the
seabed.

The Active Heave Compensation and Auto Tension modes are closely related, and will be described in this
section.

A motion reference unit (MRU) is mounted in control cabinet CC-300 in the pedestal, and feeds information
into the control system about vessel heave amplitude, heave velocity, roll and pitch.

The actual position of the jib tip is calculated by the control system. The most important information related to
AHC and AT is presented on the Main Screen on the HMI display.

When a mode is selected and confirmed, the system performs several preparation steps before it is ready for
AHC or AT. When the system is prepared, the selected mode can be activated by pressing the blue AHC/AT
Activate push button.

Compensation performance can be monitored on the HMI display.

5 Operation
CARGOTEC NORWAY AS 43
 User Manual for Crane

7.2. AHC / AT Restrictions

Before any lifting operation which includes AHC/AT mode, the following must be verified at the minimum:

 Check the weather forecast for the duration of the lifting operation being planned.
o Verify that the anticipated maximum nominal displacement (rise and fall) speed during
the operation will not exceed the maximum speed handled by the AHC system (see
Main Data in Ch 2.)
o Verify that wind speed will not exceed the maximum permitted wind speed during
operation (see Main Data in Ch 2 of this manual).
 Determine the optimum ship heading to reduce heave movement.
 Determine the position of the jib tip relative to the ship when in AHC/AT mode.

All possible measures should be taken to reduce dynamic forces on the crane by assessing ship position, crane
slew angle and radius. The closer to the ship’s side the lift can be undertaken, the lower the additional dynamic
forces on the crane.

Prior to the lifting operation:

 Derate the crane as described in Section 5.7.2 Crane Ratings (see also sections 5.9.1 and 5.9.2 on
derating).
 Verify that the heave velocity (as registered by the
control system) is below the max permissible speed.
To find this reading, starting from the Main
Winch/Whip Winch screen, touch the i button
halfway down the right screen border to open the
crane info list. On the Info List, touch i next to
Crane Status to open the Crane Status popup, which
displays a number of crane status readings,
including Heave Velocity.

Lower right corner of Crane Status popup

AHC/AT performance is usually stated in terms of wave height and period, i.e. A = 3.2m and T = 10 sec. This
combination will give the maximum continuous (nominal) heave velocity (v) according to the formula:

v = (2Aπ)/T

Example: (2 x 3.2 x 3.14) / 10 = 2.0 m/s.

Note: There are no limitations or interlocks in the control system that prohibit the operator from enabling
AHC/AT under adverse sea states, so the operator must first verify that crane tip motions are within the crane’s
AHC specifications for the load in question.

Weather reports usually give the expected sea state for the next 3, 6 or 12 hours in terms of anticipated wave
height Hs. Predicted figures are only a guideline and do not necessarily predict actual jib tip movement, which
also depends on the ship’s heading and where the jib tip is with reference to the ship CG.

5 Operation

44 CARGOTEC NORWAY AS
 User Manual for Crane

7.3. AHC and AT Mode Operating Instructions

General For all of these modes, the operator follows the same start-up procedure to put the
system in the ready state of the desired mode. From that point the operator activates
the selected mode.

The preparatory steps to get the system into a ready state will first be described. Then
the procedure for activating each mode and how to switch between the AHC and AT
modes will be presented.

Interlocks It is impossible to activate AHC, AHC High Speed or AT if any of the interlocks are
active; the mode buttons will then be inhibited (text shaded).

If an interlock condition occurs while in an active mode, the mode will deactivate and
the system will transfer to the Off mode.

Interlock conditions:

 Emergency stop activated

 No main pump running
 AOPS activated
 MOPS activated
 Hook less than 5.0 meters below jib tip
 Position Deviation more than 1.5 meters for more than 0.2 seconds.

In addition, the mode selection buttons will be inhibited if the Ctrl Enable switch on
the left operating panel is On or if the hook load exceeds SWL.

Preparation procedure 1. Start the HPU as described in sections 5.5.1 and 5.5.2.
(mode selection) 2. Open the relevant Winch Mode selection popup (next page) by touching the
S button next to the Main/Whip Winch Mode status indicator.
3. In the Mode Selection popup, touch the AHC, AHC High Speed or Auto
Tension mode button and then touch Confirm to start the preparation
sequence. The selected button now starts flashing while the sequence enables
the required valves and commands the required pressure. When the
preparation sequence is complete, the system is in the AHC/AT ready state,
and the mode selection button turns a steady yellow.

5 Operation
CARGOTEC NORWAY AS 45
 User Manual for Crane

If the buttons in
the Mode Select
popup are
inhibited, check
that none of the
interlocks listed in
section 5.7.1 are
active.

Ready mode The text in the upper status field has now changed to display the selected mode. Now,
the selected mode is in the ready state, and can be activated by the operator.

Activating a winch The current winch mode state, and whether the mode is active, are displayed in the
mode two indicator fields below the Main/Whip Winch Mode text on the main screen.
Three possibilities are displayed below.

OFF MODE AHC AUTO TENSION

READY MODE
READY MODE

During preparation for the ready state, which normally takes a few seconds, the
relevant mode selection button will flash (yellow/grey).

When the ready state is established (steady yellow mode selection button, white lower
status field with “Active” in grey text), turn the CTRL ENABLE switch on the left
control panel ON and then press the blue AHC/AT ACTIVATE button on the same
panel. The system will now proceed to the active state for the selected mode, indicated
by the lower status indicator field flashing “ACTIVE”.

5 Operation

46 CARGOTEC NORWAY AS
 User Manual for Crane

When the system reaches the active state, the lower status
field turns blue with white text while the upper status field
continues to display the mode.

Pressing the blue AHC/AT ACTIVATE push button again

deactivates the mode and returns the system to a ready state.
During this transfer, the lower status field flashes until the
ready state is reached and then turns a steady white with
black text.

It is possible to alternate between AHC and Auto Tension

modes, even when they are in the active state. Selecting the other mode in the mode
selection popup will tell the system that the next time the operator presses the blue
AHC/AT ACTIVATE push button, the system should switch to the selected mode and
remain in an active state.

If the system is in a ready state, the transfer between modes is done by simply
selecting the other mode in the mode selection popup. The text in the upper field then
changes to the selected mode.

When the other mode has been selected in the mode selection popup, the information
status field flashes one of the following texts:

AHC ACTIVE, AT READY AT ACTIVE, AHC READY

Pressing the blue AHC/AT ACTIVATE push button will initiate the transfer and the
lower status field will flash during transfer.

5 Operation
CARGOTEC NORWAY AS 47
 User Manual for Crane

Deactivating any The following steps deactivate any mode:

mode
1. Ensure that the Ctrl Enable switch is On.
2. Push the blue AHC/AT ACTIVATE push button, and the “Active” status
background on the main screen will turn white.
3. The active mode will now stop smoothly, taking a few seconds to come to a
complete stop. The system is now in the ready state for that mode.
4. The operator can reactivate that mode by performing the same procedure used
to activate it.
5. The operator can otherwise exit that mode completely by opening the mode
selection pop-up and touching Off. The “Off” button will start flashing to
indicate that shutdown is in progress.
6. When the Off button has stopped flashing, the stop procedure is complete,
and the system is now in normal mode.

Note: Pushing the emergency stop button during the shutdown procedure will prevent
the system from shutting down correctly.

Auto Tension The Auto Tension force is initially set to the actual hook load. Once AT is activated,
the operator can increase or decrease the force by pressing and/or holding the arrows.

By pressing R and then Reset , the tension force is reset to the initial hook load.

Note: The Auto Tension mode is still active if the Ctrl Enabled switch is turned off.

AHC High Speed AHC High Speed mode is used if a higher acceleration is needed due to choppy seas.
mode If the operator activates the wrong AHC mode, an alarm is given.

Note! When Auto Tension or AHC/AHC High Speed Mode is enabled, it is impossible, for
safety reasons, to deactivate an active winch (the relevant Winch On button on the
Main Screen left side banner is inhibited). When winch mode is turned off in the
MW/WW Mode Selection popup and the Winch Mode status box on the main screen
shows “Off”, it is possible to deactivate an active winch by touching the relevant
Winch On button on the Main Screen left side banner.

When Auto Tension is enabled, it is impossible, for safety reasons, to switch active
winches. The buttons for doing so are inhibited.

Slow Speed When this mode is activated, the whip winch speed is reduced by 50 0/0.

5 Operation

48 CARGOTEC NORWAY AS
 User Manual for Crane

8. Derating
8.1. Derating Overview
To prevent peak loads and dynamic forces from exceeding a crane’s design limits, it is necessary to restrict hook
load and operating radius in heavy seas (high significant wave height). A calm sea creates little need for
regulating maximum allowed hook load, and a crane can operate at full rated capacity. But rough seas and a
swaying crane subject the crane to considerable dynamic forces, and capacity must be reduced through a
procedure called derating. Each crane is supplied with its own load/derating curves which roughly indicate load
limits relative to radius in defined operating modes:

 Ship to Ship lift – This applies to a pickup or landing point defined by another vessel which is
moving independently. The derated capacity is based on an increase in the dynamic amplification
factor resulting from the higher relative velocities of the jib tip and the other vessel.
 Subsea Lift – This applies to a load landed on or retrieved from the sea bed. It presents special
challenges not present in the other two lift situations, with the geometry of the specific load
introducing unique variables, that cannot be reduced to parameters that can be programmed into a
control system. We provide the dynamic load capacity of the crane, but a full hydrodynamic analysis
based on the load’s specific geometry must be performed prior to the operation. This produces the
load’s Dynamic Factor, which the operator enters into the Crane Rating pop-up instead of Significant
Wave Height. Subsea lifts must be planned/calculated according to relevant regulations.
 Shipboard Lift – This applies to lifting appliances onboard being used to handle cargo both within
and outside the vessel, inside a harbour or sheltered waters (also within the vessel while at sea).

The fundamental factors involved in the overall derating challenge are:

 Higher forces acting on the crane as a result of increased crane base motion.
 Very high peak loads caused by high relative motion between the jib tip and the sea surface or the load
at rest.

If derating is required, the operator must open the Crane Rating pop-up and select the appropriate lifting mode
and enter the wave height (or dynamic factor). The control system then imposes reduced load/radius limits
automatically. But the load charts are based on analysis of normal operating practices and relevant standards,
and cannot cover all possible crane manoeuvres. The operator is therefore still responsible for careful
assessment, planning and execution of each lift and for a correct response to unforeseen situations.

See also section 5.7.2 Crane Ratings.

5 Operation
CARGOTEC NORWAY AS 49
 User Manual for Crane

Blank Page.

5 Operation

50 CARGOTEC NORWAY AS
 User Manual for Crane

8.2. Load Radius Diagrams / Work Area

See User Manual Volume 2 for:

 Engineered Subsea - Load Radius Diagram, SP2582-1-N-XX-002

 Ship to Ship Load Chart - Load Radius Diagram, SP2582-1-N-XX-003

5 Operation
CARGOTEC NORWAY AS 51
 User Manual for Crane

Blank Page.

5 Operation

52 CARGOTEC NORWAY AS
 User Manual for Crane

9. Emergency Procedures
9.1. Emergency Stop
Emergency stop (red When activated: All HPU pumps will shut down and all crane functions will stop. All
mushroom buttons) valves are de-energized.
Warning: An emergency stop will not de-energize all components in the system, and
the control system will still be powered up.
An alarm indication is displayed on the operator’s screen to inform the operator.

9.2. Restart After an Emergency Stop

Alarm Activation of the emergency stop will cause an alarm to appear on the operator’s
screen. This alarm must be acknowledged.

Identify cause of Check reason for emergency stop.

emergency stop
Check and correct errors and other potential problems.

Emergency stop Turn emergency stop button counter clockwise to release. Check emergency stop
buttons must be buttons in king (2) and in cabin (1).
reset

Execute start Resetting the emergency stop button will not start the system.
procedure from
HMI touch-screen

9.3. Emergency Release Functions (AOPS – MOPS) (MW and

WW)
9.3.1. Automatic Overload Protection System (AOPS)
The Automatic Overload Protection System automatically releases the wire in a controlled payout if the sensed
load exceeds maximum load including dynamic factor. As long as AOPS is activated, the winch will maintain a
retaining force corresponding to the relevant SWL.

AOPS is inaccessible when the jib tip is over deck, and is automatically made accessible when the jib tip is over
water.

AOPS enabled and/or active is displayed on the control terminal.

9.3.2. Manual Overload Protection System (MOPS)

A MOPS button for each winch is located on OP-103 (next to left joystick) and is fitted with a protective cover
to prevent inadvertent use.

5 Operation
CARGOTEC NORWAY AS 53
 User Manual for Crane

When the MOPS button is pressed, the winch will pay out wire while the system maintains a retaining force of
approximately 10-20% of maximum rated winch capacity. MOPS works independently of the control system
and is powered by batteries.

Both emergency release functions are inaccessible to winches operating in personnel-lift mode.

9.4. Emergency HPU Operation

A 75 kW emergency HPU is mounted inside the king for use in the event of control system (PLC/PC) failure,
HPU failure or power failure. This unit can power the crane for operation at reduced speeds.

When needed, the motor is connected to the ship’s normal or emergency power system by means of a jumper
cable and started from the emergency starter panel on cabinet ES-404 inside the king.

In the event of HPU or power failure, the crane can be operated from the cabin in the normal way using the
control system. If the control system has failed, the crane is operated from the emergency control unit stored
inside the king.

9.4.1. Emergency Operation Procedures

The emergency operation procedures are provided at Annex C - "Emergency Operation Procedures", and consist
of the following:

 Emergency operation procedure, part 1

 Crane emergency operation procedure, part 2
 Winch emergency operation procedure, part 2

5 Operation

54 CARGOTEC NORWAY AS
 User Manual for Crane

10. Alarms
10.1. General
This section describes the structure of the alarm functions in the operator panel.

1 2 3 4 6
5

Alarms are shown as follows:

1. Date is when the alarm was received and stamped by the front screen application system.
2. Time is the time the alarm was received and stamped by the front screen application system.
3. Priority shows alarm priority, from 1 (highest priority) to 19 (lowest alarm priority). Priority 1 to 4 is
sound alarms.
4. Group defines the alarm group the alarm is put in.
5. Comment shows the alarm description.
6. Value shows the status of the alarm when it was received.

5 Operation
CARGOTEC NORWAY AS 55
 User Manual for Crane

Buttons to sort and manage the alarms are located at the bottom of the display as the Alarm Control and Alarm
Query buttons. These functions are described in detail below.

Alarm structure The alarm system is organized as follows:

o All alarms are issued with a priority which specifies certain attributes that
determine whether they are sounded audibly and how they are displayed visually.
o A new alarm is always displayed in the alarm banner and in the alarm list. A
group connection is automatically created for sorting and grouping alarms.
o All alarms issued require operator acknowledgement.
o Returned alarms (the alarm condition has been resolved) are automatically
removed from the display. However, if an alarm state has existed and
subsequently been corrected, the received alarm will still be displayed until
acknowledged by the operator.

The alarm display will be continuously updated with new received and returned
alarms.

Alarm colours The following text colours are used in the alarm display:

TEXT COLOUR MEANING

Red New alarm waiting for operator

acknowledgement

Blue Alarm status ON, acknowledged

Green Disappeared, returned alarm, yet to

be acknowledged

Alarm Alarms can be acknowledged in two ways, either by pressing the dedicated “Alarm
acknowledgement Ack” button (yellow) on top of the left joystick or by using the “Ack Selected” or
“Ack All” buttons in the alarm display.

Pressing the alarm acknowledge button will acknowledge the last incoming alarm
shown in the alarm banner.

From the alarm display alarms can be acknowledged individually or by groups. To

select alarm to acknowledgement, click on the alarm in the display. Press and hold on
the touch screen to select several alarms.

o Click “Ack Selected” to acknowledge selected alarms.

o Click “Ack ALL” to acknowledge all alarms in the alarm group.

5 Operation

56 CARGOTEC NORWAY AS
 User Manual for Crane

Status Banner The Status Banner (top of screen) indicates alarm states in different alarm groups by
means of:

o A red frame indicating an active (standing) alarm within the alarm group.
o A blinking red frame indicating a new (unacknowledged) alarm within the alarm
group.

Touch the desired alarm group. The alarm display for that group will appear with
alarms sorted in chronological order.

The Status Banner is further described in other parts of the user manual.

Alarm Banner The Alarm Banner (single line) displays at all times the latest received alarm until the
alarm is acknowledged. If no alarm is present, no alarm is shown in the alarm banner.

Alarms are sorted by original alarm time, meaning that they are buffered for the alarm
banner according to the time they were received by the HMI system. When the user
acknowledges alarms with the Alarm Acknowledge button on the left joystick, they
are acknowledged in the order they were received by the buffer. This order may differ
slightly between the two display modes described below.

Alarm status vs. alarm The alarm display may appear in either of two modes:
history
o If the alarm display is in Alarm Status mode, the current alarm situation with
only standing alarms plus unacknowledged returned alarms (alarms that have
been resolved but not acknowledged) is displayed. Alarms are listed in
chronological order.
o If the alarm display is in Alarm History mode, all alarm events (received alarms,
acknowledged alarms and returned alarms) in the selected alarm groups are
displayed. This list, too, is presented in chronological order.

Touch the appropriate button to select the desired alarm display.

Display mode is shown in the top left corner of the alarm display. Alarm status is the
default mode.

Responsibility of the The alarm system is a vital part of the operator’s perception of the overall information
user! and safety environment at all times. Every effort has been made to implement a safe
and simple system to focus the user’s attention on important alarms and to keep lesser
alarms from causing a distraction.

It is also important that the operator informs other users of alarms that are blocked or
silenced whenever such situations may present a safety hazard.

Alarm query Sometimes the operator needs to investigate and identify alarms and alarm
combinations. The HMI interface provides comprehensive functions to help the
operator in such cases.

5 Operation
CARGOTEC NORWAY AS 57
 User Manual for Crane

The alarm system is divided into different alarm groups. Alarm groups have been
defined around logical groups, i.e. typically one alarm group per part of the crane.

Each alarm group may consist of one or more subgroups. These subgroups are
accessible by selecting and performing a new alarm query. The alarm display shows
alarms for selected alarm groups according to the latest alarm query.

There are two ways to do an alarm query:

o Touch the group symbol in the status banner. The alarm status display will appear
with the alarm query for the selected group.
o In the alarm status display a new alarm query can be selected with the “New
Query” button. A menu for query selection will appear.

Touch “Alarm Query” to bring up the alarm query pop-up which will place itself over
the lower buttons in the alarm display.

Alarm query The alarm query pop-up offers two ways of selecting alarm groups:
functions
o Touch “All Alarms” to see all defined alarm groups.
o Touch “System” to see all global alarms.

Use the following buttons to structure your search for alarms:

Alarm groups:

GROUP DESCRIPTION

HPU Hydraulic power unit alarms

CR Crane alarms

MW Main winch alarms

WW Whip winch alarms

AHC Active heave compensation alarms

MISC Misc alarms

The following parameters may also be included in the query:

o Status or history display (Status is default)

o Select unacknowledged
o Select acknowledged
o Select all (default)

5 Operation

58 CARGOTEC NORWAY AS
 User Manual for Crane

10.2. Alarm Description

The following list presents the main operational alarms of the system. The alarms are presented with Tag info,
alarm text, alarm group and alarm description.

5 Operation
CARGOTEC NORWAY AS 59
 User Manual for Crane

10.2.1. Alarm List

General System
Item TAG info (HMI) Alarm text (HMI) Group Alarm description Activation criteria Alarm Effect
(HMI) delay [s]

2.0 CR_Emergenc Emergency Stop CR Any emergency stop  Any emergency None All crane functions
yStop Activated activated stop button except MOPS are
activated aborted/stopped.
 NOT Service mode
activated.

2.1 CR_Emergenc Emergency stop CR Emergency stop  Emergency stop None All crane functions
yStop_S0 on/off activated –ES400 button on –ES400 except MOPS are
cubicle activated aborted/stopped.
 NOT Service mode
activated.

2.2 CR_Emergenc Emergency stop CR Emergency stop  Emergency stop None All crane functions
yStop_S04 on/off activated –ES404 button on –ES404 except MOPS are
cubicle activated aborted/stopped.
 NOT Service mode
activated.

2.3 CR_ServiceMo Emergency Stop CR Service mode switch  “Crane control None Crane disabled.
de - Service Mode activated – crane lock system” key switch
out put in disabled
MOPS still available.
position.

5 Operation
CARGOTEC NORWAY AS 60
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm description Activation criteria Alarm Effect
(HMI) delay [s]

2.4 CR_IntLockOv Interlock CR Interlock button  Interlock override None Overrides crane
erride_STA Override override – all activated. function interlocks.
interlocks disabled

2.5 CR_JS_Right_ Right Joystick COM Right Joystick -  Profibus None Joystick operation of
ERR error - DP19 Profibus communication Winch and Knuckle
communication error error with right Jib disabled.
Joystick.
2.6 CR_JS_Left_E Left Joystick COM Left Joystick -  Profibus None Joystick operation of
RR error - DP18 Profibus communication Slew and Main Jib
communication error error with left disabled.
Joystick.
2.7 CR_MOPS_Ch MOPS Battery CR MOPS battery  Missing input from None Alarm only.
gBrk_TRP charging breaker charging error – Fuse breaker delivering
- Tripped tripped charging power to
the MOPS
batteries.
2.8 CR_MOPS_Ba MOPS Battery CR MOPS Battery NOT  Missing OK input None Alarm only.
ttery_Fault1 NOT OK OK signal from MOPS
battery guard.
2.9 CR_MOPS_Ba MOPS Battery CR MOPS Battery NOT  Missing ready None Alarm only.
ttery_Fault2 NOT ready ready input signal from
MOPS battery
guard.
2.10 CR_MOPS_Ba MOPS Battery < CR MOPS Battery < 85%  Battery < 85% None Alarm only.
ttery_LOW 85% charged charged charged. Signal
from MOPS
battery guard.
2.11 MISC_RollAngl Roll Angle High MISC MRU roll ≥ 6,0  MRU roll > 6,0 1 Alarm only.
e_H degree. degree.

5 Operation
CARGOTEC NORWAY AS 61
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm description Activation criteria Alarm Effect
(HMI) delay [s]

2.12 MISC_MRU_E MRU - Signal MISC MRU error – analog  Error signal None AHC/AT
RR Error outputs from MRU not received from the terminated/inhibited.
OK. MRU.

2.13 IC300_ERR CC-300 - COM CC-300 – Profibus  Profibus None Loss of remote i/o
Remote IO Error communication error communication station will cause
- DP3 error with more alarms.
communication
module in CC300.
2.14 IC400_ERR ES-400 - Remote COM ES-400 - Profibus  Profibus None Loss of remote i/o
IO Error - DP4 communication error communication station will cause
error with more alarms.
communication
module in CC400.
2.15 Encoder_MW_ Main Winch COM Main Winch Encoder -  Profibus None Stops winch in any
ERR Encoder IO Error Profibus communication mode.
- DP11 communication error error with Main
Winch encoder.

2.16 Encoder_MJ_A Main Jib Encoder COM Main Jib Encoder A  Profibus None Main Jib Encoder B is
_ERR A IO Error - Profibus communication automatically
DP13 communication error error with Main Jib selected.
A encoder.
Stops jib if both
encoders are failing.

2.17 Encoder_MJ_B Main Jib Encoder COM Main Jib Encoder B -  Profibus None Main Jib Encoder A is
_ERR B IO Error - Profibus communication automatically
DP14 communication error error with Main Jib selected.
B encoder.

5 Operation

62 CARGOTEC NORWAY AS
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm description Activation criteria Alarm Effect
(HMI) delay [s]

Stops jib if both

encoders are failing.

2.18 Encoder_WW_ Whip Winch COM Whip Winch Encoder  Profibus None Stops winch in any
ERR Encoder IO Error - Profibus communication mode.
- DP12 communication error error with Whip
Winch encoder.

2.19 Encoder_KJ_A Knuckle Jib COM Knuckle Jib Encoder -  Profibus None Knuckle Jib Encoder
_ERR Encoder A IO Profibus communication B is automatically
Error - DP16 communication error error with Knuckle selected.
Jib A encoder.
Stops jib if both
encoders are failing.

2.20 Encoder_KJ_B Knuckle Jib COM Knuckle Jib Encoder -  Profibus None Knuckle Jib Encoder
_ERR Encoder B IO Profibus communication A is automatically
Error - DP17 communication error error with Knuckle selected.
Jib B encoder.
Stops jib if both
encoders are failing.

2.21 Encoder_Slew Slew Encoder IO COM Slew Encoder -  Profibus None Stops slew operation
_A_ERR Error - DP10 Profibus communication if both encoders are
communication error error with Slew A failing.
encoder.
2.22 Encoder_Slew Slew Encoder IO COM Slew Encoder -  Profibus None Stops slew operation
_B_ERR Error - DP30 Profibus communication if both encoders are
communication error error with Slew B failing.
encoder.

5 Operation
CARGOTEC NORWAY AS 63
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm description Activation criteria Alarm Effect
(HMI) delay [s]

2.23 Encoder_WW_ Whip Winch COM Whip Winc Spooling  Profibus None Stops spooling
SpoolPos_ER Spooling Encoder - Profibus communication device.
R Encoder IO Error communication error error with Whip
- DP15 Winch Spooling
encoder.
2.24 CR_Overload Grease Pump CR Grease Pump M55 for  To long interval 7 Alarm only.
M55 M55 overloaded crane functions is between feedback
overloaded and not pulses.
moving  Grease Pump
activated.
2.25 CR_GreasePu Grease Pump CR Grease pump for  Grease pump for None Alarm only.
mpM55Disable M55 disabled crane functions crane functions
d disabled. disabled.

2.26 CR_Overload Grease Pump CR Grease Pump M56 for  To long interval 7 Alarm only.
M56 M56 overloaded Main Winch is between feedback
overloaded and not pulses.
moving  Grease Pump
activated.
2.27 CR_GreasePu Grease Pump CR Grease pump for  Grease pump for None Alarm only.
mpM56Disable M56 disabled Main Winch disabled. Main Winch
d disabled.

2.28 CR_LubeMon1 No grease flow - CR No grease flow  No pulses from the None Alarm only.
NoFlowM55 Lubrication detected by the lubrication monitor
Monitor 1 on - lubrication monitor 1  More than 20
M55 on –M55 pulses from the
lubrication pump
2.29 CR_LubeMon2 No grease flow - CR No grease flow  No pulses from the None Alarm only.
NoFlowM55 Lubrication detected by the lubrication monitor
Monitor 2 on - lubrication monitor 2  More than 20
pulses from the
lubrication pump

5 Operation

64 CARGOTEC NORWAY AS
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm description Activation criteria Alarm Effect
(HMI) delay [s]

M55 on –M55

2.30 CR_LubeMon3 No grease flow - CR No grease flow  No pulses from the None Alarm only.
NoFlowM56 Lubrication detected by the lubrication monitor
Monitor 3 on - lubrication monitor3  More than 20
M56 on –M56 pulses from the
lubrication pump
2.31 Software_ERR Software error CR Error in PLC software  PLC has None Alarm only.
encountered a
program error in
the software
2.32 Module_ERR I/O-Access error CR PLC I/O access error  PLC has detected None Alarm only.
an I/O access error
2.33 CR_WindSpee Wind Speed – CR Cable break or faulty  Input signal <> 4- None Alarm only.
d_ERR Sensor Fault sensor. 20mA.

2.34 CR_WindDirec Wind Direction – CR Cable break or faulty  Input signal <> 4- None Alarm only.
tion_ERR Sensor Fault sensor. 20mA.

5 Operation
CARGOTEC NORWAY AS 65
 User Manual for Crane

Hydraulic Power Unit (HPU)

Item TAG info (HMI) Alarm text (HMI) Group Alarm description Activation criteria Alarm Effect
(HMI) delay [s]

3.0 HPU_TankLev HPU Reservoire HPU Cable break or faulty  Input signal <> 4- None Alarm only. (HPU is
el_ERR Level - Signal sensor. 20mA. stopped if both
Error pressure transmitter
error and level switch
error.)

3.1 HPU_Tank1Le Oil Tank 1 Level HPU HPU oil level sensor  Signal from Low None Alarm only. (HPU is
velSwitch_ERR Switch - Sensor fault. Cable break or Low switch stopped if both
Fault faulty sensor.  NOT Signal from pressure transmitter
Low switch error and level switch
error.)

3.2 HPU_TankLev HPU Reservoire HPU HPU oil tank level less  Signal from Low None Alarm only.
el_L Level - Low than 55 % level switch
Alarm  IF “HPU reservoir
Level switch –
sensor fault” is
active:
o PT-level
sensor ≤
55 %.
3.3 HPU_TankLev HPU Reservoire HPU HPU oil tank level less  Signal from Low None HPU is
el_LL Level - Low Low than 50 % Low switch stopped/disabled.
Alarm  IF “HPU reservoir
Level switch –
sensor fault” is
active:
o PT-level
sensor ≤
50 %.

5 Operation

66 CARGOTEC NORWAY AS
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm description Activation criteria Alarm Effect
(HMI) delay [s]

3.4 HPU_TankLev HPU Reservoire HPU HPU oil tank level  HPU tank level > 1 Alarm only.
el_H Level - High above 95 % 95 %
Alarm

3.5 HPU_TankLev HPU Reservoire HPU HPU oil tank level  HPU tank level > 1 Alarm only.
el_HH Level - High High above 100 % 100%
Alarm

3.6 HPU_Tank1Te Oil Tank 1 HPU HPU oil temperature  Signal from high None Alarm only.
mpSwitch_ER Temperature sensor fault. Cable high switch
R Switch - Sensor break or faulty sensor.  NOT Signal from
Fault high switch

3.7 HPU_TankTem HPU Tank HPU Cable break or faulty  Input signal <> 4- None Alarm only.
p_ERR Temperature - temperature sensor. 20mA.
Signal Error (TT201)

3.8 HPU_TankTem HPU Tank HPU HPU tank temperature  HPU tank None Inhibits HPU start.
p_L Temperature Too below 10 degrees temperature < 10
Low To Start Celsius. Main pumps degrees
Main Pumps start inhibited to  NO main motors
prevent damage. running
 Main motor start
button activated
3.9 HPU_TankTem HPU Tank HPU HPU reservoir - high  Temperature None Alarm only.
p_H Temperature - temperature readout from
High Alarm PT100 - element >
70 ºC
 NOT tank
temperature
sensor error
3.10 HPU_TankTem HPU Tank HPU HPU reservoir - high  Temperature None Alarm only.
p_HH Temperature - high temperature readout from
PT100-element ≥
80 ºC

5 Operation
CARGOTEC NORWAY AS 67
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm description Activation criteria Alarm Effect
(HMI) delay [s]

High High Alarm  IF PT100 element

signal error (input
outside 4-20mA
range)
o High high
temp.
switch
3.11 HPU_MP1_TR HPU M1 - Main HPU Motor start/stop  Motor running None Alarm only.
P Pump 1 - Tripped tripped feedback not
received within
specified start/stop
time
 Loss of running
signal when stop is
not commanded
 Tripped signal from
motor “thermal
protection”
3.12 HPU_MP2_TR HPU M2 - Main HPU Motor start/stop  Motor running None Alarm only.
P Pump 2 - Tripped tripped feedback not
received within
specified start/stop
time
 Loss of running
signal when stop is
not commanded
 Tripped signal from
motor “thermal
protection”
3.13 HPU_MP3_TR HPU M3 - Main HPU Motor start/stop  Motor running None Alarm only.
P Pump 3 - Tripped tripped feedback not
received within
specified start/stop
time
 Loss of running
signal when stop is
not commanded

5 Operation

68 CARGOTEC NORWAY AS
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm description Activation criteria Alarm Effect
(HMI) delay [s]

 Tripped signal from

motor “thermal
protection”
3.14 HPU_MP4_TR HPU M4 - Main HPU Motor start/stop  Motor running None Alarm only.
P Pump 4 - Tripped tripped feedback not
received within
specified start/stop
time
 Loss of running
signal when stop is
not commanded
 Tripped signal from
motor “thermal
protection”
3.15 HPU_CircPum HPU M10 - Circ HPU Motor start/stop  Motor running None Alarm only.
p_TRP Pump - Tripped tripped feedback not
received within
specified start/stop
time
 Loss of running
signal when stop is
not commanded
 Tripped signal from
motor “thermal
protection”
3.16 HPU_CJCPum HPU M11 - CJC HPU Motor start/stop  Motor running None Alarm only.
p_TRP Pump - Tripped tripped feedback not
received within
specified start/stop
time
 Loss of running
signal when stop is
not commanded
 Tripped signal from
motor “thermal
protection”

5 Operation
CARGOTEC NORWAY AS 69
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm description Activation criteria Alarm Effect
(HMI) delay [s]

3.17 HPU_Cooler1_ HPU M20 - HPU Motor start/stop  Motor running None Alarm only.
TRP Cooler 1 - tripped feedback not
Tripped received within
specified start/stop
time
 Loss of running
signal when stop is
not commanded
 Tripped signal from
motor “thermal
protection”
3.18 HPU_Cooler2_ HPU M21 - HPU Motor start/stop  Motor running None Alarm only.
TRP Cooler 2 - tripped feedback not
Tripped received within
specified start/stop
time
 Loss of running
signal when stop is
not commanded
 Tripped signal from
motor “thermal
protection”
3.19 HPU_Cooler3_ HPU M22 - HPU Motor start/stop  Motor running None Alarm only.
TRP Cooler 3 - tripped feedback not
Tripped received within
specified start/stop
time
 Loss of running
signal when stop is
not commanded
 Tripped signal from
motor “thermal
protection”
3.20 HPU_Cooler4_ HPU M23 - HPU Motor start/stop  Motor running None Alarm only.
TRP Cooler 4 - tripped feedback not
Tripped received within
specified start/stop

5 Operation

70 CARGOTEC NORWAY AS
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm description Activation criteria Alarm Effect
(HMI) delay [s]

time
 Loss of running
signal when stop is
not commanded
 Tripped signal from
motor “thermal
protection”
3.21 HPU_Cooler5_ HPU M24 - HPU Motor start/stop  Motor running None Alarm only.
TRP Cooler 5 - tripped feedback not
Tripped received within
specified start/stop
time
 Loss of running
signal when stop is
not commanded
 Tripped signal from
motor “thermal
protection”
3.22 HPU_Cooler6_ HPU M25 - HPU Motor start/stop  Motor running None Alarm only.
TRP Cooler 6 - tripped feedback not
Tripped received within
specified start/stop
time
 Loss of running
signal when stop is
not commanded
 Tripped signal from
motor “thermal
protection”
3.23 HPU_Cooler7_ HPU M26 - HPU Motor start/stop  Motor running None Alarm only.
TRP Cooler 7 - tripped feedback not
Tripped received within
specified start/stop
time
 Loss of running
signal when stop is
not commanded

5 Operation
CARGOTEC NORWAY AS 71
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm description Activation criteria Alarm Effect
(HMI) delay [s]

 Tripped signal from

motor “thermal
protection”
3.24 HPU_EmPump Emergency HPU Motor start/stop  Motor running None Alarm only.
_TRP Pump M31 tripped feedback not
tripped received within
specified start/stop
time
 Loss of running
signal when stop is
not commanded
 Tripped signal from
motor “thermal
protection”
3.25 HPU_CoolingF HPU M61 - HPU Motor start/stop  Motor running None Alarm only.
an_TRP Cooling Fan - tripped feedback not
Tripped received within
specified start/stop
time
 Loss of running
signal when stop is
not commanded
 Tripped signal from
motor “thermal
protection”

3.26 HPU_MP1_Po Main Pump 1 - HPU Main motors, power  Signal from starter 5 Motor stops.
werMissing Power Missing missing. Check supply cabinet (digital).
and fuses. Voltage < 90% of
normal.
3.27 HPU_MP2_Po Main Pump 2 - HPU Main motors, power  Signal from starter 5 Motor stops.
werMissing Power Missing missing. Check supply cabinet (digital).
and fuses. Voltage < 90% of
normal.

5 Operation

72 CARGOTEC NORWAY AS
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm description Activation criteria Alarm Effect
(HMI) delay [s]

3.28 HPU_MP3_Po Main Pump 3 - HPU Main motors, power  Signal from starter 5 Motor stops.
werMissing Power Missing missing. Check supply cabinet (digital).
and fuses. Voltage < 90% of
normal.
3.29 HPU_MP4_Po Main Pump 4 - HPU Main motors, power  Signal from starter 5 Motor stops.
werMissing Power Missing missing. Check supply cabinet (digital).
and fuses. Voltage < 90% of
normal.
3.30 HPU_Circ_Po Cicrulation Pump HPU Circulation Pump  Signal from starter None Motor stops.
werMissing - Power Missing power missing. Check cabinet (digital).
supply and fuses. Voltage < 90% of
normal.
3.31 HPU_CJC_Po CJC Pumps - HPU CJC Pump power  Signal from starter None Motor stops.
werMissing Power Missing missing. Check supply cabinet (digital).
and fuses. Voltage < 90% of
normal.
3.32 HPU_Cooler1_ Cooler 1 - Power HPU Cooler motor power  Signal from starter None Motor stops.
PowerMissing Missing missing. Check supply cabinet (digital).
and fuses. Voltage < 90% of
normal.
3.33 HPU_Cooler2_ Cooler 2 - Power HPU Cooler motor power  Signal from starter None Motor stops.
PowerMissing Missing missing. Check supply cabinet (digital).
and fuses. Voltage < 90% of
normal.
3.34 HPU_Cooler3_ Cooler 3 - Power HPU Cooler motor power  Signal from starter None Motor stops.
PowerMissing Missing missing. Check supply cabinet (digital).
and fuses. Voltage < 90% of
normal.
3.35 HPU_Cooler4_ Cooler 4 - Power HPU Cooler motor power  Signal from starter None Motor stops.
PowerMissing Missing missing. Check supply cabinet (digital).
and fuses. Voltage < 90% of
normal.

5 Operation
CARGOTEC NORWAY AS 73
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm description Activation criteria Alarm Effect
(HMI) delay [s]

3.36 HPU_Cooler5_ Cooler 5 - Power HPU Cooler motor power  Signal from starter None Motor stops.
PowerMissing Missing missing. Check supply cabinet (digital).
and fuses. Voltage < 90% of
normal.

3.37 HPU_Cooler6_ Cooler 6 - Power HPU Cooler motor power  Signal from starter None Motor stops.
PowerMissing Missing missing. Check supply cabinet (digital).
and fuses. Voltage < 90% of
normal.

3.38 HPU_Cooler7_ Cooler 7 - Power HPU Cooler motor power  Signal from starter None Motor stops.
PowerMissing Missing missing. Check supply cabinet (digital).
and fuses. Voltage < 90% of
normal.

3.39 HPU_DrainFilt Main pump drain HPU Clogged oil filter.  Oil tank 10 Alarm only.
er filter pressure Replace filter element. temperature ≥
switch 30ºC
 Loss of signal from
pressure switches

3.40 HPU_WinchDr Winch motor HPU Clogged oil filter.  Oil tank 10 Alarm only.
ainFilter Drain Filter Replace filter element. temperature ≥
30ºC
 Loss of signal from
pressure switches
3.41 HPU_ReturnFil Return filter 1 HPU Clogged oil filter.  Oil tank 10 Alarm only.
ter1 pressure switch Replace filter element. temperature ≥
30ºC
 Loss of signal from
pressure switches

3.42 HPU_ReturnFil Return filter 2 HPU Clogged oil filter.  Oil tank 10 Alarm only.
temperature ≥

5 Operation

74 CARGOTEC NORWAY AS
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm description Activation criteria Alarm Effect
(HMI) delay [s]

ter2 pressure switch Replace filter element. 30ºC

 Loss of signal from
pressure switches

3.43 HPU_ReturnFil Return filter 3 HPU Clogged oil filter.  Oil tank 10 Alarm only.
ter3 pressure switch Replace filter element. temperature ≥
30ºC
 Loss of signal from
pressure switches

3.44 HPU_ReturnFil Return filter 4 HPU Clogged oil filter.  Oil tank 10 Alarm only.
ter4 pressure switch Replace filter element. temperature ≥
30ºC
 Loss of signal from
pressure switches

3.45 HPU_CJCFilter CJC Filter HPU Clogged oil filter.  Oil tank 10 Alarm only.
pressure switch Replace filter element. temperature ≥
30ºC
 Loss of signal from
pressure switch

3.46 HPU_MainFilte Main filter 1A HPU Clogged oil filter.  Oil tank 10 Alarm only.
r1A pressure switch Replace filter element. temperature ≥
30ºC
 Loss of signal from
pressure switches

3.47 HPU_MainFilte Main filter 1B HPU Clogged oil filter.  Oil tank 10 Alarm only.
r1B pressure switch Replace filter element. temperature ≥
30ºC
 Loss of signal from
pressure switches

5 Operation
CARGOTEC NORWAY AS 75
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm description Activation criteria Alarm Effect
(HMI) delay [s]

3.48 HPU_MainFilte Main filter 2 HPU Clogged oil filter.  Oil tank 10 Alarm only.
r2 pressure switch Replace filter element. temperature ≥
30ºC
 Loss of signal from
pressure switches
3.49 HPU_MainFilte Main filter 2 HPU Clogged oil filter.  Oil tank 10 Alarm only.
r2B pressure switch Replace filter element. temperature ≥
30ºC
 Loss of signal from
pressure switches
3.50 HPU_MainFilte Main filter 3 HPU Clogged oil filter.  Oil tank 10 Alarm only.
r3 pressure switch Replace filter element. temperature ≥
30ºC
 Loss of signal from
pressure switches
3.51 HPU_MainFilte Main filter 3B HPU Clogged oil filter.  Oil tank 10 Alarm only.
r3B pressure switch Replace filter element. temperature ≥
30ºC
 Loss of signal from
pressure switches
3.52 HPU_MainFilte Main filter 4 HPU Clogged oil filter.  Oil tank 10 Alarm only.
r4 pressure switch Replace filter element. temperature ≥
30ºC
 Loss of signal from
pressure switches
3.53 HPU_MainFilte Main filter 4B HPU Clogged oil filter.  Oil tank 10 Alarm only.
r4B pressure switch Replace filter element. temperature ≥
30ºC
 Loss of signal from
pressure switches
3.54 HPU_KingDrai Slew / Tugger HPU Clogged oil filter.  Oil tank 10 Alarm only.
nFilter Drain Filter Replace filter element. temperature ≥
30ºC
 Loss of signal from
pressure switches

5 Operation

76 CARGOTEC NORWAY AS
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm description Activation criteria Alarm Effect
(HMI) delay [s]

3.55 HPU_OilRecov Oil Recovery HPU Clogged oil filter.  Signal received None Alarm only.
eryFilter Filter pressure Replace filter element. from Oil Recovery
switch Filter pressure
switch.
3.56 HPU_DrainTan Level switch oil HPU Oil leakage detected  Signal received None Alarm only.
kLevel_H draintank in drain tank/king. from level switch in
drain tank.
3.57 HPU_MainPres Main Pressure - HPU Main pressure below  LS-controller active 1 Alarm only.
s_L Low Alarm 50 bar. > 3 sec.
 Main pressure <
50 bar
 Main motor running
> 3 sec
3.58 HPU_MainPres Main Pressure - HPU Main pressure above  HPU main 1 Alarm only.
s_H High Alarm 350 bar. pressure > 350 bar

3.59 HPU_EmPump Emergency HPU Emergency pump  Running signal None Emergency pump is
_RUN Pump M31 running. received from running – alarm.
emergency motor.
Inhibits all other
motors.

3.60 HPU_LS_Pres LS pressure A HPU Cable break or faulty  Input signal <> 4- None LS pressure B
s_A_ERR (PT219A) - sensor. 20mA. transmitter is
Sensor Fault automatically
selected. If both
transmitters are
failing, value from last
selected transmitter
will be kept.

3.61 HPU_LS_Pres LS pressure B - HPU Cable break or faulty  Input signal <> 4- None LS pressure A
s_B_ERR Sensor Fault sensor. 20mA. transmitter is
automatically

5 Operation
CARGOTEC NORWAY AS 77
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm description Activation criteria Alarm Effect
(HMI) delay [s]

selected. If both
transmitters are
failing, value from last
selected transmitter
will be kept.

3.62 HPU_LS_Pres LS pressure - HPU Deviation between  Deviation between 3 Alarm only.
s_DEV Deviation Error sensor A and B. sensor A and B > 5
bar.
3.63 CR_PowerReq Power request HPU Request sent from  Power request sent 90 Alarm only.
M1_Failed for M1 failed crane to ship’s PMS  No start
but no confirmation confirmation
within 90 seconds.

3.64 CR_PowerReq Power request HPU Request sent from  Power request sent 90 Alarm only.
M2_Failed for M2 failed crane to ship’s PMS  No start
but no confirmation confirmation
within 90 seconds.

3.65 CR_PowerReq Power request HPU Request sent from  Power request sent 90 Alarm only.
M3_Failed for M3 failed crane to ship’s PMS  No start
but no confirmation confirmation
within 90 seconds.

3.66 CR_PowerReq Power request HPU Request sent from  Power request sent 90 Alarm only.
M4_Failed for M4 failed crane to ship’s PMS  No start
but no confirmation confirmation
within 90 seconds.

3.67 HPU_MainPres Main Pressure - HPU Cable break or faulty  Input signal <> 4- None Alarm only.
s_ERR Signal Error sensor. 20mA.

5 Operation

78 CARGOTEC NORWAY AS
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm description Activation criteria Alarm Effect
(HMI) delay [s]

3.68 HPU_AuxSupE Aux Supply HPU Earth fault detected  Digital signal None Alarm only.
arthFault (230V) - Earth on 230V supply to received from earth
Fault control system. fault monitoring
system.
3.69 HPU_MainSup Main Supply 1 HPU Earth fault detected  Digital signal None Alarm only.
1EarthFault (A) - Earth Fault on 690V main supply received from earth
1. fault monitoring
system.
3.70 HPU_MainSup Main Supply 2 HPU Earth fault detected  Digital signal None Alarm only.
2EarthFault (B) - Earth Fault on 690V main supply received from earth
2. fault monitoring
system.
3.71 HPU_MainSup Main Supply 3 HPU Earth fault detected  Digital signal None Alarm only.
3EarthFault (C) - Earth Fault on 690V main supply received from earth
3. fault monitoring
system.
3.72 HPU_MainSup Main Supply 4 HPU Earth fault detected  Digital signal None Alarm only.
4EarthFault (D) - Earth Fault on 690V main supply received from earth
4. fault monitoring
system.

5 Operation
CARGOTEC NORWAY AS 79
 User Manual for Crane

Slew System
Item TAG info (HMI) Alarm text (HMI) Group Alarm text Activation criteria Alarm Effect
(HMI) delay [s]

4.0 CR_SlewAccu Slew accu. CR Cable break or faulty  Input signal <> 4- None Alarm only.
Press_ERR pressure - sensor. 20mA.
Sensor Fault

4.1 CR_SlewPosD Slew Position CR Measured slew  Slew Encoder None Alarm only.
eviation Deviation position deviates from Position Control
preset slew position Prox activated
 Measured slew
angle differs from
preset slew angle
(+/- deviation limit)
4.2 CR_SlewBrake Slew Brake CR Cable break or faulty  Input signal <> 4- None Alarm only.
Press_ERR Pressure – sensor. 20mA.
Signal Error

4.3 CR_SlewBrake Slew Brake CR Slew brake pressure  Slew brake 1 Alarm only.
Prs_L Pressure Low is to low when brakes pressure < 15 bar
should be off

4.4 CR_SlewBrake Slew Brake is CR Slew brake pressure  Slew brake 10 Alarm only.
_OFF OFF is to high when brakes pressure > 15 bar
should be applied

4.5 CR_Slew_Enc Slew Encoders – CR Deviation between  Deviation between 3 Alarm only.
_DEV Deviation Error slew encoder A and B encoders > 2
> limit degrees

5 Operation

80 CARGOTEC NORWAY AS
 User Manual for Crane

Jib System
Item TAG info (HMI) Alarm text (HMI) Group Alarm text Activation criteria Alarm Effect
(HMI) delay [s]

5.0 CR_MainJibMo Main Jib Moving CR Main jib moving  Jib moving more 1 Jib command aborted.
ving_ERR Error without joystick than +/-1,0 deg
command. when no command
is given
 Main jib moving in
wrong direction
5.1 CR_MJ_Enc_D Main Jib CR Deviation between  Deviation between 3 Alarm only.
EV Encoders - sensor A and B. sensor A and B > 2
Deviation Error degrees.

5.2 CR_KJ_Enc_D Knuckle Jib CR Deviation between  Deviation between 3 Alarm only.
EV Encoders - sensor A and B. sensor A and B > 2
Deviation Error degrees.

5 Operation
CARGOTEC NORWAY AS 81
 User Manual for Crane

Whip Line Winch (WW) System

Item TAG info (HMI) Alarm text (HMI) Group Alarm text Activation criteria Alarm Effect
(HMI) delay [s]

6.0 WW_Load_H Whip Winch WW Whip winch load >  Whip winch load > 2 Cabin buzzer is
Load > 90% 90% of allowed load. 90 % of allowed activated
load at actual
radius

6.1 WW_Load_HH Whip Winch WW Whip winch load >  Whip winch load > 2 Bull horn is activated.
Load > 110% 110% of allowed load. 110 % of allowed Stops MJ and KJ from
load at actual increasing radius.
radius

6.2 WW_Load_HH Whip Winch WW Whip winch load >  Whip winch load > 0.5 Stops winch from
H Dynamic Dynamic limit. Dynamic limit at lifting.
Overload actual radius
 Whip winch load >
110% SWL

6.3 WW_LoadCell Whip Winch WW Deviation between  Deviation between 5 AOPS disabled.
_DEV Load Cell - WW load cell the calibrated load
Deviation Error channels. from the two load
cells > 20 % of
SWL (min 3 mT)

6.4 WW_AOPS_E Whip Winch WW AOPS disabled due to  AI-error on BOTH 0.01 AOPS disabled.
RR AOPS - Disabled deviation between of the two load
Due To Sensor WW load cell channels
Fault channels.  Main winch load
cell deviation alarm
active and NOT AI-
error on any of the
load channels

5 Operation

82 CARGOTEC NORWAY AS
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm text Activation criteria Alarm Effect
(HMI) delay [s]

6.5 WW_AOPS Whip Winch WW WW AOPS activated  Load exceeded None Winch is paying out.
AOPS - Active by control system. AOPS limit
 WW On
 Main motor running
 NOT slew encoder
error
 NOT crane tip over
deck
 Deviation between
load cell channels
> 20 % of SWL
6.6 WW_MOPS Whip Winch WW WW MOPS activated  MOPS button None Winch is paying out.
MOPS - Active by operator. activated
 NOT Personnel Lift
active

6.7 WW_HookStop Whip Winch WW WW hook stop  Calculated hook None Winch hoisting is
Hook Stop activated either by pos ≤ 0m stopped. Knuckle jib is
mechanical hook stop stopped from folding
sensor or by the hook in. AHC/AT is
position terminated.
measurement.

6.8 WW_Mechanic Whip Winch WW WW hook stop  Signal from BOTH 0,1 Winch hoisting is
alHookStop Mechanical Hook activated by hook stop proximity stopped. Knuckle jib is
Stop mechanical hook stop sensors stopped from folding
sensors. (mechanical hook in.
stop)
6.9 WW_HookPos Whip Winch WW WW hook position  Hook position < 50 None Alarm only.
_H Position High close to lower hook meters from lower
stop (end stop). hook stop

5 Operation
CARGOTEC NORWAY AS 83
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm text Activation criteria Alarm Effect
(HMI) delay [s]

6.10 WW_LowerHo Whip Winch WW WW lower hook stop  Calculated hook None Winch is stopped from
okStop Lower Hook Stop active (end stop). pos > position paying out.
where there is
three (3) turns of
wire left on the
drum.
6.11 WW_MOPS_A Whipline Winch WW WW MOPS  Accumulator 1 Alarm only.
ccuPress_L MOPS accumulator pressure pressure < 280
Accumulator low. bar
Pressure - Low  NOT AHC/AT
Alarm

6.12 WW_Personne Personnel Lift WW WW personnel lift  Key switch for None MOPS and AHC/AT
lLift_Active active activated by key personnel lift set in disabled.
switch. enabled
 NOT AHC/AT/CT
 Crane load ≤ 1 mT

6.13 WW_Personne Load Too High WW Load too high to  Hook load > 1 ton None Personnel lift not
lLift_NAvail To Activate activate personnel lift.  Key switch for available.
Personnel Lift personnel lift set in
enabled
 NOT Personnel lift
active

6.14 WW_BrakeOff WW Brake Off - WW Whip winch brake off  NOT Whip winch 3 Alarm only.
Alarm without joystick commanded > 5
command. sec
 Whip winch brake
pressure > 20 bar
 NOT WW MOPS
active

5 Operation

84 CARGOTEC NORWAY AS
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm text Activation criteria Alarm Effect
(HMI) delay [s]

6.15 WW_MotorDis WW Motor WW WW Motor  Deviation between 3 Alarm only.

p_DEV Displacement - displacement command and
Deviation pressure deviation pressure readout >
mode alarm 5 bar
 Whip winch
activated > 5 sec
 Main motor running
> 5 sec
6.16 WW_AHC_Pos WW AHC AHC Position deviation  AHC heave 0,5 Alarm only.
Dev_H Position more than 0.5 meters deviation > 1,5 m
Deviation High of hook relative to the  WW AHC/AT
seabed in AHC. enabled

6.17 WW_AHC_Pos WW AHC AHC Position deviation  AHC heave 0,2 AHC/AT is terminated.
Dev_HH Position more than 1.5 meters deviation > 1,5 m
Deviation High of hook relative to the  WW AHC/AT
High seabed in AHC. enabled

6.18 WW_MOPS_A Whipline Winch AHC Cable break or faulty  Input signal <> 4- None Alarm only.
ccuPress_ERR MOPS sensor. 20mA.
Accumulator
Pressure - Signal
Error

6.19 WW_AHC_Co WW AHC Control AHC Deviation between  Deviation between 5 Alarm only.
ntrolValve_DE Valve Deviation commanded and read valve command
V signal. and valve feedback
> 30%
 AHC activated ≥ 10
sec.

5 Operation
CARGOTEC NORWAY AS 85
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm text Activation criteria Alarm Effect
(HMI) delay [s]

6.20 WW_AHC_Val WW AHC Ctrl. AHC Cable break or faulty  Input signal <> 4- None Alarm only.
ve_FBK_ERR Valve - Sensor sensor. 20mA.
Fault

6.21 WW_BrakePre WW brake WW Cable break or faulty  Input signal <> 4- None Alarm only.
ss_ERR pressure - sensor. 20mA.
Sensor Fault

6.22 WW_DispPres WW disp. WW Cable break or faulty  Input signal <> 4- None Disables displacement
s_ERR pressure - sensor. 20mA. valve regulator.
Sensor Fault

6.23 WW_LoadCell Whip Winch WW Cable break or faulty  Input signal <> 4- None Load cell B is
_A_ERR Load Cell A - sensor. 20mA. automatically
Signal Error selected. AHC/AT and
AOPS is disabled if
both loadcells have
failed.

6.24 WW_LoadCell Whip Winch WW Cable break or faulty  Input signal <> 4- None Load cell A is
_B_ERR Load Cell B - sensor. 20mA. automatically
Signal Error selected. AHC/AT and
AOPS is disabled if
both loadcells have
failed.

6.25 WW_Speed_H WW Speed High WW WW hook speed  WW Hook speed > 0,1 Alarm only.
- Alarm higher than specified. specified speed

5 Operation

86 CARGOTEC NORWAY AS
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm text Activation criteria Alarm Effect
(HMI) delay [s]

6.26 WW_AHC_Sto AHC stop AHC AHC stop conditions:  Emergency stop None Alarm only.
pped condition active activated
on Auxiliary  NOT WW On
Emergency stop
Winch
active, NOT WW On  NOT any main
selected, no main pumps running
pumps running,  AOPS active
MOPS/AOPS active,  MOPS active
hook pos < 5 meters,  Hook position < 5
AHC deviation > 1,5 meters
meters, MRU error or  Heave deviation >
load cell sensor error 1,5 meters
(only in AT). AHC/AT  MRU error
has to be enabled to  Load cell sensor
generate this alarm. fault AND AT mode
active
 AHC/AT mode
enabled
6.27 WW_OutsideW Whip Winch WW Whip Winch outside  Angle relative to None Alarm only.
orkingArea outside working working area vertical < 0° (20° in
area ship to ship mode)
 Crane Tip height <
0m
 Crane Radius <
15m
 WW load > 5t
6.28 WW_Spooling Whip Winch WW Whip Winch Spooling  Whip Winch 1 Alarm only.
Dev_H Spooling device – difference Spooling device –
Deviation – High between setpont and difference between
Alarm (>3%) actual position >3% setpoint and actual
position >3%
6.29 WW_Spooling Whip Winch WW Whip Winch Spooling  Whip Winch 1 Winch is stopped.
Dev_HH Spooling device – difference Spooling device –
Deviation – High between setpont and difference between
High Alarm actual position >5% setpoint and actual
(>5%) position >5%

5 Operation
CARGOTEC NORWAY AS 87
 User Manual for Crane

Main Winch (MW) System

Item TAG info (HMI) Alarm text (HMI) Group Alarm text Activation criteria Alarm Effect
(HMI) delay [s]

7.0 MW_Load_H Main Winch Load MW Main winch load >  Main winch load > 2 Cabin buzzer is
> 90% 90% of allowed load. 90 % of allowed activated.
load at actual
radius and sea
state

7.1 MW_Load_HH Main Winch Load MW Main winch load >  Main winch load > 2 Bull horn is activated.
> 110% 110% of allowed load. 110 % of allowed Stops MJ and KJ from
load at actual increasing radius.
radius

7.2 MW_Load_HH Main Winch MW Main winch load >  Main winch load > 0.5 Stops winch from
H Dynamic Dynamic limit. Dynamic limit at lifting.
Overload actual radius
 Main winch load >
110% SWL

7.3 MW_LoadCell_ Main Winch Load MW Deviation between  Deviation between 5 AOPS disabled.
DEV Cell - Deviation MW load cell the calibrated load
Error channels. from the two load
cells > 15 mT

7.4 MW_LoadCell_ Main Winch Load MW Cable break or faulty  Input signal <> 4- None Load cell B is
A_ERR Cell A - Signal sensor. 20mA. automatically
Error selected. AHC/AT and
AOPS is disabled if
both loadcells have
failed.

5 Operation

88 CARGOTEC NORWAY AS
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm text Activation criteria Alarm Effect
(HMI) delay [s]

7.5 MW_LoadCell_ Main Winch Load MW Cable break or faulty  Input signal <> 4- None Load cell A is
B_ERR Cell B - Signal sensor. 20mA. automatically
Error selected. AHC/AT and
AOPS is disabled if
both loadcells have
failed.

7.6 MW_AOPS_E Main Winch MW AOPS disabled due to  AI-error on BOTH 0,01 AOPS disabled.
RR AOPS - Disabled deviation between of the two load
Due To Sensor MW load cell channels
Fault channels.  Main winch load
cell deviation alarm
active and NOT AI-
error on any of the
load channels
7.7 MW_AOPS Main Winch MW MW AOPS activated  Load exceeded None Winch is paying out.
AOPS - Active by control system. AOPS limit
 MW On
 Main motor running
 NOT slew encoder
error
 NOT crane tip over
deck
 Deviation between
load cell channels
> 20 % of SWL
7.8 MW_MOPS Main Winch MW MW MOPS activated  MOPS button None Winch is paying out.
MOPS - Active by operator. activated

7.9 MW_HookStop Main Winch MW MW hook stop  Calculated hook None Winch hoisting is
Hook Stop activated by the hook pos < 0m stopped. Knuckle jib is
position stopped from folding
measurement. in. AHC/AT is

5 Operation
CARGOTEC NORWAY AS 89
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm text Activation criteria Alarm Effect
(HMI) delay [s]

terminated.

7.10 MW_Mechanic Main Winch MW MW hook stop  Signal from BOTH 0,1 Winch hoisting is
alHookStop Mechanical Hook activated by the hook stop proximity stopped. Knuckle jib is
Stop mechanical hook stop sensors stopped from folding
sensors (mechanical hook in.
stop)
7.11 MW_HookPos Main Winch MW MW hook position  Hook position < 50 None Alarm only.
_H Position High close to lower hook meters from lower
stop (end stop). hook stop

7.12 MW_LowerHoo Main Winch MW MW lower hook stop  Calculated hook None Winch is stopped from
kStop Lower Hook Stop active (end stop). pos > position paying out.
where there is
three (3) turn of
wire left on the
drum.
7.13 MW_HookStop Main Winch MW Only signal from one  Signal from only 3 Alarm only.
_ERR Hook Stop - of the proximity one of the two
Sensor Fault switches in the hook stop sensors.
mechanical hook stop
sensor.

7.14 MW_Speed_H Main Winch MW MW hook speed  MW Hook speed > 0,1 Alarm only.
Speed - High higher than specified. specified speed in
Alarm High Speed Mode
AHC/AT (m/s)
 MW Hook speed >
specified speed in
double part (m/s)
AND double part
active

5 Operation

90 CARGOTEC NORWAY AS
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm text Activation criteria Alarm Effect
(HMI) delay [s]

7.15 MW_MOPS_A Main Winch MW MW MOPS  MW accumulator 1 Alarm only.

ccuPress1_L MOPS accumulator pressure press < 280 bar
Accumulator 1 LOW.  NOT AHC/AT
Pressure 1 - Low
Alarm

7.16 MW_MOPS_A Main Winch MW MW MOPS  MW accumulator 1 Alarm only.

ccuPress2_L MOPS accumulator pressure press < 280 bar
Accumulator 2 LOW.  NOT AHC/AT
Pressure 2- Low 
Alarm

7.17 MW_Personnel Personnel Lift MW MW personnel lift  Key switch for None MOPS and AHC/AT
Lift_Active active (Recovery activated by key personnel lift set in disabled.
Mode) switch. enabled
 NOT AHC/AT/CT
 Crane load ≤ 1 mT

7.18 MW_Personnel Wrong mode MW Wrong mode or Load  Hook load > 1 ton None Personnel lift not
Lift_NAvail orLoad Too High too high to activate  Key switch for available.
To Activate personnel lift. personnel lift set in
Personnel Lift enabled
 NOT Personnel lift
active

7.19 MW_BrakeOff Main Winch MW MW brake off without  NOT Main winch 3 Alarm only.
Brake OFF Alarm joystick command. commanded > 5
sec
 NOT AHC/AT
enabled > 5 sec
 Main winch left or
right brake
pressure > 20 bar
 NOT MW MOPS

5 Operation
CARGOTEC NORWAY AS 91
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm text Activation criteria Alarm Effect
(HMI) delay [s]

active
7.20 AHC_WrongM AHC - Wrong AHC Load too high for  AHC/AT High None Alarm only.
ode Mode According AHC/AT High Speed Speed Mode
To Load Mode. Switch to enabled
AHC/AT Normal  AHC enabled
Mode.  Actual load >
AHC/AT High
Speed Mode load
limit
7.21 AHC_HeaveVe Heave Velocity > AHC True heave velocity in  True heave 0,5 Alarm only.
locity_H 2,0 m/s (120 crane tip higher than 2 velocity > 2m/s
m/min) m/s or 1m/s in double AND NOT AHC/AT
part. enabled
 True heave
velocity > 1m/s
AND double part
AND NOT AHC/AT
enabled
7.22 AHC_PosDev_ AHC Position AHC AHC position  AHC heave 0,5 Alarm only.
H Deviation High deviation. More than deviation error, dev
0,5 meters deviation > 0,5 m
between hook and set
point relative to the
seabed.

7.23 AHC_PosDev_ AHC Position AHC AHC position  AHC heave 0,2 AHC/AT is stopped.
HH Deviation High deviation. More than deviation error, dev
High 1,5 meters deviation > 1,5 m
between hook and set
point relative to the
seabed.

7.24 MW_AHC_Con Main AHC AHC Deviation between  Deviation between 5 Alarm only.
trolValve1_DE Control Valve 1 - commanded and read valve command
V Deviation Error signal. and valve feedback
> 30%

5 Operation

92 CARGOTEC NORWAY AS
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm text Activation criteria Alarm Effect
(HMI) delay [s]

 AHC activated >

10 sec.
7.25 MW_AHC_Con Main AHC AHC Deviation between  Deviation between 5 Alarm only.
trolValve2_DE Control Valve 2 - commanded and read valve command
V Deviation Error signal. and valve feedback
≥ 30%
 AHC activated >
10 sec

7.26 MW_AHC_Con Main AHC AHC Deviation between  Deviation between 5 Alarm only.
trolValve3_DE Control Valve 3 - commanded and read valve command
V Deviation Error signal. and valve feedback
> 30%
 AHC activated >
10 sec.

7.27 MW_AHC_Con Main AHC AHC Deviation between  Deviation between 5 Alarm only.
trolValve4_DE Control Valve 4 - commanded and read valve command
V Deviation Error signal. and valve feedback
> 30%
 AHC activated >
10 sec.

7.28 MW_MOPS_A Main Winch AHC Cable break or faulty  Input signal <> 4- None Alarm only.
ccuPress1_ER MOPS sensor. 20mA.
R Accumulator
Pressure 1 -
Signal Error

7.29 MW_MOPS_A Main Winch AHC Cable break or faulty  Input signal <> 4- None Alarm only.
ccuPress2_ER MOPS sensor. 20mA.
R Accumulator
Pressure 2 -
Signal Error

5 Operation
CARGOTEC NORWAY AS 93
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm text Activation criteria Alarm Effect
(HMI) delay [s]

7.30 MW_MOPS_A Main Winch MW Deviation between  Deviation between 3 Alarm only.
ccuPress_DEV MOPS sensor A and B. sensor 1 and 2 >
Accumulator 10 bar.
Pressure
Sensors -
Deviation

7.31 MW_BrakePre Main Winch MW Cable break or faulty  Input signal <> 4- None Alarm only.
ss1_ERR Brake Pressure 1 sensor. 20mA.
- Signal Error

7.32 MW_BrakePre Main Winch MW Cable break or faulty  Input signal <> 4- None Alarm only.
ss2_ERR Brake Pressure 2 sensor. 20mA.
- Signal Error

7.33 MW_DoublePa Main Winch MW Double part sensor  NOT double part None Alarm only.
rtDet Double Part active but mode not selected
Detected (not selected.  Signal from
selected) proximity switch
received
7.34 MW_DoublePa Main Winch MW Double part selected  Double part None Alarm only.
rtSel Double Part but not detected by selected
Selected (not double part proximity  NOT signal from
detected) switch. proximity switch
received
7.35 MW_MotorDisp Main Winch MW Deviation between  Deviation between 3 Alarm only.
1_DEV Motor Disp. 1 - commanded and read valve command
Deviation Error signal. and sensor
feedback > 5 bar.
 Main motor running
 Main Winch On > 5
sec
7.36 MW_MotorDisp Main Winch MW Deviation between  Deviation between 3 Alarm only.
Motor Disp. 2 - commanded and read valve command
and sensor

5 Operation

94 CARGOTEC NORWAY AS
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm text Activation criteria Alarm Effect
(HMI) delay [s]

2_DEV Deviation Error signal. feedback > 5 bar.

 Main motor running
 Main Winch On > 5
sec
7.37 MW_MotorDisp Main Winch MW Deviation between  Deviation between 3 Alarm only.
Press_DEV Motor Disp. sensor A and B. sensor 1 and 2 > 2
Pressure bar.
Sensors -
Deviation
+CC100

7.38 MW_MotorDisp Main Winch MW Cable break or faulty  Input signal <> 4- None Inhibits displacement
Press1_ERR Motor Disp. sensor. 20mA. regulator for Valve 1
Pressure 1 -
Signal Error

7.39 MW_MotorDisp Main Winch MW Cable break or faulty  Input signal <> 4- None Inhibits displacement
Press2_ERR Motor Disp. sensor. 20mA. regulator for Valve 2
Pressure 2 -
Signal Error

7.40 MW_AHC_Sto AHC stop AHC AHC stop conditions:  Double part None AHC/AT is stopped.
pped condition active selected but not
on Main Winch enabled bit
Emergency stop
“MW_DoublePart_
active, NOT MW On
AHC_EN” in DB96.
selected, no main
 Emergency stop
pumps running,
activated
MOPS/AOPS active,
hook pos < 5 meters,  NOT MW On
AHC deviation > 1,5  NOT any main
meters, MRU error or pumps running
load cell sensor error  AOPS active
(only in AT). AHC/AT  MOPS active
has to be enabled to  Hook position < 5
meters
 Heave deviation >

5 Operation
CARGOTEC NORWAY AS 95
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm text Activation criteria Alarm Effect
(HMI) delay [s]

generate this alarm. 1,5 meters

 MRU error
 Load cell sensor
fault AND AT mode
active
 AHC/AT mode
enabled
7.41 AHC_MW_Mo AHC Main Winch AHC Speed too high for  MW Hook speed > None Alarm only.
deSpeed_H Mode – High normal AHC/AT specified speed in
Speed mode. Select High normal AHC/AT
Speed Mode. mode (m/s)
 NOT AHC/AT High
Speed Mode
selected
 NOT MW double
part selected
 AHC/AT mode
enabled
7.42 AHC_MainPres AHC - Main MW Main pressure below  AHC/AT activated. 1 Alarm only.
s_L Pressure Low 220 bar.  Main pressure <
220 bar
7.43 MW_OutsideW Main Winch MW Main Winch outside  Angle relative to None Alarm only.
orkingArea outside working working area vertical < 0° (20° in
area ship to ship mode)
 Crane Tip height <
0m
 Crane Radius <
15m
 MW load > 5t
7.44 MW_EncAndC MW Primary and MW MW Primary and  Deviation between None Alarm only
ounter_DEV Secondary Secondary Position primary and
Position Sensor Sensor – Deviation secondary sensor
– Deviation Error Error > 100 pulses

5 Operation

96 CARGOTEC NORWAY AS
 User Manual for Crane

Item TAG info (HMI) Alarm text (HMI) Group Alarm text Activation criteria Alarm Effect
(HMI) delay [s]

7.45 MW_Encoder_ MW Primary MW MW Primary Position  Deviation between 0.25 In AHC/AT mode
Stopped Position Sensor Sensor Stopped primary and Secondary sensor is
Stopped secondary sensor automatically
> 100 pulses selected.

7.46 MW_Counter_ MW Secondary MW MW Secondary  Deviation between 0.25 Alarm only.

Stopped Position Sensor Position Sensor primary and
Stopped Stopped secondary sensor
> 100 pulses
7.47 MW_Counter_ MW Secondary MW MW Secondary  Deviation between None Alarm only.
Error Position Sensor Position Sensor Error primary and
Error secondary sensor
> 100 pulses

5 Operation
CARGOTEC NORWAY AS 97
 User Manual for Crane

Moon Pool Mode

Item TAG info (HMI) Alarm text (HMI) Group Alarm text Activation criteria Alarm Effect
(HMI) delay [s]

8.1 CR_MoonPool Moon Pool Mode CR Moon Pool Mode Pilot  Moon Pool Mode 3 Alarm only.
SlewBrakesOn not ready - Slew Pressure too low to Pilot Pressure <
Brakes On activate moon pool 30bar
mode.  Moon Pool Mode
activated
8.2 CR_SlewBypa Slew Bypass CR Slew Bypass Error  Moon Pool Mode 3 Alarm only.
ssError Error Pilot Pressure >
5bar
 Moon Pool Mode
not activated
8.3 CR_MoonPool Wrong crane CR Wrong crane rating for  An illegal crane None Alarm only.
WrongRating rating for moon moon pool mode. rating mode is
pool mode selected
 Moon Pool Mode
selected
8.4 CR_MoonPool Load too high to CR Load too high to exit  Crane Load > 5t None Alarm only.
LoadTooHigh exit moon pool moon pool mode  Moon Pool Mode
mode selected

8.5 CR_MoonPool Wrong position CR Wrong position for  Crane tip not in None Alarm only.
NotInPosition for moon pool moon pool mode configured moon
mode pool mode area
 Moon Pool Mode
selected
8.6 CR_MoonPool Moon Pool Pilot CR Cable break or faulty  Input signal <> 4- None Alarm only.
PilotPres_ERR Pressure - sensor. 20mA.
Sensor Fault

5 Operation

98 CARGOTEC NORWAY AS
 User Manual for Crane

11. Trend Display Screen

The Trend Display presents historical data as curves. By nature it may be complex and difficult to work with.
Some special features have therefore been built in to the trend chart to simplify the day-to-day operation.

The Trend display can show both real time and historical data, and can show up to 6 simultaneous plots.

2
1

Display functions The large trend chart (1) shows historical or real-time trends colour-coded for the
various parameters that may be displayed.

To select a parameter for display, click inside the trend chart. The Historical Trend
Setup popup now opens (next page, bottom), displaying a list of parameters and a
range of fields for defining the chart.

The left side of the chart shows the chart’s vertical scale (2) (in either metric or
oilfield units), and the top shows the time scale.

At the bottom of the display, trend-related controls enable the user to set range, zoom
and other chart properties.

5 Operation
CARGOTEC NORWAY AS 99
 User Manual for Crane

Mode It is possible to show both real-time data and historical data. The historical data is
stored in the computer for 28 days.

While in real time, the right side of the trend is always ‘now’. In historic mode, the
right side of the trend is not necessarily ‘now’.

Pan time Pan time is only available in Historical Mode. It is used to pan forward or backward in
time to display the desired time period.

Vertical range The vertical scale (2) is actually a bar graph showing the magnitude of the selected
parameter. The colour of the scale lines indicates which parameter it applies to.

Horizontal range The standard horizontal range is 30 minutes, but this can be changed with the “Zoom
Time” buttons.

Zoom Time (Zoom The horizontal scale is adjusted using the “Zoom Time” buttons. This is a real-time
horizontal) trend factor that can be scaled from one second up to approximately 20 hours.

Min Value/ To adjust a specific

Max Value parameter’s vertical scale,
select it by touching the
(Zoom vertical) relevant “pen button” in the
Historical Trend Setup box.
Enter “Min Value” and “Max
Value” in the input fields in
the same way as other
analogue value input fields.

5 Operation

100 CARGOTEC NORWAY AS

 User Manual for Crane

12. Misc Screen

The operator can manage various settings and system surveillance tasks on this screen. The screen items will
first be presented, and then the functions will be described in more detail.

Miscellaneous Screen

4
1

2 5

3
6

Screen items 1. Information button to access a screen showing details regarding the Profibus
description network.
2. Information button to access a screen showing details regarding Digital Inputs
and Outputs to the PLC system.
3. Information button to access a screen showing details regarding Analogue
Inputs and Outputs to the PLC system.
4. Radio buttons used for globally changing the units between Metric and
Oilfield. (If implemented – this may be an option)
5. Button for setting and resetting the Main Interlock override function. When
activated, the button turns yellow, and the IntLock Override icon in the status
banner at the top of the screen is activated.

WARNING: When interlock override is active, all safety features in the crane
and control system are deactivated. We recommend that a report is prepared
stating the reason for activating this function each time it is used.

6. Counter for the Interlock override, increases by one each time the override
function is activated.
7. Buttons for turning jib floodlights and other lights on. These buttons turn
yellow when the lights are on.
8. Activation button to put the CCTV cameras into automatic mode for the. This
ensures that the active winch is always the one displayed on the winch video
monitor.
9. Hour counter

5 Operation
CARGOTEC NORWAY AS 101
 User Manual for Crane

13. Network Status Screen

This screen gives the user an overview of which components are connected to the Profibus network, and
whether or not there are problems with any of the units.

If a node on the network is not communicating with the PLC, this is indicated by a red light. When the node is
“healthy” and connected, the light is green.

5 Operation

102 CARGOTEC NORWAY AS

 User Manual for Crane

14. Setup Screen

The setup screen is for the maintenance personel on board for easier troubleshooting and adjustments of
parameters in the control system.

The menu is password protected, so only authorized personel can enter the menu. Password is 1000.

4
4

6
3

1. Radio buttons for selecting which of each set of dual sensors is used as system reference. Analogue
information fields to the right display reference and realtime values.
2. Area to be used only by Cargotec Norway AS personel, this activates a simulated heave in the control
system and is only to be used for test purposes.
3. Menu buttons to access encoder, lubrication and joystick calibration, setup and reset screens.
4. Button for shutting down front screen HMI software application.
5. Button for reinitializing I/O values.
6. Button for starting uninitiated I/O conversations.

5 Operation
CARGOTEC NORWAY AS 103
 User Manual for Crane

Resetting the encoders

It is of utmost importance to follow the directions below when resetting encoders or position measuring devices.
Incorrect position settings can cause serious damage or personal injury. The interlock override may be used if
neccesary to reach the required reset position.

With the device in the desired position, press the relevant S button on the encoder reset screen (below) to reset
the device’s “null point”.

Encoder Instructions
Main winch position Place hook in desired upper position (about 1.5 metres from sheaves), knuckle jib fully in,
main jib fully down, when resetting main winch position encoder.
Whip winch position Place hook in desired upper position (about 1.5 meter from sheaves), knuckle jib fully in,
main jib fully down, when resetting whip winch position encoder.
Slew angle The crane must be parked, with the knuckle jib resting in the parking cradle.
Knuckle Jib angle The knuckle jib encoders are to be reset with the knuckle jib folded all the way in.
Main Jib angle The main jib encoders are to be reset with the main jib lowered completely.

Encoder reset screen

5 Operation

104 CARGOTEC NORWAY AS

 User Manual for Crane

15. Joystick Setup Screen

The screen is divided in three parts, Left Joystick, Right Joystick and Tugger winch joysticks. The left and right
parts are nearly identical.

2 3

1. Indicators for whether or not the direction switches and buttons for the joystick axes are active.
2. Potentiometer X axis force reading.
3. Potentiometer Y axis force reading.
4. Button for Lubrication System Setup window (see below)

5 Operation
CARGOTEC NORWAY AS 105
 User Manual for Crane

16. Troubleshooting
Although the Control System is designed for a long and trouble-free service life, problems may occur with the
equipment.

Trouble-shooting then becomes necessary. Technicians must have drawings, descriptions and component data
sheets as their primary aids. These will normally be sufficient for 90% of the problems occurring on systems
that have been operative for some time.

By experience, the PLC system, software and input/output modules are very rarely the cause of failure!

Note that all software changes should be done subsequent to filling out a Software Change Request form
(contact MacGregor service for request form). This is required to ensure that all parties have an updated base of
system features, as well as to ensure that the built-in safety and functions are not jeopardised.

This trouble-shooting section mainly contains PLC system failure procedures.

For detailed information on the components used, refer to the component data sheet section of this manual.

5 Operation

106 CARGOTEC NORWAY AS

 User Manual for Crane

17. Crane Setup

17.1. General
The following procedures comprise the main setup items:

 Crane slew initialisation

 Winch initialisation
 Main jib angle sensor setup
 Knuckle jib angle sensor setup

17.2. Crane Slew Initialisation

When to perform This procedure must be performed after the PLC has been repaired or replaced, or
after an absolute encoder failure.

What to do Select “Setup” from the menu sidebar on the touch screen terminal. The setup menu is
password protected.

Password: 1000.

Park the crane as precisely as possible.

Press S next to Slew Angle sensor, then R (Reset) in the Slew Angle popup.

Comments The AOPS system will not be operational if the crane slew angle is not initialised.

Troubleshooting the crane slew angle sensor is thus essential.

17.3. Winch Initialisation

When to perform This procedure must be performed if the PLC has been repaired or replaced, or after
an absolute encoder failure.

What to do Select Setup from the menu sidebar on the touch-screen terminal. The Setup menu is
password-protected.

Password: 1000.

Park the crane and run the main winch hook to the correct hook-stop position relative
to the jib tip.

Press S next to Main/Whip Winch Hook Position, then R (Reset) in the popup.

5 Operation
CARGOTEC NORWAY AS 107
 User Manual for Crane

Comments It is not possible to run the hook past the position set when the winch was last
initialised. To set a new “final hook-stop” the PLC has to be restarted.

17.4. Main Jib Angle Sensor Initialisation / Replacement

When to perform This procedure must be performed when the absolute encoder gives a wrong readout
or has been repaired.

Indication Wrong readout on main jib angle.

What to do Select Setup from the menu sidebar on the touch-screen terminal. This menu is
password protected.

Password: 1000.

Lower the Main Jib until it reaches its mechanical end stop.

Press S next to Main Jib Angle, then R (Reset) in the popup.

Comments An incorrect setting on this encoder will affect hook load calculations, winch position
calculations and the AOPS system.

17.5. Knuckle Jib Angle Sensor Initialisation / Replacement

When to perform This procedure must be performed when the absolute encoder gives a wrong readout
or has been repaired.

Indication Wrong readout on knuckle jib angle.

What to do Select Setup from the menu sidebar on the touch-screen terminal. This menu is
password protected.

Password: 1000.

Retract the knuckle jib until it reaches its mechanical end stop.

Press S next to Knuckle Jib Angle, then R (Reset) in the popup.

Comments An incorrect setting on this encoder will affect hook load calculations, winch position
calculations and the AOPS system.

5 Operation

108 CARGOTEC NORWAY AS

 User Manual for Crane

18. SIEMENS PLC CONTROL SYSTEM –

SIMATIC S7 300
18.1. General
This section contains troubleshooting guidelines for standard equipment used by Cargotec Norway AS.
Therefore, this section may contain descriptions of equipment not installed in the actual delivery.

18.2. PLC System LEDs

The various PLC modules have LEDs that indicate normal operation as well as fault information. This section
describes the LEDs and their functions in the various modules.

18.3. Power Supply Module LEDs

PS 305/307 power supplies have only one LED that indicates 24VDC either present or not present.

5 Operation
CARGOTEC NORWAY AS 109
 User Manual for Crane

18.4. S7 300 CPU LEDs

The table below describes the functions of the SF, 5VDC, FRCE, RUN, STOP LEDs.

LED Meaning
SF DC5V FRCE RUN STOP

D D D D D CPU power supply missing

D L X D L CPU is in STOP mode

Start the CPU

L L X D L CPU is in STOP mode as result of error

X L X D F CPU requesting memory reset

(0,5Hz)

X L X D F CPU executing memory reset

(2Hz)

X L X F L CPU is in startup mode

(2 Hz)

X L X F L CPU was halted by a programmed break point

(0,5Hz

L L X X X Hardware or software error

X X L X X User enabled the force function

X X F X X Node flashing test was activated

(2 Hz)

F F F F F CPU has an internal system error.

Proceed is as follows:

1. Set mode selector switch to STOP

2. Perform POWER ON/OFF
3. Read diagnostics buffer, see STEP 7
4. Contact your local SIEMENS partner

5 Operation

110 CARGOTEC NORWAY AS

 User Manual for Crane

18.5. DP Interface LEDs

The table below describes the functions of the BF, BF1, BF2 LEDs.

LED Meaning
SF 5VDC BF BF1 BF2

L L L/F - - PROFIBUS DP interface error

L L - L/F X Fault at the second PROFIBUS DP interface of CPU 317 or CPU

319-3 PN/DP

L L - X L/F Fault at the second PROFIBUS DP interface of CPU 317 or CPU

319-3 PN/DP

5 Operation
CARGOTEC NORWAY AS 111
 User Manual for Crane

18.6. Ethernet (PN) Interface LEDs

The table below describes the functions of the LINK, RX/TX, BF2 or BF3 LEDs.

LED LED status Description of status

Not Flashes Lit

lit

LINK - - X There is no connection between the PROFINET interface of

your PROFINET device and a communication partner in the
Ethernet (a switch, for example).

- X - Only with an i/o device:

User-activated flashing from STEP 7

X - - The Ethernet connection between the PROFINET interface of

the PROFINET device and the communication partner is
down.

RX - - X At the current time, data are being received from a

communication partner on Ethernet via the PROFINET
(flickers) device’s PROFINET interface.

X - - No data are currently received via the PROFINET interface.

TX - - X Data are currently being sent to a communication partner on

Ethernet via the PROFINET device’s PROFINET interface.
(flickers)

X - - No data are currently being transmitted via the PROFINET

interface.

BF2 - - X Error on the PROFINET interface, communication no longer

or possible (for example, with a CPU as i/o controller, when the
BF3 communication is down)

- X - Error on the PROFINET interface (for example, due to station

failure of one or more i/o devices)

X - - No error at the PROFINET interface.

5 Operation

112 CARGOTEC NORWAY AS

 User Manual for Crane

18.7. Interface Module IM 360 LED

The table below describes the function of the SF LED.

Display element Meaning Explanation

SF Group error The LED lights up if

- The connection cable is missing

- IM 361 is switched off

18.8. Interface Module IM 361 LEDs

The table below describes the function of the SF and 5 VDC LEDs.

Display element Meaning Explanation

SF Group error The LED lights up if

- The connection cable is missing

- IM 361 connected in series is
switched off
- The CPU is in POWER OFF state
5 VDC 5 VDC supply for the s7-300 -
backplane bus

18.9. Digital Input / Output Modules

The table below describes the fault status of the digital I/O modules.

Fault Description
SF Some i/o modules have the ability to indicate group-error.

Reason for indication may be loss of power to module or module failure.

Remedy: check fuses and/or replace module (when power is switched off).

5 Operation
CARGOTEC NORWAY AS 113
 User Manual for Crane

18.10. Analogue Input / Output Modules

The table below describes the fault status of the analogue I/O modules

Fault Description
SF Some i/o modules have the ability to indicate group-error.

Reason for indication may be loss of power to module or module failure.

Remedy: check fuses and/or replace module (when power is switched off).

5 Operation

114 CARGOTEC NORWAY AS

 User Manual for Crane

19. REPLACING SIEMENS S7

COMPONENTS
19.1. General
Several components require special handling when replacing. This may include special precautions in handling,
setting of switches or transfer of software.

19.2. PLC Modules

Care must be taken whenever you are working with PLC modules to prevent unexpected CPU shutdown. Do
not work with PLC modules while the system is in operation.

19.3. Power supply

The module to be replaced is installed and wired up. A new module of the same type is to be fitted. If you have
provided the modules in your system with slot numbering, you must remove the number from the old module
when replacing it and apply the number to the new module. To remove a module, follow the steps outlined
below:

1. Set the PLC mode switch to STOP.

2. Set the Standby switch of the power supply module down (0 V output voltages).
3. Open the PLC supply circuit-breaker. Refer to the loop diagrams for identifying the correct circuit-
breaker.
4. Open the power supply cover.
5. Disconnect the power supply from the power supply module.
6. Loosen the module’s mounting screws.
7. Swivel the module out.

To fit the new module, follow the steps outlined below:

1. Check the voltage selector switch.

2. Hook the new module of the same type on and swivel it downward.
3. Screw the module on.
4. Check that the PLC supply-circuit breaker is open and the Standby switch is down.
5. Connect the power supply to the power supply module.
6. Close the power supply cover.
7. Close the PLC supply circuit-breaker.
8. Set the power supply module’s Standby switch up (output voltages at rated value).
9. Set the PLC mode switch to RUN if applicable.

5 Operation
CARGOTEC NORWAY AS 115
 User Manual for Crane

19.4. PLCs
PLC modules may only be replaced by modules with the exact same part number. The part number is printed on
the lower left corner of the module front. If another PLC module is to be used this must be done by qualified
Cargotec service personnel.

Note that all accumulated data is stored in the Micro Memory Card on the PLC module so no data will be lost.
This may include data such as motor run time, wire usage and similar integrated information.

To remove the module, follow the steps outlined below:

1. Set the PLC mode switch to STOP.

2. Set the power supply module’s Standby switch down (0 V output voltages).
3. Open the PLC cover.
4. Disconnect all connectors.
5. Remove the micro memory card.
6. Loosen the module’s mounting screws.
7. Swivel the module out.

To fit the new module, follow the steps outlined below:

1. Hook the new module of the same type on and swivel it downward.
2. Screw the module on.
3. Connect all connectors.
4. Set the PLC mode switch to STOP.
5. Insert the micro memory card.
6. Set the power supply module’s Standby switch up (output voltages at rated values).
7. Set the PLC mode switch to RUN.
8. Close the cover.

5 Operation

116 CARGOTEC NORWAY AS

 User Manual for Crane

19.5. Digital or Analogue Modules

1. To remove a module, follow the steps outlined below:
2. You cannot replace analogue and digital modules while in RUN mode. Therefore, switch the Standby
switch on the power supply down.
3. Loosen the front connector’s mounting screw and pull it off.
4. Loosen the module mounting screw.
5. Swivel the module out.

Before fitting the front connector, you must remove (break off) the front part of the coding key, because this
part is already fitted in the wired front connector.

Caution: The module can be damaged.

If, for example, you insert a front connector for a digital module in an analogue module, the module may be
damaged.

Modules are only to be operated with their complete front connector-coding key.

To fit the new module, follow the steps outlined below:

1. For analogue modules make sure that the measurement type-coding key on the side of the new module
matches that of the old module. If in doubt refer to the loop diagrams for further information.
2. Hook the new module of the same type on at the appropriate slot and swivel it downward.
3. Screw the module on with the mounting screw.
4. Fit the front connector.
5. Switch the power supply Standby switch up.
6. After fitting, each programmable module will be reinitialised by the PLC with parameters.

To replace a front connector, follow the steps outlined below:

1. Set the power supply Standby switch down and switch off all load power supplies for the module.
2. Loosen the front connector screw and pull it off.
3. Remove the labels from the front connector and insert them into the new front connector.
4. Wire the new front connector.
5. Insert the front connector in the module.
6. Screw the front connector on.
7. Switch on the load voltage and set the power supply Standby switch up.

5 Operation
CARGOTEC NORWAY AS 117
 User Manual for Crane

20. End Notes

 denotes optional equipment that may not be part of the specific crane delivery.

All winches have software hook stops.

Winches with AHC/AT mode, and winches with Constant Tension (CT) mode and >1000
metres of hook travel are also fitted with mechanical hook stops.

5 Operation

118 CARGOTEC NORWAY AS

Doc type User Manual

Doc. ID I-MA - Annex A - Crane Load Calculator

Document revision: Document owner: Document revised by:

1 Software Lead 07.09.2015/JSR

Annex A - Crane Load Calculator

Table of Contents
1 Introduction .............................................................................................................................. 2
1.1 Abbreviations .................................................................................................................... 2
1.2 Required 3rd party software ............................................................................................... 2
2 Using the Load Calculator ........................................................................................................ 3
2.1 The Three Main Graphical Windows ................................................................................. 3
2.1.1 Load Charts (1) .......................................................................................................... 3
2.1.2 Crane Geometry (2) ................................................................................................... 4
2.1.3 Bird’s Eye View (3) .................................................................................................... 4
2.2 Input Area (4) .................................................................................................................... 4
2.3 Running Mode Window (5) ............................................................................................... 6
2.4 Load Calculator on Touch Screen ..................................................................................... 7
3 Load Calculator Planning Mode ............................................................................................... 8
4 Lift Mode .................................................................................................................................. 8
4.1 Shipboard ......................................................................................................................... 8
4.2 Ship To Ship Lift ............................................................................................................... 8
4.3 Engineered Subsea Lift..................................................................................................... 8
4.4 Offshore Lift ...................................................................................................................... 8
5 Load Calculator Running Mode ................................................................................................ 9

Page 1 of 11
Doc type User Manual

Doc. ID I-MA - Annex A - Crane Load Calculator

1 Introduction
This annex describes and explains how to use the MacGregor Crane Load Calculator (CLC). The
load calculator is a graphical planning tool for crane operators, which helps determine if the crane
capacity is sufficient to perform a specific operation under a specific condition. However, there may
be required some second hand calculations depending on mode selections (further elaboration
later). The load calculator can also show the current state of the crane in running mode (crane
position, hook load, wire out, etc.).

Figure 1 – Files in delivered folder

Note: This is a tool under continuous development. Appearances and functionality may therefore
vary.

1.1 Abbreviations

 HMI - Human Machine Interface

 DAF - Dynamic Amplification Factor
 PLC - Programmable Logic Controller
 MRU - Motion Reference Unit
 SWL - Safe Working Load
 AOPS - Automatic Overload Protection System
 MOPS - Manual Overload Protection System
 AHC - Active Heave Compensation

1.2 Required 3rd party software

1. Java™, minimum version 1.7.

2. Adobe Reader

Java™, minimum version 1.7., must be installed. This is most likely already installed on your
computer.

1. Check first if Java™ installed by looking for the Java™ directory in “Program Files” and
“Program Files (x86)”.
2. If it does not exists, please download and install from java.com.

Page 2 of 11
Doc type User Manual

Doc. ID I-MA - Annex A - Crane Load Calculator

2 Using the Load Calculator

Figure 2 - Window numbers (planning mode)

2.1 The Three Main Graphical Windows

2.1.1 Load Charts (1)
The load chart window shows the crane lift capacity at different radii with the current wire out, wave
height, etc. In the upper right corner, there is a yellow box with current values (rest capacity,
current load, DAF, wave height, etc.). It also shows if buffer contact is present (green when
contact) and if the crane is in high lift mode (green when present). The yellow box can also show
the available load radius, with a specified load and wire out (see Figure 3). However, when the
notes are selected (button: ), it shows the notes for the selected lift mode instead. The notes
contain guide lines and/or restrictions for the load chart. The grey field limited by a stippled line
indicates the buffer area created by the DAF-factor; the stippled line represents DAF 1.0.
Additional line for high lift (if applicable).

Figure 3 – Yellow box in load chart

Page 3 of 11
Doc type User Manual

Doc. ID I-MA - Annex A - Crane Load Calculator

2.1.2 Crane Geometry (2)

The crane geometry window shows the crane geometry (jib angles) and the hook position relative
to the radius, the ship’s deck and the waterline. In the upper right corner there is a yellow box with
current values (jib angles, radius, height above deck, etc.).

2.1.3 Bird’s Eye View (3)

The bird’s eye view window shows the crane on the vessel from above. This makes it possible to
see the hook position relative to the vessel. In the upper right corner there is a yellow box with
current values (jib position alongside and abeam (x, y coordinates) and slew angle). The origin is in
the centre of the pedestal and 0 degree is usually when the crane is parallel to the direction of
travel and in parked position.

The window also has a radius indication, showing the sector you can lift in with a specified weight
in the hook.

Figure 4 – Bird’s Eye View, with lifting sector

2.2 Input Area (4)

The input area at the top is used to fill in crane parameters and ambient conditions as well as some
general settings. The number editors ( ) work by click and drag of the mouse, or just drag if it
is on a touch screen. It is also possible to use a keyboard, and use Alt + left and right and Alt + up
and down to adjust the scale. The number editors on the left are used to finely adjust the crane’s
geometric position. The number editors to the right adjust wire out, wave height and dynamic
factor. Notice that a blue crosshair moves upwards perpendicular to ‘wire out’ in the load chart
diagram (1 in Figure 2); this line indicates the reduction in lift capacity.

The vertical line in the blue crosshair indicates the maximum radius with the specific reduction in
capacity. It depends on what lift mode is selected regarding wave height and dynamic factor
availability. If a lift mode without adjustable dynamic factor is selected, the dynamic factor is still
displayed even though the number editors are unavailable. Load weight dry is the weight of the
payload in the air and the Load weight wet is the weight of the payload in sea water. The Load
weight wet is automatically calculated based on an equivalent massive steel block (worst case). To
get more lift capacity at greater depth, the operator has to type in the calculated weight of the
specific payload in water.

The input area also features the lift mode select drop down menu, the selection of whip/main winch
and double part mode.
Page 4 of 11
Doc type User Manual

Doc. ID I-MA - Annex A - Crane Load Calculator

The MacGregor logo at the left is a link to the Cargotec web page. The pin is to display notes while
the moon/star button selects night mode.

The two dropdown menus all the way to the right contain language selection (English or
Norwegian) and unit selection (Metric or oilfield).

The pin button ( ) shows or hides the notes for each lift mode; the “moon/stars” button ( )
shows the calculator in night mode (meant to prevent blinding light from the monitor during night
time). The print button to the left ( ) is used for direct print while the button at the right ( )
selects print setup. NB! It is not recommended to print in night mode as it will use a lot of ink or
powder.

Figure 5 - Input area

Note: When double part mode is selected,

the hook position is defined as wire out
divided by two. For example; 1000m wire
out equals 500m hook pos.

Figure 6 - Crane with double part

Page 5 of 11
Doc type User Manual

Doc. ID I-MA - Annex A - Crane Load Calculator

2.3 Running Mode Window (5)

When running mode is selected, an additional window will appear (Figure 7). This window
provides information which is normally shown in the HMI (further elaboration on running mode
later).

Figure 7 - Window numbers (running mode)

Page 6 of 11
Doc type User Manual

Doc. ID I-MA - Annex A - Crane Load Calculator

2.4 Load Calculator on Touch Screen

The load calculator can be implemented on the HMI touch screen. One practical use is on the
ship's bridge together with a HMI read only version.

The close and minimize button are supersized for touch use. If the load calculator and a read only
HMI is on the same PC, the easiest way to switch between the HMI and the calculator without a
keyboard is with the minimiser button in the calculator and the Crane Load Calculator button in the
HMI (see arrow Figure 8).

Figure 8 - HMI with Crane Load Calculator button

Page 7 of 11
Doc type User Manual

Doc. ID I-MA - Annex A - Crane Load Calculator

3 Load Calculator Planning Mode

When considering taking on an assignment, the vessel’s crane operator(s) may use the planning
mode to determine whether it is viable.

In planning mode all of the crane’s joints can be manipulated to check if reach and lift height are
sufficient for a specific task and at the same time check that the crane SWL is not exceeded.
For subsea lifts at greater depth, the object buoyancy and wire weight make a big impact on the
crane lifting capacity. In extreme cases the object can weigh as much as max. SWL on board, but
have high buoyancy in water. In such a case there is no problem reaching maximum depth even
though the load is very heavy. The crane operator can type in load weight dry and wet to check if
the operation is possible.

4 Lift Mode
Depending on the conditions and type of lifting operation, the crane operator can choose from
different lift modes: shipboard, ship to ship, engineered subsea and offshore lift. When choosing
different lift modes, different notes can be displayed describing the different lift mode guidelines.

4.1 Shipboard
Shipboard lift is defined as cargo handling outside the vessel (not including ship to ship) while in
harbour or in sheltered waters or within the vessel at sea.

4.2 Ship To Ship Lift

Ship to ship lift is defined as pick up point when lifting from ship to ship within sheltered area or at
sea.

4.3 Engineered Subsea Lift

Engineered subsea lift requires an insight in the dynamic forces that influence the crane during a
specific lift. In this mode it is not possible to adjust the wave height, only the dynamic factor.

4.4 Offshore Lift

Offshore lift is defined as cargo handling outside the vessel (not including ship to ship) while at
sea.

Page 8 of 11
Doc type User Manual

Doc. ID I-MA - Annex A - Crane Load Calculator

5 Load Calculator Running Mode

Running mode shows the crane position, hook load, lift mode etc. in real time. Running mode also
provides some critical information like oil level and temperature, AOPS and MOPS.

Figure 9 - Running mode window (caught in the moment, AHS settling)

The running mode window (Figure 9) has three different aspects; the indicator lights at the top use
different colour and text to indicate status. The line diagram below shows true heave, relative hook
position, hook speed and deviation. This may be of interest when AHC is active. In Figure 9 AHC
has just been activated and the relative hook position (magenta) is settling alongside the simulated
sine wave (blue). The bar diagram at the right is the oil level and temperature which also shows the
critical levels.

Figure 10 - Indicator lights in running mode

Page 9 of 11
Doc type User Manual

Doc. ID I-MA - Annex A - Crane Load Calculator

The indicator lights in detail:

Light Function State (colour indication)
Control Enabled Indicates if the control enable is on or off. On = green
Off = white
Crane in operation If the crane or winch is moving the crane in Not in operation = white
operation will blink In operation = blinking green
Interlock Override Overrides some of the inhibited functions On = red
Off = white
Main Winch Main winch mode On = green
(Indicates with both text and colour) Off = white
Text: Off, Manual, AHC and AT Activating= blinking green
Deactivating= blinking green
Inhibited = grey
Whip Winch Whip winch mode On = green
(Indicates with both text and colour) Off = white
Text: Off, Manual, AHC and AT Activating= blinking green
Deactivating= blinking green
Inhibited = grey
Main AOPS Automatic overload protection system, on the Enabled = green
main winch. Inhibited = grey
Activated = blinking red
Main MOPS Manual Overload Protection System, on the Enabled = green
main winch. Inhibited = grey
Activated = blinking red
Whip AOPS Automatic overload protection system, on the Enabled = green
whip winch. Inhibited = grey
Activated = blinking red
Whip MOPS Manual Overload Protection System, on the Enabled = green
whip winch. Inhibited = grey
Activated = blinking red
Personnel Lift Personnel lift on/off On = blinking green
Off = white

Figure 11 - Deviation true heave and hook speed editing window

Page 10 of 11
Doc type User Manual

Doc. ID I-MA - Annex A - Crane Load Calculator

By clicking or tapping (if shown on a touch screen) once on a diagram (once again to remove), an
editing window appears (Figure 13). This window shows some general information about the
diagram as well as some editing features like zoom, pause, reset, etc. By clicking on the different
lines in the editing box (True heave, Relative Hook Position, Deviation and Hook speed), the lines
will toggle on and off.

The max/min values below each line can be reset by clicking on the clock button ( ). The max/min
values are also viewed as stippled lines in the line diagram window. There are two different zooms;
the plain magnifying glasses zoom in on both the X and Y axis ( ), the magnifying glasses with
a Y and a bar zoom only in the Y axis ( ). After zooming (magnifying glasses), or after sliding
around the diagram by drag and drop, it is possible to return to the default view by clicking on the
home button ( ).

It is possible to stop the curves by clicking on the pause button ( ) to study the curves, afterwards
press play ( ) to resume. The last button is the delete button ( ); this deletes the buffered curve
data. By enabling Mark (clicking on it), it is possible to set a brake line in the line diagram. Note
that when mark is active it is not possible to pan in the diagram without the use of a mouse.

Page 11 of 11
Doc type User Manual

Doc. ID I-MA - Annex B - Wire life-cycle calculator

Document revision: Document owner: Document revised by:

0 Software Lead 21.01.2015/GHA

Annex B – Wire life-cycle calculator

Table of Contents
1 Introduction .............................................................................................................................. 2
1.1 Abbreviations .................................................................................................................... 2
1.2 3rd party software .............................................................................................................. 3
2 Wire life-cycle calculator (WLCC)............................................................................................. 4
2.1 Usage of the WLCC .......................................................................................................... 4
2.2 The theory behind the WLCC calculation results............................................................... 7
3 Disclaimer .............................................................................................................................. 10

Page 1 of 10
Doc type User Manual

Doc. ID I-MA - Annex B - Wire life-cycle calculator

1 Introduction
This annex describes and explains how to use the MacGregor wire life-cycle calculator (WLCC).
The WLCC is a tool that can visualize wear on the wire and help to determine the life expectancy
continuously. It can also help to increase the lifetime by showing the most worn areas, and thereby
where to spread the load.
Note: This is a tool under continuous development. Appearances and functionality may therefore
vary.

1.1 Abbreviations

 HMI - Human Machine Interface

 DAF - Dynamic Amplification Factor
 PLC - Programmable Logic Controller
 MRU - Motion Reference Unit
 SWL - Safe Working Load
 AOPS - Automatic Overload Protection System
 MOPS - Manual Overload Protection System
 AHC - Active Heave Compensation
 WLCC - Wire life-cycle calculator
 PCD - Pitch Circle Diameter

Page 2 of 10
Doc type User Manual

Doc. ID I-MA - Annex B - Wire life-cycle calculator

1.2 3rd party software

The WLCC requires Java (from Oracle) with minimum version 1.7 installed on the computer.
To check if java is installed (on windows system) go to the control panel and look for the java icon

Figure 1 - Control Panel

If not present, please install from http://java.com

Double click the icon, go to the tab ‘java’, click the button ‘view...’ and select the tab ‘system’

Figur 2 - Java Runtime Environment Settingg

Page 3 of 10
Doc type User Manual

Doc. ID I-MA - Annex B - Wire life-cycle calculator

2 Wire life-cycle calculator (WLCC)

2.1 Usage of the WLCC

The WLCC are built on the same platform as the crane load calculator and has therefore a similar
user interface.

Figur 3 : WLCC User Interface

The wire maintenance program consist of two windows: General info and Wire condition curves.
The general info window shows some general info regarding the specific crane or system. The wire
condition curves window shows the wear on the wire as a curve, and the maximum tension. The x
axis is wire on drum and y axis is a percentage that represents the wear of the wire (when 100% is
reached, the wire should be replaced if the factors are correct) or tension (100% is the maximum
SWL for the wire).

Figure 4– Editing of the wire condition curves

In the upper left corner of the wire condition curves window there are some editing features like
zoom, pause, reset, etc. And in the lower left corner the different lines hare named. By clicking on
the different lines, the lines will toggle on and off. There are two different zooms; the plain
magnifying glasses ( ) zoom in on both the X and Y axis, the magnifying glasses with a Y bar (
) zoom only in the Y axis. After zooming (magnifying glasses), or after sliding around the
diagram by drag and drop, it is possible to return to the default view by clicking on the home icon (
). By enabling Mark (clicking on it), it is possible to set a break line in the line diagram. Note that
when mark is active it is not possible to pan in the diagram.
In the top right corner there are two icons, the question mark ( ) opens this document, and the
cogwheel ( ) opens settings.

Page 4 of 10
Doc type User Manual

Doc. ID I-MA - Annex B - Wire life-cycle calculator

Figur 5– Settings / Wire tension

Settings have two tabs, Wire items and Wire tension. Wire tension shows the max load divided into
segments, each segment has an individual factor. All of the factors together represent 100% wire
tension contribution. Normalized_factor shows how the 100% is divided. The factor can be
adjusted by sliding back and forth on a touch screen, otherwise use alt and arrows (left, right) or
click and drag with mouse. (tip: alt - arrow up and down adjust how much gain on the adjustment)

Figur 6 - Settings / Wire items

Wire items show the different objects that inflict wear on the wire. Bending count is the number of
times the wire is bent when interacting with the object, typically one time on a winch and two times
on a sheave. Radius is the worst case PCD on winch and sheaves. Offset on wire is the distance
from the origin (the winch) to the different objects, a summation of the distances shown on the
illustration (Error! Reference source not found.). Factor determines how much wear each object
inflict the wire. On the top of the Settings window there is an Overall factor this adjust the total
wear, and can be used to tune the curve so it shows a 100% wear when the wire needs to be
replaced. Same as on the other factors the factor can be adjusted by sliding back and forth on a
touch screen, otherwise use alt and arrows (left, right) or click and drag with mouse (tip: alt - arrow
up and down adjust how much gain on the adjustment).

Page 5 of 10
Doc type User Manual

Doc. ID I-MA - Annex B - Wire life-cycle calculator

Figur 7 - Offset on wire

On the top left side of the WLCC there is an open icon ( ) and an export icon ( ), if the operator
wants to have the graphs on a different PC he can export the data, and open the same data with
the same program on a different PC.

Page 6 of 10
Doc type User Manual

Doc. ID I-MA - Annex B - Wire life-cycle calculator

2.2 The theory behind the WLCC calculation results

To understand how to utilize the WLCC best, it may be necessary to know how it calculates the
result.

Figur 8 – Wire segmentation

When sampling data, the WLCC uses approximately 1m segments to store data, in other words a
resolution of 1m. This is assumed to adequate or even maybe too much.

Page 7 of 10
Doc type User Manual

Doc. ID I-MA - Annex B - Wire life-cycle calculator

Figur 9 – Wire travel distribution

As shown in Error! Reference source not found. the WLCC stores the data as an area in each
segment, the area is in turn the number of meters the segment has passed over one wear object
(eks: a sheave). It will also distribute the amount of wear proportionally between two segments as
shown in Error! Reference source not found..
Table 1 - distribution over each segment between forces and wear objects

Winch Sheave 1 Sheave 2 Sheave 3 Sheave 4

Load 1
XX.Xm XX.Xm XX.Xm XX.Xm XX.Xm
eks: 0-10t
Load 2
XX.Xm XX.Xm XX.Xm XX.Xm XX.Xm
eks: 10-20t
Load 3
XX.Xm XX.Xm XX.Xm XX.Xm XX.Xm
eks: 20-50t
Load 4
XX.Xm XX.Xm XX.Xm XX.Xm XX.Xm
eks: 50-100t
Load 5
XX.Xm XX.Xm XX.Xm XX.Xm XX.Xm
eks: 100-250t

This table will be used in a formula which adds factors to each condition to get the resulting wear
factor.
Example on segment calculation:

Page 8 of 10
Doc type User Manual

Doc. ID I-MA - Annex B - Wire life-cycle calculator

Table 2 – Example, segment calculation

Load Winch Sheave 1 Sheave 2 Sheave 3 Sheave 4 Sum

Travle Travle Travle Travle Travle
Load range Factor Factor [m]* Factor [m]* Factor [m]* Factor [m]* Factor [m]*
0-14% 0.035 0.215 84 0.452 84 0.501 81 0.452 70 0.398 70 5.463815
14-28% 0.071 0.215 52 0.452 52 0.501 50 0.452 42 0.398 42 6.775814
28-42% 0.107 0.215 74 0.452 74 0.501 71 0.452 60 0.398 60 14.544403
42-57% 0.143 0.215 51 0.452 51 0.501 49 0.452 20 0.398 20 10.805938
57-71% 0.179 0.215 20 0.452 20 0.501 19 0.452 10 0.398 10 5.613261
71-85% 0.214 0.215 10 0.452 10 0.501 9 0.452 5 0.398 5 3.301806
85-100% 0.25 0.215 0 0.452 0 0.501 0 0.452 0 0.398 0 0
Sum [%] 46.505037
* The distance the wire has travelled over a wear object within the segment. Ex: one segment of one meter
has travelled back and forth 10 times over an object, the segment has than logged 20m travel.
The factors can be changed at any time to get the correct wear sum, if any anomalies are detected
in the posterity. The calculation of each partial sum is done like so: load factor * (winch factor *
travel + sheave 1 factor* travel + ......+sheave n factor* travel)
The Load factor is based on a converging function, in other words the differences in low loads is
more significant then the differences in high loads. (Source: Calculating the service life of running
steel wire ropes by Disl. –Ing. Roland Verreet)

Figure 10 - Load factor graph

Page 9 of 10
Doc type User Manual

Doc. ID I-MA - Annex B - Wire life-cycle calculator

3 Disclaimer

1. MacGregor takes no responsible for the condition of wires or the consequences for a wires breakage.
2. WLCC is just a system for logging the total travel of wire segments over sheaves and drum in
different tensions ranges. Factors are applied to make a presentation of the distribution of fatigue
over the total wire.
3. The values of the factors to reflect correct conditions of the wire must be provided by the customer
in co-operation with the wire manufacturer

Page 10 of 10
Name: SP2582-1-L-KA-002, Number: 306527, Version: 0.1, State: RELEASED, Modifier: greibth

EMERGENCY OPERATION PROCEDURE CABIN OPERATIONS Project: SP2582-1

PART 1

1. Main power supply (440 Voltage), FAULT

2. PLC &230 Voltage supply, RUNNING/OK

A. CONNECT THE 440V EMERGENCY POWER SUPPLY CABLE TO ES404

B. ON THE REMOTE I/O CUBICLE (CC200)

Switch to remain in "Emergency Mode OFF" position

C. STARTER CUBICLE ES404

Switch to "Remote" position/control.
After steps D, E, F, G, H → Start Em. Pump from cabin (Ref. User Manual)

D. ENSURE SUCTION VALVE FOR EMERGENCY PUMP IS OPEN (MH03)

EMERGENCY
IT IS RECOMMENDED THAT THIS VALVE IS OPEN, AT ALL TIME. (This valve OPERATION

is equipped with a lever locking device. Unlock it by lifting up the plug on top of the
valve). NORMAL
OPERATION

E. CLOSE SLEW ACCUMULATOR BLOCK SUPPLY (SH17) NORMAL

OPERATION
THIS WILL INCREASE SPEED DURING EMERGENCY OPERATION.

EMERGENCY
OPERATION

EMERGENCY
F. OPEN EMERGENCY PUMP “SUPPLY” SHUT OFF VALVE FOR OPERATION

EMERGENCY OPERATION OF CRANE FUNCTIONS (MH66)

NORMAL
OPERATION

EMERGENCY
OPERATION
G. OPEN EMERGENCY PUMP “LS” SHUT OFF VALVE FOR EMERGENCY
OPERATION OF CRANE FUNCTIONS (MH63.3)
NORMAL
OPERATION

NORMAL
H. CLOSE MAIN PUMP “LS” REGULATOR SUPPLY (MH63.2) OPERATION

EMERGENCY
OPERATION

Page 1 of 1
Name: SP2582-1-L-KA-003, Number: 306528, Version: 0.1, State: RELEASED, Modifier: greibth

EMERGENCY OPERATION PROCEDURE FROM EM. PANEL Project: SP2582-1

PART 2

1. Main power supply (440 Voltage), FAULT

2. PLC & 230 Voltage supply, FAULT

A. CONNECT THE 440V EMERGENCY POWER SUPPLY CABLE.

Pull the jumper cable through king door. Socket is located in bottom plate of starter
cabinet ES404.

B. CONNECT THE 230V EMERGENCY SUPPLY & EMERGENCY PANEL IN

CC200

C. REMOTE I/O CUBICLE CC200.

Switch to “Emergency Mode ON” position

D. STARTER CUBICLE ES404

Switch to "Local" position.
After → H Start Em.pump. from local panel.

E. OPERATE HYDRAULIC VALVES ACCORDING TO PART 1 -

SEE PART 1
PROCEDURE: Step D → H

F. ACTIVATE EMERGENCY PANEL

Operate crane with hand held panel OP206 (Ref Operation/ User Manual)

Page 1 of 1
 User Manual for Crane

6 Maintenance
Table of Contents
1. General Inspection and Maintenance Instructions ............................................................................1
2. Definitions ........................................................................................................................................1
2.1. Inspections ................................................................................................................................1
2.2. Maintenance ..............................................................................................................................2
3. General Inspection Instructions ........................................................................................................3
4. Periodic Inspections and Maintenance .............................................................................................5
5. Interpreting the Periodic Inspection and Maintenance Program Matrix .............................................6
6. MOPS Function Test ......................................................................................................................17
7. Annexes .........................................................................................................................................18

6 Maintenance
MACGREGOR NORWAY AS
User Manual for Crane

Blank page.

6 Maintenance
MACGREGOR NORWAY AS
 User Manual for Crane

1. General Inspection and Maintenance Instructions

The Inspection and Maintenance program has been developed by MacGregor Norway AS in accordance with
our supplier’s maintenance program for each component. The program involves the following actions:
Inspection, Lubrication, Overhaul and Replace. These actions are implemented in a Periodic Maintenance
Program. Conforming to this maintenance program will ensure a long, trouble-free service life. The importance
of the operator's continuous attention during operation of the equipment is strongly emphasized. If any
irregularities should occur, immediately shut down the equipment, detect the cause and take the necessary
corrective action.

Regular inspection and maintenance will:

Prevent accidents and maintain safe operation of your MacGregor equipment through inspections and
operator training.
Avoid unnecessary interruptions in up-time.
Ensure peak efficiency throughout your crane's long life.
Address potential problems before they become more costly or inconvenient.
Reduce overhead costs associated with parts, lubricants and tools.
Reduce downtime by scheduling when production will not be interrupted.

2. Definitions
2.1. Inspections
Inspections are defined as frequent visual check-ups of the equipment. Any abnormalities discovered during
inspections are to be logged and fixed as part of the maintenance procedures.

The following routines are identified as part of the inspection programme:

Check component for any damage.

Check for correct function of each component.
Check for any unfamiliar noise from each component.
Check for any abnormal vibration from rotating components.
Check for correct oil quantity.
Check condition of paint and other surfaces on all components.
Check for leaks.
Check for corrosion.
Check lifting umbilical for wear.

6 Maintenance
MACGREGOR NORWAY AS 1
 User Manual for Crane

2.2. Maintenance
Maintenance routines are typically more complex and less frequent than inspection routines. Physical work and
changes to the equipment are performed during these routines.

The following routines are identified as part of the maintenance programme:

Lubrication:

Apply grease to grease nipples.

Apply lubricant or oil onto surfaces to reduce friction or corrosion.
Refill or change oil to system or component.

Overhaul:

Remove the component from the system.

Disassemble the component and inspect each part.
Repair if necessary:
o Bearings.
o O-rings, gaskets and seals.
o Wear of mechanical parts.
o Hydraulic valves fittings and hoses.
o All bolts, nuts and washers.
Clean all components before reassembling and remounting.
Replace or repair components as needed, before mounting assembly.
Repair damaged paint surfaces.

Replacements:

Remove original component and replace with a new component.

6 Maintenance

2 MACGREGOR NORWAY AS
 User Manual for Crane

3. General Inspection Instructions

In addition to the periodic maintenance program, it is recommended to perform daily / pre-start inspections:

Visually check for hydraulic oil leaks on the crane, both internal and external.
Visually check of the hydraulic reservoir fluid level.
Visually check of the oil coolers.
Visually check of the aircraft warning light as required.
Visually check of the crane hook latch.
Visually check of wire sheaves and spooling.
Visually check of wire rope for evident deterioration and damage or improper reeving.
Visually check for loose, missing or corroded bolts, pins, keepers or locking wire.
Visually check loose gear to be used, such as slings, sling hooks and shackles.
Ensure the correct load-rating chart for the configuration in use is visible to the crane operator.
Perform a “walk-around” visual examination of the crane structure to ensure that no damage exists.
Visually check that the crane can rotate freely in its working area.
Verify mechanical hook function.
Check control system alarm log.
Lubricate components and correct deficiencies as required based on the results of these inspections.

Inspector qualification criteria:

Inspectors should be familiar with the crane and user manual.

It is important that all inspectors are qualified mechanics or service engineers.

Yearly and five-yearly safety inspections:

National and recertification requirements by classification bodies like DNV, Lloyds Register of Shipping,
Germanischer Lloyd, Bureau Veritas and American Bureau of Shipping include yearly and five-yearly safety
inspections and retesting. These inspections have to be made by the original equipment manufacturer (OEM) or
OEM certified service companies.

Inspections on your advanced MacGregor Active Heave Compensated Offshore Cranes produce neutral reports
on equipment condition and provide recommendations for necessary actions when required. The main purpose
of an inspection is to assess and maintain the condition of the equipment. Our experience and high standards of
design and manufacturing of your advanced crane is the basis for all inspections.

A proactive approach can help to avoid catastrophic breakdowns, downtime and off hire situations. MacGregor,
the original equipment manufacturer (OEM), have the resources of personnel that provide the skill and
experience necessary to guide a proactive approach, helping you as our customer to focus on and to predict the
most effective maintenance needs.

The inspection of advanced cranes rely on equipment specific inspection programs, where MacGregor advanced
cranes are looked at not only with respect to mandatory standards but also to specified technical and operational
requirements.

6 Maintenance
MACGREGOR NORWAY AS 3
 User Manual for Crane

The final inspection report is a document that complies with industrial and mandatory requirements. The full
report includes two documents; an ”Inspection summary report” which is an evaluation of the overall equipment
condition in terms of safety and operation, based on what the inspection reveals, and a ”Service report” where
you will receive recommendations for actions and spare parts when needed.

6 Maintenance

4 MACGREGOR NORWAY AS
 User Manual for Crane

4. Periodic Inspections and Maintenance

Inspection and Maintenance of the crane is organized in different time intervals. The intervals are specified as
follows:

xx Weeks: xx W
xx Months : xx M
xx Years: xx Y
xx Hours: xx H (operating hours)

Examples:

3 months interval: 3M
2 years interval : 2Y
1 Week interval: 1W
2 months / 200 hours: 2 M / 200 h

Maintenance Log
During the warranty period, either the enclosed maintenance log or the
vessel’s own maintenance log should be used to document crane
maintenance, as this will be called upon should a warranty issue occur.

All necessary inspection and maintenance points are identified in the periodic maintenance program tables.

As a general recommendation all hydraulic motor bearings should be replaced after 15000 operating hours.

To prevent corrosion of the main jib cylinder rods, the crane should not be parked with the cylinder rods left
exposed.

In longer periods of inactivity, to avoid shortening of the main jib cylinder’s service life, repeatedly extend and
retract the cylinders to maintain internal lubrication and tightness.

Safe work positions:

Ensure that all maintenance actions are performed from safe and secure working positions; these include the
provided crane platforms and areas within guiderails.
Do not attempt any maintenance in possibly dangerous positions; these include positions outside the
provided platforms and guiderails, areas that may be slippery or areas without secure footing and
balance.

Personal protective equipment (PPE):

When performing any maintenance or service work on the equipment, it is important to always wear
personal protective equipment (e.g. protective clothing, helmet, goggles, gloves, steel tip shoes and
harness where applicable).

6 Maintenance
MACGREGOR NORWAY AS 5
 User Manual for Crane

5. Interpreting the Periodic Inspection and Maintenance

Program Matrix

Maintenance action reference (this is the first maintenance action listed)

Shows which of the crane/winch systems that is involved
Shows which of the crane/winch systems that is affected
Shows the recommended lubrication interval (here; N/A indicates no lubrication necessary)
Shows the recommended Inspection interval (here; every 3 M or 100 hrs)
Shows the recommended Overhaul interval (here; every 5 years)
Indicates component replacement
Short description of the maintenance action

Reference to the full description of the maintenance action

Note: Maintenance actions that are greyed out do NOT apply.

Periodic maintenance program appendices:

Where referred to, please find the applicable annex in section 7 – Annexes.

6 Maintenance

6 MACGREGOR NORWAY AS
 User Manual for Crane

PERIODIC MAINTENANCE PROGRAM

No System Equipment / Lubrication Inspection Overhaul Replace Short Description Reference /
Function Interval Interval Interval Procedure
1 Hydraulic Slew motor N/A.
Inspect for abnormal noise, vibration, leaks, paint
3M/500H
condition and corrosion.
-
Overhaul component. Contact
5Y/15000H
MacGregor Norway AS.
 Replace if damaged.
2 Hydraulic Slew gearbox 1Y/2500H Change oil in gear and brake.
6M/1000H Change grease, by filling new.
1M/300H Check gear oil level.  User Manual volume
2 Lubrication charts
3M/500H Inspect for any abnormal noise, vibration.
 Annex A: LSS- 03
Overhaul component. Contact BRE
5Y
MacGregor Norway AS.
 Replace if damaged.
3 Hydraulic Winch motor N/A.
(MW, WW, TW) Inspect for abnormal noise, vibration, leaks, paint
1M/300H
condition and corrosion.
Overhaul component. Contact -
5Y/15000H
MacGregor Norway AS.
 Replace if damaged.
4 Hydraulic Winch gearbox 1Y/2500H Change oil in gear and brake.
(MW, WW, TW) 6M/1000H Change grease, by filling new.
1M/300H Check gear oil level.  User Manual volume
2 Lubrication charts
3M/500H Inspect for any abnormal noise, vibration.
 Annex A: LSS- 04
Overhaul component. Contact BRE
5Y
MacGregor Norway AS.
 Replace if damaged.
5 Hydraulic Tubes, fittings N/A.
and couplings 3M/500H Condition check, leaks, denso tape. -
N/A.

6 Maintenance
MACGREGOR NORWAY AS 7
 User Manual for Crane

PERIODIC MAINTENANCE PROGRAM

No System Equipment / Lubrication Inspection Overhaul Replace Short Description Reference /
Function Interval Interval Interval Procedure
 Replace if damaged.
6 Hydraulic Oil filters N/A.
N/A.
N/A.  Annex F
1Y/1000
Replace filter elements.
H
7 Hydraulic Manual Valves 1Y Apply grease/Vaseline to the valve levers.
3M/1000H Inspect for any malfunction or damage.
-
N/A.
 Replace if damaged.
8 Hydraulic Accumulators N/A.
Inspect general condition, brackets and bolts,
6M/1000H
check pre-charge pressure.
 Annex I
 Overhaul or replace if unable to hold the
necessary pre-charge. Contact

MacGregor Norway AS.
9 Hydraulic Jib cylinders 6M/1000H Apply grease to the cylinder rod end nipples.
6M/1000H Inspect all exposed cylinder rods.
-
 Overhaul or replace if damaged.
 Contact MacGregor Norway AS.
10 Hydraulic System oil 6M/1000H Take oil sample for analysis.
At start-up. Inspect reservoir oil level / quantity.  Annex A: LSS 05
N/A.  Annex G
 Replace oil as necessary after analysis.
11 Hydraulic Open Loop N/A.
Variable Pump Inspect for abnormal noise, vibration, corrosion
(Main pumps) 3M/500H
and leaks. -
5Y/15000H Overhaul component.
 Contact MacGregor Norway AS.
12 Hydraulic Hydraulic hoses N/A
 Annex E
6M/1000H Visual inspection, replace if damaged.

6 Maintenance

8 MACGREGOR NORWAY AS
 User Manual for Crane

PERIODIC MAINTENANCE PROGRAM

No System Equipment / Lubrication Inspection Overhaul Replace Short Description Reference /
Function Interval Interval Interval Procedure
N/A.
5Y Replace all outdoor hoses
10Y Replace all indoor hoses
13 Hydraulic Air breather N/A.
filters N/A.
N/A.  Annex F
1Y/1000
Replace filter elements.
H
14 Hydraulic Air/oil cooler N/A.
6M/1000H Visual inspection; leakage & corrosion.
-
N/A.
 Replace if damaged.
15 Hydraulic Servo valves N/A.
6M/1000H Visual inspection and functional check
-
N/A.
 Replace if damaged.
16 Hydraulic Open Loop N/A.
Variable Pump Inspect for abnormal noise, vibration, corrosion,
(axial piston 3M/500H
leaks or damage on attached components.
pump) -
Overhaul component.
5Y/15000H
Contact MacGregor Norway AS.
N/A.
17 Hydraulic Open Loop Fixed N/A.
Displacement Inspect for abnormal noise, vibration, corrosion,
Pump (screw 3M/500H
leaks or damage on attached components.
pump) -
Overhaul component.
5Y
Contact MacGregor Norway AS.
N/A.
18 Hydraulic Emergency Pump N/A.
-
1Y Inspect for function, abnormal noise, vibration,

6 Maintenance
MACGREGOR NORWAY AS 9
 User Manual for Crane

PERIODIC MAINTENANCE PROGRAM

No System Equipment / Lubrication Inspection Overhaul Replace Short Description Reference /
Function Interval Interval Interval Procedure
corrosion, leaks or damage on attached
components.
N/A.
N/A.
19 Hydraulic Accumulators NA
(piston) 1Y/2000H Inspect cylinder for damage, leak.
-
Overhaul or replace if damaged.
5Y
Contact MacGregor Norway AS.
20 Mechanical Grease nipples, 1M/300H Apply grease to all grease nipples.
(not part of the N/A  User Manual volume
automatic lubr. 2 Lubrication charts
N/A.
System)  Annex A: LSS- 01
 Replace if damaged.
21 Mechanical Slew rotation N/A
encoder Inspect for proper function, no damage and
3M/500H
corrosion.  Annex Q
N/A.
 Replace if damaged.
22 Mechanical Main and knuckle Apply grease to grease nipples.
jib 1Y
Grease until excess grease is visible.  User Manual volume
6M/1000H Check for plate damage/grease nipple condition. 2 Lubrication charts
N/A.  Annex C
 Replace if damaged.
23 Mechanical Slewing ring/ gear Apply special grease to drive pinion and slewing
1M/100H  User Manual volume
drive pinion ring.
1Y/500H Check for wear/abnormal tooth clearance. 2 Lubrication charts
 Annex A: LSS- 08
N/A.
 Replace if damaged.
24 Mechanical Slewing bearing  Part of the Central lubrication system.  User Manual volume
1Y Remove blanking bolts for grease sampling 2 Lubrication charts
Fresh collar of grease must be visible.  Annex B
6M/1000H
Inspect seal for condition/damage.

6 Maintenance

10 MACGREGOR NORWAY AS
 User Manual for Crane

PERIODIC MAINTENANCE PROGRAM

No System Equipment / Lubrication Inspection Overhaul Replace Short Description Reference /
Function Interval Interval Interval Procedure
6M/1000H Perform slew bearing wear measurement.
25 Mechanical Slewing bearing N/A
and foundation 1M after Initial re-tensioning of all bolts.
bolt connection crane
delivery
26 Mechanical Slewing bearing Inspect all slewing bearing and foundation bolts
1M/500H
and foundation and nuts. (Bolts / nuts in place).
bolt connection 6M/500H Periodic re-tensioning of all bolts.
continued
6M/500H Knock – test  Annex K
 Annex L
1Y Individual bolt removal and examination
N/A
 Replace if damaged.
27 Mechanical Wire sheaves  Part of the Central lubrication system.
Verify that the sheaves rotate freely.
Verify fresh collar of grease at bearings. Inspect
6M/1000H
for corrosion, wear and cracks. Inspect bolts.  Annex B
Initial groove measure.  Annex M
N/A.
 Replace if damaged.
28 Mechanical Winch gear drive  Part of the Central lubrication system.  User Manual volume
pinion & gear Check for wear/damage of the gear wheel. Verify 2 Lubrication charts
wheel rim 6M/500H
fresh collar of grease on gear wheel rim.  Annex A: LSS- 08,
N/A. LSS-20
 Replace if damaged.
29 Mechanical Bondura bolts 3M/500H Apply grease after re-torque.
3M/500H  User Manual volume
Inspect all Bondura bolts on crane. Check
after first 2 Lubrication charts
makeup torque for bolt screws.
year  Annex C
Inspect all Bondura bolts on crane. Check  Annex J
6M/1000H
makeup torque for bolt screws.

6 Maintenance
MACGREGOR NORWAY AS 11
 User Manual for Crane

PERIODIC MAINTENANCE PROGRAM

No System Equipment / Lubrication Inspection Overhaul Replace Short Description Reference /
Function Interval Interval Interval Procedure
 Replace if damaged.
30 Mechanical Bolts & nuts in N/A.
general. Inspect all bolts and nuts on the equipment.
6M/500H
Ensure they are not loose or damaged.  Annex K
Superbolts (if  Annex U
N/A.
applicable)
 Replace if damaged.
31 Mechanical Mechanical N/A.
components in Inspect the entire equipment for structural
general 6M/1000H damage. Check for corrosion. Inspect paint
condition. -
N/A.
Replace component if damaged. Contact

MacGregor Norway AS.
32 Mechanical Jib angle encoder N/A.
3M/500H Inspect condition of the arrangement.
 Annex Q
N/A
 Replace component if damaged.
33 Mechanical Lift wire Use of a high-pressure lubrication tool is

(MW, WW) recommended.
Inspect for wear, corrosion and general condition.
1M/2000H
See reference.  Annex D
N/A.
Replace if damaged. Contact

MacGregor Norway AS.
34 Mechanical Swivels/hooks 1W See reference.
4Y Inspect swivels/hooks.
N/A.  Annex D
Replace if damaged. Contact

MacGregor Norway AS.
35 Mechanical Wire spooling 3M/200H Grease nipples on w. sheave / cylinders  User Manual volume
device 3M/200H Inspect for wear, corrosion and general condition. 2 Lubrication charts
N/A.  Annex A: LSS-11

6 Maintenance

12 MACGREGOR NORWAY AS
 User Manual for Crane

PERIODIC MAINTENANCE PROGRAM

No System Equipment / Lubrication Inspection Overhaul Replace Short Description Reference /
Function Interval Interval Interval Procedure
Replace if damaged. Contact

MacGregor Norway AS.
36 Mechanical Denso tape N/A
1Y Inspect Denso tape condition
-
N/A
 Repair/replace if damaged
37 Mechanical Winch rotation N/A.
encoder Inspect for proper function, no damage or
3M/500H
corrosion.  Annex Q
N/A.
 Replace if damaged.
38 Mechanical Spooling encoder N/A.
Inspect for proper function, no damage or
3M/500H
corrosion.  Annex Q
N/A.
 Replace if damaged.
39 Mechanical El. Motor/pump N/A.
connection 1Y Inspect for damage.
-
N/A.
 Replace if damaged.
40 Mechanical Cooling System Check oil in compressor before starting, check air  See cooling system
6M conditioner grill is free of dust and if so clean datasheet, volume 2
filter.
41 Electrical Pressure N/A.
transmitters Recalibration. Contact
2Y
MacGregor Norway AS.
 Annex P
N/A.
 Replace if damaged. Contact
MacGregor Norway AS.

6 Maintenance
MACGREGOR NORWAY AS 13
 User Manual for Crane

PERIODIC MAINTENANCE PROGRAM

No System Equipment / Lubrication Inspection Overhaul Replace Short Description Reference /
Function Interval Interval Interval Procedure
42 Electrical Electric motors  Apply grease.
Inspect for abnormal noise, vibration, corrosion
3M/200H
and signs of over-heating.
5Y Overhaul motor.  Annex A: LSS-22
 Replace if damaged. Contact
MacGregor Norway AS.
43 Electrical MRU. N/A.
(Motion 3M Visually in Trend log.
Reference Unit.) 4Y Recalibration. Contact
 Annex O
MacGregor Norway AS.
 Replace if damaged. Contact
MacGregor Norway AS.
44 Electrical Control cabinets N/A
Inspect for loose parts, loose cable terminations,
3M
broken fuse or any water.  Annex N
N/A
 Replace if damaged.
45 Electrical Cables N/A
1Y Inspect all cables for mechanical damage.
-
N/A
 Replace if damaged.
46 Electrical Cable glands N/A
1Y Check that all cable glands are tight.
-
N/A
 Replace if damaged.
47 Electrical MOPS battery N/A
Load test the 24 VDC backup battery package for
1Y
the MOPS system. -
N/A
 Replace if damaged.
48 Electrical Load cells N/A. -

6 Maintenance

14 MACGREGOR NORWAY AS
 User Manual for Crane

PERIODIC MAINTENANCE PROGRAM

No System Equipment / Lubrication Inspection Overhaul Replace Short Description Reference /
Function Interval Interval Interval Procedure
Recalibrate Load cells. Contact MacGregor
1Y
Norway AS.
N/A.
 Replace if damaged.
49 Electrical El. Cabinets / N/A.
Junction Boxes 1Y Check Cortec VCI Device due date.
-
N/A.
 Replace if due.
50 Electrical Main / whip N/A
winch MOPS 1Y Test MOPS functionality  Section 6; MOPS
function test
N/A Function Test
N/A
51 Electrical Hook up  N/A.
(mechanical) 6M Visual inspection and functional check.
-
N/A.
 Replace if damaged.
52 Electrical PC Replace PC in crane cabin. Contact MacGregor
5Y
Norway AS.

Blank page.

6 Maintenance
MACGREGOR NORWAY AS 15
 User Manual for Crane

6. MOPS Function Test

At least once a year it is recommended to test the Manual Overload Protection Systems (MOPS). All offshore
winches have separate MOPS system with separate controls and must therefore be tested separately, according
to the description below.

The MOPS test load must be minimum 10-20 % of winch SWL.

The MOPS controls are located in the operator cabin as indicated in the
picture to the right (yellow buttons with safety guard).

Safety measures:

 Verify that the test area is adequately marked.

 Inform the immediate surroundings about the planned test before
running the test.

Winch MOPS functional test:

1. Run the crane/winch in “Normal” mode.

2. Attach the test load to the winch hook.
3. Hoist the load just above the deck or ground (Approximately 10- 15 cm).
4. Stop the HPU and shut down the crane power (If possible).
5. Open the protective cover and press the yellow MOPS push button to activate the MOPS.

Observe:

 Load is lowered to the deck/ground

 Bull horn warning
 MOPS notification on operator’s screen
 With the load resting on deck/ground, the winch is stopped.
 Test duration should be 5 minutes to verify
 MOPS functions and the UPS supply (bull horn sounds for 5 minutes).

6. Open the protective cover and press the yellow MOPS push button again to de-activate the MOPS
7. Start up the HPU and crane to verify correct behavior of the system.

6 Maintenance
MACGREGOR NORWAY AS 17
 User Manual for Crane

7. Annexes
The following annexes are provided at the end of this chapter:

Annex A Lubrication Standard Specifications (LSS’s)

Annex B Automatic Lubrication System
Annex C Manual Lubrication
Annex D Lift wires and Lifting Hooks
Annex E Hydraulic Hoses
Annex F Replacement of Hydraulic Filters
Annex G Oil Analysis
Annex H Oil Filling and Air Bleed Procedure (Semi-active cranes only)
Annex I Accumulator Pre-Charge Pressures
Annex J Bondura Bolts
Annex K Slew and Foundation Bolts
Annex L Slew Bearing Wear Measurement
Annex M Wire Sheave Wear Measurement
Annex N General Electrical System
Annex O Motion Reference Unit (MRU)
Annex P Pressure Transmitters
Annex Q Encoders
Annex S Decommissioning
Annex T Disposal of Waste
Annex Z Maintenance Log
Annex V Retension and Control of Slew Bearing Bolt

Annexes that are greyed out, do not apply.

6 Maintenance

18 MACGREGOR NORWAY AS
 User Manual for Crane

Annex A -
Lubrication Standard Specifications (LSS)
MacGregor Norway standard lubrication specifications:
Please refer to the following Lubrication Standard Specifications where applicable.

• Lubrication Nipples in General LSS-01

• Wire and Sliding Surfaces LSS-02
• Slew Gearbox LSS-03
• Winch Gearbox LSS-04 Winch Gear
• Winch Gearbox LSS-04 Tugger Winch
• Hydraulic System Oil LSS-05
• Drive Pinions / Gear Rim LSS-08
• Heavy Duty Equipment Grease LSS-11
• Winch with Gear Rim LSS-20 Main Winch
• Winch without Gear Rim LSS-21 Whip Winch
• Electric motors LSS-22

6 Maintenance - Annex A

MACGREGOR NORWAY AS
A1
 User Manual for Crane

MAINTENANCE SYSTEM FOR

MACGREGOR NORWAY PRODUCTS
Doc. ID. : Rev. / date : Page:

LSS-01 nipples.doc 02 / 28.04.09 1 of 1

STANDARD LUBRICATING SPECIFICATION

Specification no.: LSS-01

Lubrication equipment: GREASE NIPPLES IN GENERAL

General Instruction: Operate the equipment while applying grease. Use

enough grease so that excess grease can be seen on
the bearings.
For location of grease nipples, refer lubrication chart for
the actual product.
General Lubrication DIN 51502 KP 2 K 30
Specification: ISO 6743-09 ISO-L-XCCEB 2

Suppliers Lubrication Hydro Texaco MULTIFAK EP2

Specification: Castrol SPHEEROL SX 2/ LMX grease

Comments / notes:

6 Maintenance - Annex A

MACGREGOR NORWAY AS
A2
 User Manual for Crane

MAINTENANCE SYSTEM FOR

MACGREGOR NORWAY PRODUCTS
Doc. ID. : Rev. / date : Page:

LSS-02 wire.doc 03 / 28.04.09 1 of 1

STANDARD LUBRICATING SPECIFICATION

Specification no.: LSS-02

Lubrication equipment: WIRE AND SLIDING SURFACES

General Instruction: Apply grease to wire and sliding surfaces according to

the maintenance program.

General Lubrication DIN 51502

Specification: ISO 6743-09

Suppliers Lubrication Hydro Texaco FLOATCOAT/ TEXCLAD 2

Specification: Castrol SPHEEROL SX 2

Comments / notes:

6 Maintenance - Annex A

MACGREGOR NORWAY AS
A3
 User Manual for Crane

MAINTENANCE SYSTEM FOR

MACGREGOR NORWAY PRODUCTS
Doc. ID. : Rev. / date : Page:

LSS-03 Slew Gear 03 / 28.04.09 1 of 3

STANDARD LUBRICATING SPECIFICATION

Specification no.: LSS-03

Lubrication equipment: SLEW GEAR BOX (VERTICAL MOUNTING)

General Instruction: Specified in lubricating instruction next pages.

For location of lubricating points, refer lubrication chart
for the actual product.

General Lubrication DIN 51517 / 3 CLP

Specification: ISO VG 150

Suppliers Lubrication Hydro Texaco MEROPA 150

Specification: Castrol ALPHA 150

Comments / notes: The lubricating specification above is valid for gear unit.
For brake unit, see instructions next page.

6 Maintenance - Annex A

MACGREGOR NORWAY AS
A4
 User Manual for Crane

MAINTENANCE SYSTEM FOR

MACGREGOR NORWAY PRODUCTS
Doc. ID. : Rev. / date : Page:

LSS-03 Slew Gear 03 / 28.04.09 2 of 3

GEAR LUBRICATING INSTRUCTION

GENERAL
All gears for vertical mounting: completely fill with oil.

Check the table next page for correct plug positions. For vertical mounting a header
oil tank can be supplied. Continuous working temperature must not exceed 90° C.

OIL CHANGES
Oil intervals may be modified, depending on actual operating conditions. During oil
change, we recommend that the inside of the gear case is flushed out with flushing
fluid recommended by lubricant manufacturer. Oil should be changed when hot to
prevent buildup of sludge deposit. It is advisable to check oil level at least once per
month. If more than 10 % of total oil capacity has to be added, check for oil leaks. Do
not mix oils of different types even of the same make.

Never mix mineral and synthetic oils. Pay attention to oil and gear temperature during
oil change, to avoid the risk of scalding. Be conscious of the pollution hazard due to
the oil.

DISC BRAKES TYPE FL

For lubrication of the brake plates we recommend to use mineral oils, heat and aging
resistant, having viscosity ISO VG 32. See LSS-05. Hydraulic oil is normally suitable.
The hydraulic fluid in the motor and the brake release is normally suitable.

The brake and gear units are separately lubricated, and it is essential that both oil
levels are checked independently.

 For brake oil specification see LSS-05

FOR SLEW GEARBOXES “RPR”

The main bearing (nearest to the output pinion) from the series 065/150/250/400 and
600 is grease lubricated. Take care to fill the bearing compartment with grease
before starting. This is done by pumping grease into the grease-nipple until the
grease comes out of the main bearing which is protected by a so called “NILOS” ring.
Grease should be completely exchanged every 1000 hours or six months, whatever
occurs first.

 For grease specification see LSS-01

6 Maintenance - Annex A

MACGREGOR NORWAY AS
A5
 User Manual for Crane

MAINTENANCE SYSTEM FOR

MACGREGOR NORWAY PRODUCTS
Doc. ID. : Rev. / date : Page:

LSS-03 Slew Gear 03 / 28.04.09 3 of 3

LUBRICATING INSTRUCTION

Brake: Always unscrew the oil level

plug to ensure escaping of air when
filling.

Gear: The expansion tank must be

connected to a top level plug outlet
(ensures no entrapped air), and the
minimum level mark must be above
top level in gear box.
When filling oil through expansion
tank – always unscrew an oil level
plug to ensure the oil level and for
escaping of air. When gear
box is full, continue filling to
MIN level on expansion tank.
Normally there is a drain hose
connected, in which also can be used
for filling. The air will escape through
bleeder plug on expansion tank. For
first time filling and when change of
oil it can be effective to fill through
the drain plug by overpressure filling
method to ensure evacuation of all
air.

6 Maintenance - Annex A

MACGREGOR NORWAY AS
A6
 User Manual for Crane

MAINTENANCE SYSTEM FOR

MACGREGOR NORWAY PRODUCTS
Doc. ID. : Rev. / date : Page:

LSS-04 Winch Gear 02 / 29.04.09 1 of 3

STANDARD LUBRICATING SPECIFICATION

Specification no.: LSS-04 Winch Gear

Lubrication equipment: WINCH GEAR BOX (HORIZONTAL MOUNTING)

General Instruction: Specified in lubrication instruction next pages.

For location of lubrication points, refer lubrication chart
for the actual product.

General Lubrication DIN 51517 / 3 CLP

Specification: ISO VG 150

Suppliers Lubrication Hydro Texaco MEROPA 150

Specification: Castrol ALPHA 150

Comments / notes: The lubricating specification is valid for gear unit.

For brake unit, see instructions next page.

6 Maintenance - Annex A

MACGREGOR NORWAY AS
A7
 User Manual for Crane

MAINTENANCE SYSTEM FOR

MACGREGOR NORWAY PRODUCTS
Doc. ID. : Rev. / date : Page:

LSS-04 Winch Gear 02 / 29.04.09 2 of 3

GEAR LUBRICATING INSTRUCTION

GENERAL
Check the table next page for correct plug positions. Check oil filling carefully in all
cases. Extension pipes may be installed to facilitate checking of oil level. Continuous
working temperature must not exceed 90° C.

OIL CHANGES
Oil intervals may be modified, depending on actual operating conditions. During oil
change, we recommend that the inside of the gear case is flushed out with flushing
fluid recommended by lubricant manufacturer. Oil should be changed when hot to
prevent buildup of sludge deposit. It is advisable to check oil level at least once per
month. If more than 10 % of total oil capacity has to be added, check for oil leaks. Do
not mix oils of different types even of the same make. Never mix mineral and
synthetic oils. Pay attention to oil and gear temperature during oil change, to avoid
the risk of scalding. Be conscious of the pollution hazard due to the oil.

DISC BRAKES TYPE FL

For lubrication of the brake plates we recommend to use mineral oils, heat and aging
resistant, having viscosity ISO VG 32. See LSS-05. Hydraulic oil is normally suitable.
The hydraulic fluid in the motor and the brake release is normally suitable. The brake
and gear units are separately lubricated, and it is essential that both oil levels are
checked independently.

 For brake oil specification see LSS-05

FOR SLEW GEARBOXES “RPR”

The main bearing (nearest to the output pinion) from the series 065/150/250/400 and
600 is grease lubricated. Take care to fill the bearing compartment with grease
before starting. This is done by pumping grease into the grease-nipple until the
grease comes out of the main bearing which is protected by a so called “NILOS” ring.
Grease should be completely exchanged every 1000 hours or six months, whatever
occurs first.

 For grease specification see LSS-01

6 Maintenance - Annex A

MACGREGOR NORWAY AS
A8
 User Manual for Crane

MAINTENANCE SYSTEM FOR

MACGREGOR NORWAY PRODUCTS
Doc. ID. : Rev. / date : Page:

LSS-04 Winch Gear 02 / 29.04.09 3 of 3

Break breather plug

Brake oil level plug
Brake drain plug
Filling and breather plug
Oil level plug
Magnetic and drain plug
Greasing
Brake release plug

3 – Graser for oil sealing GI/8

(N.2 at 180˚)

5 – Brake releasing hole MI2XI.5

6 – Filling/breather and drain oil plug for

brake disc-room

7 – Use mineral oil with viscosity ISO

VG32.

• The gearbox filling/breather port is fitted with a pressure relief breather valve. Inspect
and replace if necessary before refitting.
• The gear section lower plugs are equipped with magnetic tips. At oil change intervals
check for metal particles. Thoroughly clean plug before refitting.
• Each individual gear housing will be slightly rotated compared to each other due to
the eccentric mounting. Therefore identify the plug nearest to the gear centerline
when checking oil levels in the chambers.
• After removing centreline plug for oil level checks and no oil is visible through port,
make a simple dipstick from a plastic strip or equal to verify oil level.
6 Maintenance - Annex A

MACGREGOR NORWAY AS
A9
 User Manual for Crane

MAINTENANCE SYSTEM FOR

MACGREGOR NORWAY PRODUCTS
Doc. ID. : Rev. / date : Page:

LSS-04 Tugger Winch 0 / 05.02.10 1 of 3

STANDARD LUBRICATING SPECIFICATION

Specification no.: LSS-04 Tugger Winch

Lubrication equipment: WINCH GEAR BOX

General Instruction: Check the oil level monthly or after 300 operating hours.
Change oil annually or after 2500 operating hours.
Se next pages for oil plug placing and further
instructions.

General Lubrication GEAR OIL

Specification: DIN 51517 / 3 CLP
ISO VG 150

BRAKE OIL
ISO VG 32
Suppliers Lubrication GEAR OIL
Specification: Texaco MEROPA 150
Castrol ALPHA 150

BRAKE OIL
Texaco HD 32
Comments / notes:

6 Maintenance - Annex A

MACGREGOR NORWAY AS
A10
 User Manual for Crane

MAINTENANCE SYSTEM FOR

MACGREGOR NORWAY PRODUCTS
Doc. ID. : Rev. / date : Page:

LSS-04 Tugger Winch 0 / 05.02.10 2 of 3

GEAR LUBRICATING INSTRUCTION

GENERAL
Check the next pages for plug positions.
Continuous working temperature must not exceed 90° C.
OIL CHANGES
Oil intervals may be modified, depending on actual operating conditions. During oil
change, we recommend that the inside of the gear case is flushed out with flushing
fluid recommended by lubricant manufacturer. Oil should be changed when hot to
prevent buildup of sludge deposit. It is advisable to check oil level at least once per
month. If more than 10 % of total oil capacity has to be added, check for oil leaks. Do
not mix oils of different types even of the same make. Never mix mineral and
synthetic oils. Pay attention to oil and gear temperature during oil change, to avoid
the risk of scalding. Be conscious of the oil pollution hazard.
The gear section oil plugs are equipped with magnetic tips. At oil change intervals
check for metal particles. Thoroughly clean plug before refitting.
Rotate winch (Oil level inspection):

 Working with warm oil, rotate winch until 2 off

oil plugs are lined up horizontally (oil plug
visible in center of inner access hole).
Oil plug
access  Remove the upper and the outer oil plug. Add
hole. oil until excess oil exits the gearbox through
outer oil plug hole.

 Refit oil plugs.

Oil plugs (4),
outer plug in  Run winch and check for leaks.

DISC BRAKES TYPE FL

For lubrication of the brake plates we recommend to use mineral oils, heat and aging
resistant, having viscosity ISO VG 32. See LSS-05. Hydraulic oil is normally suitable.
The brake and gear units are separately lubricated, and it is essential that both oil
levels are checked independently.
 For oil brake specification see LSS-05

6 Maintenance - Annex A

MACGREGOR NORWAY AS
A11
 User Manual for Crane

MAINTENANCE SYSTEM FOR

MACGREGOR NORWAY PRODUCTS
Doc. ID. : Rev. / date : Page:

LSS-04 Tugger Winch 0 / 05.02.10 3 of 3

Gear box oil quantity (l): 2

Brake oil quantity (l): 0.6

GEARBOX OIL PLUG G ¼”

BRAKE OIL PLUG G ¼”

BRAKE OIL PLUG WITH BREATHER G ¼”

BRAKE OIL PLUG G ¼”

BRAKE OIL PLUG G ¼”

6 Maintenance - Annex A

MACGREGOR NORWAY AS
A12
 User Manual for Crane

MAINTENANCE SYSTEM FOR

MACGREGOR NORWAY PRODUCTS
Doc. ID. : Rev. / date : Page:

LSS-05 Hydraulic oil.doc 02 / 26.10.05 1 of 1

STANDARD LUBRICATING SPECIFICATION

Specification no.: LSS-05

Lubrication equipment: HYDRAULIC SYSTEM OIL

General Instruction: Oil levels and quantity specified in the maintenance

procedure in the User manual.

General Lubrication DIN 51524 / 3 HVLP ISO VG 68 For temp >+35 °C

Specification: DIN 51524 / 3 HVLP ISO VG 46 For temp >+20 °C <+35 °C
DIN 51524 / 3 HVLP ISO VG 32 For temp >÷10 °C <+20 °C
DIN 51524 / 3 HVLP ISO VG 22 For temp <÷10 °C **)
Suppliers Lubrication Texaco RANDO OIL HDZ68 For temp >+35 °C
Specification: RANDO OIL HDZ46 For temp >+20 °C<+35 °C
RANDO OIL HDZ32 For temp >÷10 °C<+20 °C
RANDO OIL HDZ22 For temp <÷10 °C
Castrol HYSPIN AWH 68 For temp >+35 °C
HYSPIN AWH 46 For temp >+20 °C<+35 °C
HYSPIN AWH 32 For temp >÷10 °C<+20 °C
HYSPIN AWH 15 For temp <÷10 °C
Comments / notes: **) For low temperature operation below ÷20 °C, special arctic
oil Is recommended. Please contact relevant supplier for
exact specification.
Ex.:
Statoil: HYDRAULIC OIL 131 For temp >÷40 °C < +65 °C

6 Maintenance - Annex A

MACGREGOR NORWAY AS
A13
 User Manual for Crane

MAINTENANCE SYSTEM FOR

MACGREGOR NORWAY PRODUCTS
Doc. ID. : Rev. / date : Page:

LSS-08 Drive pinion.doc 05 / 30.04.09 1 of 1

STANDARD LUBRICATING SPECIFICATION

Specification no.: LSS-08

Lubrication DRIVE PINIONS / GEAR RIM

equipment:

General Instruction: Use a brush to apply grease to all tooth flanks of pinions and gear
ring.
Re-lubricate in accordance with the maintenance program.
For location of pinions, refer to the lubrication chart for the product
in question.
Approved Suppliers’ Klüber: Klüberplex AG 11-462
Lubrication  Norsk Industriolje AS: Omega 73
Specifications:  Hydro Texaco / YX Energy / Chevron: Texclad 2
General Lubrication DIN 51502MF 2C-10/KF 2C-10
Specification: ISO 6743-09 ISO-L-X AAIB2

Typical properties: Consistency: NLGI 2

Recommended temperatures: –30→110 °C (for Kluberplex
AG 11-462)
Recommended temperatures: –3→150 °C (for Omega 73)
Recommended temperatures: –10→60 °C (for Texclad 2)
Solid lubricants: Solid lubricant content (min
20 %)
Comments / notes: * : Not to be used in automatic grease pump system
The color of AG 11-462 is white. Omega73 and Texclad 2 is black.

6 Maintenance - Annex A

MACGREGOR NORWAY AS
A14
 User Manual for Crane

MAINTENANCE SYSTEM FOR

MACGREGOR NORWAY PRODUCTS
Doc. ID. : Rev. / date : Page:

LSS-11 Heavy duty grease.doc 01 / 29.04.09 1 of 1

STANDARD LUBRICATING SPECIFICATION

Specification no.: LSS-11

Lubrication HEAVY DUTY EQUIPMENT GREASE

equipment:

General Instruction: If possible, operate the equipment while applying grease.

Initial assembly and manual re-lubrication: inject grease until excess
grease can be seen on the bearings.
Assembly of roller bearings: fill bearing completely with grease.
For location of grease nipples, refer to the lubrication chart for the
product in question.
Approved Hydro Texaco / Chevron: Novatex Heavy EP 2
Suppliers’ Statoil: Statoil Chassis Grease
Lubricating
Specifications: Greaseway CaH 92

General Lubrication ISO 6743-9: L-XBCIB2 / L-XCCHB2

Specification: DIN 51502: KP2K-20 / KP2K-30

Typical properties: Method

Soap type: Calcium -
Consistency: 2 NLGI
Oil type: Mineral -
Base oil viscosity at 40 °C: 1300 mm²/s ISO 12058*
Base oil viscosity at 100 °C: 106 mm²/s ISO 12058*
Recommended temperatures: –20→120 °C -
Long polymer (“tacky”) additives: Yes -
Extreme pressure (EP) additives: Yes -
Solid lubricants: No -
*) Base oil viscosity applies to the final mixed oil including long polymer
additives.

6 Maintenance - Annex A

MACGREGOR NORWAY AS
A15
 User Manual for Crane

MAINTENANCE SYSTEM FOR

MACGREGOR NORWAY PRODUCTS
Doc. ID. : Rev. / date : Page:

LSS-20 Winch with gear rim.doc 03 / 29.04.09 1 of 3

STANDARD LUBRICATING SPECIFICATION

Specification no.: LSS-20

Lubrication equipment: WINCH WITH GEAR RIM

General Instruction: The winch has the following main components which need
lubrication:
 A set of gearboxes
 Gear rim(s) and pinions
 Main bearings
 Wire rope
 One or two pulse encoders
(pulse encoder not supplied with all winches)
Note: if the pulse encoder is of a type without grease nipple, it
does not need to be lubricated.
 Additional equipment with grease nipple (if any)
The illustration overleaf shows the location of these
components and references to specific LSS procedures.
Approved Suppliers’ Reference is made to the following LSS procedures:
Lubrication Specifications: LSS-01, LSS-02, LSS-04, LSS-08, LSS-11

General Lubrication
Specification:

Comments / notes:

6 Maintenance - Annex A

MACGREGOR NORWAY AS
A16
 User Manual for Crane

MAINTENANCE SYSTEM FOR

MACGREGOR NORWAY PRODUCTS
Doc. ID. : Rev. / date : Page:

LSS-20 Winch with gear rim.doc 03 / 29.04.09 2 of 3

Lubrication instruction:

Wire rope
LSS-02

Gear rim lubrication: LSS-08

Gearbox: LSS-04

See detail B

See detail A

Winch gear grease nipple: LSS-01

6 Maintenance - Annex A

MACGREGOR NORWAY AS
A17
 User Manual for Crane

MAINTENANCE SYSTEM FOR

MACGREGOR NORWAY PRODUCTS
Doc. ID. : Rev. / date : Page:

LSS-20 Winch with gear rim.doc 03 / 29.04.09 3 of 3

Detail A

Bearing grease nipple: LSS-11

Detail B

Bearing grease nipple: LSS-11

Other equipment (if any) on winch with grease nipple: LSS-01

6 Maintenance - Annex A

MACGREGOR NORWAY AS
A18
 User Manual for Crane

MAINTENANCE SYSTEM FOR

MACGREGOR NORWAY PRODUCTS
Doc. ID. : Rev. / date : Page:

LSS-21 Winch without gear rim.doc 01 / 29.11.06 1 of 2

STANDARD LUBRICATING SPECIFICATION

Specification no.: LSS-21

Lubrication equipment: WINCH WITHOUT GEAR RIM

General Instruction: The winch has the following main components which need
lubrication:
 One or two gearboxes
 Bearing
(winch with one gearbox only)
 Wire rope
 One or two pulse encoders
(pulse encoder not supplied with all winches)
Note: if the pulse encoder is of a type without grease nipple, it
does not need to be lubricated.
 Additional equipment with grease nipple (if any)
The illustration overleaf shows the location of these
components and references to specific LSS procedures.
Approved Suppliers’ Reference is made to the following LSS procedures:
Lubrication Specifications: LSS-01, LSS-02, LSS-04, LSS-11

General Lubrication
Specification:

Comments / notes:

6 Maintenance - Annex A

MACGREGOR NORWAY AS
A19
 User Manual for Crane

MAINTENANCE SYSTEM FOR

MACGREGOR NORWAY PRODUCTS
Doc. ID. : Rev. / date : Page:

LSS-21 Winch without gear rim.doc 01 / 29.11.06 2 of 2

Lubrication instruction:

Wire rope: LSS-02 Bearing: LSS-11

Gearbox: LSS-04

Pulse encoder: LSS-01

(Direct driven location

shown, chain driven on
some winches)

Other equipment (if any) on winch with grease nipple: LSS-01

6 Maintenance - Annex A

MACGREGOR NORWAY AS
A20
 User Manual for Crane

MAINTENANCE SYSTEM FOR

MACGREGOR NORWAY PRODUCTS
Doc. ID. : Rev. / date : Page:

LSS-22 Electric motors.docx 01 / 06.02.13 1 of 2

STANDARD LUBRICATING SPECIFICATION

Specification no.: LSS-22

Lubrication equipment: ELECTRIC MOTORS

50 / 60 Hz
General Instruction: On motors the bearings should be re-lubricated every 3
years. This is due to ageing and irrespective of operation
hours. Motors operating under special conditions, such as
frequent operation at maximum speed (n max), heavy
vibration, sudden load changes and frequent reversing
operation, the re-lubrication should be performed at a
considerably shorter interval than at the intervals stated on
page 2.
Comments / notes: Only re-lubricate bearings when the motor has a speed of at
least n >300 rpm.
Lubrication intervals are compensated for vertical mounting.
Smaller electrical motors normally have closed bearings. Re-
lubrication may not be required.

6 Maintenance - Annex A

MACGREGOR NORWAY AS
A21
 User Manual for Crane

Page: 2 of 2
Type Delivery Temp (˚C) Mount.pos Interval (h) comp. Type / Amount Notes Notes
with grease Ambient / bearing for vert.mount

B5M355L Yes 20/50 Vertical 8000 ESSO UNIREX N3 Temperature increased by 15 Information regarding bearing / greasing
intervals are noted on a plate on the motors.
4 V36 30/60 (V3/V6) 4000 First time greasing 200 gr. deg C, re-greasing interval halved
45/80 2000 Re-lubrication 50 gr.
55/90 1000

14BG1802 Yes 40 Vertical 4000 ESSO UNIREX N3 Temperature increased by 10K, re- Information regarding bearing / greasing
greasing interval halved intervals are noted on a plate on the motors with
80 V36 50 (V3/V6) 2000 Re-lubrication 20- 30 gr. 40C and in standard horizontally mounting.
60 1000

14BG315 Yes 40 Vertical 3000 ESSO UNIREX N3 Temperature increased by 10K, re- Information regarding bearing / greasing
greasing interval halved intervals are noted on a plate on the motors with
V36 50 (V3/V6) 1500 Re-lubrication 30 - 40 gr. 40C and in standard horizontally mounting.
60 750

M3BP355 Yes 25 Vertical 2000 ESSO UNIREX N3 Temperature increased by 15 deg C, Information regarding bearing / greasing
re-greasing interval halved intervals are noted on a plate on the motors.
V36 40 (V3/V6) 1000 Re-lubrication 70 gr.

7AA/BA Yes 40 Vertical 4000 ESSO UNIREX N3 Temperature increased by 10K, re- -
greasing interval halved
160 V36 50 (V3/V6) 2000 Re-lubrication 20- 30 gr.
60 1000

Y3-280M2-4 Yes 40 Horizontal 4000 ESSO UNIREX N3 Temperature increased by 10- 15 Information regarding .bearing / greasing
deg.C, re-greasing interval halved. intervals are noted on a plate on the motor with
Re-lubrication 30- 40 gr. 40c and in standard horizontal mount.

6 Maintenance - Annex A

MACGREGOR NORWAY AS
A22
 User Manual for Crane

Annex B - Automatic Lubrication System

1. General
The crane is fitted with an automatic lubrication system .The purpose of lubrication is to promote longer service
life for the equipment. The advantage of an automatic lubrication system is that it releases “a little grease
frequently”, as opposed to “too much grease infrequently”, which is often the case with manual lubrication.

2. System Overview
The system will efficiently provide lubrication for all bearings on king/main jib and knuckle jib. Grease is
stored in two container/pump units, and pumped/distributed out via several distribution blocks to each
individual lubrication point on the jib assembly among others. See picture 2 for typical installation of
container/pump unit.

The system itself is fairly simple and comprises a pump with a lubricant reservoir. The pump has 1-3 outlets,
which lead to progressive distributors (”distribution blocks”). These have one inlet port and several outlet ports.
The grease is distributed from the progressive distributor to the various lubrication points or to a new
distribution block on the crane. These distribution blocks are mechanical blocks that have been designed
according to the desired dosage. See pump unit M55 and M56 in the Lubrication Charts.

Picture 1: Principle drawing

6 Maintenance - Annex B
MACGREGOR NORWAY AS B1
 User Manual for Crane

3. The Lubrication Pump

The pump has a sequence control and up to three adjustable pump-elements. From one element the lubricant is
fed to a two or three distributor system, as shown above in the “principle drawing”. These adjustable pump
elements can easily be adjusted using an Allen key and it is important to adjust these as instructed in the flow
diagram so that the equipment connected to this element receives the correct dose of lubricant. For example; if
the flow diagram says three clicks down, it means that you must screw the element to the fully open position
(default position) and then throttle with three clicks down (clockwise).

In order for the adjustable element to receive the correct dose of lubricant, it is also important to set the pump
sequence. The adjustment screws are located behind a red cap at the front of the pump where the one set screw
is for setting the number of pump revolutions and the other is for setting the frequency of pump actuation. If the
pump setting is 30 revolutions and 30 minutes it means that the pump shall run 30 revolutions every 30 minutes
the pump has current.

The crane automatic lubrication system will also provide lubrication for the main winch bearings and main
winch drive pinions/gear wheel.

Pump M55: Pump M56:

Jib and tugger winch Main winch

Safety valve (do not cover)

Pump elements

Picture 2: Container/pump units mounted near crane cabin

6 Maintenance - Annex B

B2 MACGREGOR NORWAY AS
 User Manual for Crane

4. Pump Element Adjustment From the Operator

Terminal

Picture 3: Typical lubrication setup in the PLC

If the pump has no integrated timer / logics, it is controlled by the crane’s PLC.

Typical setup see picture 3. If the alarm is released frequently and no grease is released through the safety valve,
set Overload Time Before Alarm higher than 7 sec. The alarm can also be released when the Lubrication
monitor are mounted away from the pump unit.

5. The Progressive Distributor MX-F

The progressive piston distributors are devices with a hydraulic sequence control, where only one element port
at a time feeds lubricant to its lubrication point. If one piston - for some reason – is blocked, all distributor ports
are blocked and causing the safety valve to release. There are typically two distributor blocks for the M55 pump
located below the cabin platform and on top of the knuckle jib. For the M56 pump there is typically one
distributor block located on the top of the king near the main winch.

6 Maintenance - Annex B
MACGREGOR NORWAY AS B3
 User Manual for Crane

6. Blockage in the System

Some system have no electronic error indicators (delivered as option), but you will clearly see lubricant coming
out of a safety valve on the pump element itself (see picture 2), which indicates a blockage.

This is mainly caused by one of the following three possibilities:

 Blockage in the progressive distributor due to a jammed slide/piston in an element can occur because of
contamination in the lubricant or because the element has been under counter pressure and unused for a
long time.
Action: Disconnect the outlet connections, start the pump and observe if lubricant is released trough the
safety valve. If not: replace the progressive distributor. If lubricant is released: replace the connectors
and check the next distributor or the element.
 High counter pressure due to long tubes/hoses. Install a check valve on the pump element outlet.
 Breakage/damage of a tube/hose. Lubricant leaking on a damaged hose or a pipe can occur without
realising the alarm. In consequence one or more lubricant points are not receiving lubricant. Inspect the
hoses according to the Periodic Inspection and Maintenance Program.

7. Lubricant

1. Pump unit 1 M55 (crane): LSS-11

2. Pump unit 2 M56 (gear rim - winch): LSS-08

It is important that the grease is pump-able in the system, even at low temperatures. The system has been
designed to use NLGI class 2 grease.

6 Maintenance - Annex B

B4 MACGREGOR NORWAY AS
 User Manual for Crane

8. Filling the Pump

A) Standard filling via lubrication nipple with manual or pneumatic grease gun:

filling lubrication nipple

B) Filling via filling socket:

remove lubrication nipple and
replace with filling socket for
grease

filling socket
for grease coupling box

C) Filling via filling press:

filling press

straight filling coupling Picture 4: Filling the pump

6 Maintenance - Annex B
MACGREGOR NORWAY AS B5
 User Manual for Crane

9. Service Kit for the Automatic Lubrication

System
Item no. Description Quantity

11017148 PUMP ELEMENT PE120V W/CHECKVALVE 6MM 1

11017149 EXTENSION PIECE 21MM 1/8"-M10X1 316 6

11017189 WE 06 LLR 1/8" 316 6

11005436 WE 06 LLR 1/8" 10
11017150 WE 08 LLR 1/8" 3
10003538 GE 06 LLR 1/8" 10
10003539 GE 08 LLR 1/8" 3

11012505 G 06 LL STRAIGHT COUPLING 15

11018922 G 08 LL STRAIGHT COUPLING 10

10003724 M 06 LL NUT 10

10003723 D 06 LL PROFILE RING 10

11005432 THREADED FERRULE 6MM 16

11017158 THREADED FERRULE 8MM 2

11005431 INSERT FOR FERRULE, STRAIGHT 6MM (for 8.3mm hose) 10

11018923 INSERT FOR FERRULE, STRAIGHT 8MM (for 8.3mm hose) 3
11017159 INSERT FOR FERRULE, STRAIGHT 8MM (for 11.2mm hose) 4

11005433 INSERT FOR FERRULE, 90° BEND 6MM 6

11017169 NON-RETURN VALVE MX-F M10X1 3

11017170 NON-RETURN VALVE MX-F 10

11017171 LOCK SCREW MX-F 5

11017173 PIPE BRIDGE 2

Filling the pump units (See Picture 4) demands a high cleanliness level. Avoid any
particles. Even the slightest dirt can block the piston in the distributor blocks.

6 Maintenance - Annex B

B6 MACGREGOR NORWAY AS
 User Manual for Crane

Annex C - Manual Lubrication

1. General
The automatic lubrication system (if applicable) delivers lubrication to nearly all critical rotation points.

Most of the manual lubrication points serve preservation purposes and not lubrication of a rotation bolt. Use
LSS-01. See Manual Lubrication Grease Nipples Chart in the user manual.

Intervals: Manual lubrication according to the Periodic Inspection and Maintenance Program.

2. Preservation Points
According to the Periodic Inspection and Maintenance Program (“preservation points”) lubricate the following
points:

Lubrication of the bondura bolts:

For preservation, add a small amount of grease on both sides of the
bolt after each re-torque.

Lubrication of the main jib cylinders and knuckle jib cylinders:

For preservation of the scraper ring.

Lubrication non rotation parts:

For preservation. Different constructions on the platform behind the
king.

6 Maintenance - Annex C
MACGREGOR NORWAY AS C1
 User Manual for Crane

3. Rotation Points
According to the Periodic Inspection and Maintenance Program (“rotation points”) lubricate the following
points:

Lubrication of pulse encoders

The crane has normally 7 encoders. The angle encoders on the
main winch (each side) and the encoders on the knuckle jib
(each side) needs to be manually lubricated.

Lubrication of the tugger winch (if applicable)

The main bolts on the tugger winch must be lubricated.
However, lubrication of these bolts can be integrated to the
automatic lubrication system. If not, the bolts need manual
lubrication.

Lubrication of hinges
Lubricate door hinges and other non-critical lubrication points.

6 Maintenance - Annex C

C2 MACGREGOR NORWAY AS
 User Manual for Crane

Annex D - Lift Wires and Lifting Hooks

1. Lift Wires
1.1. General
MacGregor Norway offshore cranes use the following
wire rope type(s):

 Main winch: Fully galvanized, non-rotating

compacted type
 Whip winch (if applicable): Fully
galvanized, non-rotating compacted type
 Tugger winches (if applicable): Fully
galvanized, non-rotating compacted type

Upon delivery, the wire ropes have received offshore

lubrication. This implies that all strands are heavy
lubricated, the core is heavy lubricated during core
closing and the rope is slightly lubricated during final
closing (to avoid water trapping between the outer
strands and the core). This provides the best premise
for a long service life; good protection, low internal
friction and low friction against the wire sheaves.

Compacted strands means high wear resistance, high

transversal stiffness and corrosion resistance.

1.2. Inspection
In order to keep wire ropes in a good working condition, routine inspections and periodic maintenance is
necessary. On wire ropes frequently used in AHC operations, particular attention must be paid at the areas
where they pass over a wire sheave as the wire rope strands have a tendency to open slightly and thus making it
possible for the inspector to get a better view of the wire rope core.

Please see the Periodic Inspection and Maintenance Program for inspection intervals of wire ropes. The purpose
of the inspection is to reveal dryness, abrasion, internal/external corrosion, core or strand protrusion/distortion,
wire breaks, wear, kinks etc. before the wire rope becomes unsafe to work with (see illustrations on the
following page of unwanted situations).

Note: Any deterioration leading to a suspected loss of original rope strength should be carefully examined and
the Discard criteria provided in ISO 4309 applied in determining whether to remove the rope from service.

6 Maintenance - Annex D
MACGREGOR NORWAY AS D1
 User Manual for Crane

Wire protrusion
External corrosion

Crown wire breaks Strand protrusion

Kinked wire

Local increase in rope diameter due to core

distortion

Basket deformation (Birdcage)

6 Maintenance - Annex D

D2 MACGREGOR NORWAY AS
 User Manual for Crane

1.3. Lubrication
Over time, the factory lubrication of the wire ropes will wear off due to the environment and usage. Periodic
maintenance is therefore a necessity.

Manual lubrication with the aid of brushes, rags, gloves, or by other means is costly, risky, and ineffective. The
lubricant forms a film on the surface which water vapour can penetrate, thus becoming trapped. Temperature
changes cause condensation and rust then begins to form from the inside. This will lead to severe corrosion
which promotes premature fatigue failures in the wires and strands.

A high pressure wire lubrication system (e.g. Masto lubrication system) will be able to maintain good
lubrication of the wire rope, penetrating through to its core which is absolutely necessary to keep friction low
and corrosion away.

How often the wire ropes need to be re-lubricated depends on the environment in which the wire ropes operate
along with the usage and the result of the routine inspections. Generally, if the wire rope show signs of dryness,
lubrication should be initiated, ideally before. See Periodic Inspection and Maintenance Program for inspection
intervals of wire ropes.

6 Maintenance - Annex D
MACGREGOR NORWAY AS D3
 User Manual for Crane

2. Lifting Hooks
2.1. Inspection
The hook and hook nut are to be dismantled, inspected and retested (proof loaded) according to the Periodic
Inspection and Maintenance Program. Particular attention to be paid to the following:

 Wear in hook, centre pin, becket and threads in hook and nut.
 Play in sheave bushes or bearings.
 Spacer bolts, nuts and lynch pins.
 Check for cracks in welds.
 Condition of safety catch and grease nipples.
 Wear to holes in side plates and becket.

2.2. Lubrication
See Periodic Inspection and Maintenance Program for inspection intervals of wire ropes. Please refer to User
Manual volume 2 for lubrication charts.

2.2.1. Single Part

Single part hook arrangements have a grease nipple located in the lower part of
the hook weight (drawing at right). It provides a lubrication point for the hook
bearing which is located in the centre of the hook weight. The bearing chamber is
connected to the nipple and a secondary, plugged hole (higher up) by means of a
channel. When lubricating, any old or superfluous grease and air will be pressed
out of the upper hole when the plug is removed.

6 Maintenance - Annex D

D4 MACGREGOR NORWAY AS
 User Manual for Crane

2.2.2. Double Part

Double part blocks have two or three lubrication points; one on the lower
bearing, one for the swivel (for the largest blocks) and one for the wire sheave.
As with single part hook arrangements, a plugged hole is fitted where any old
or superfluous grease and air will be pressed out.

3. Tools & Tool Safety

 Gloves and safety glasses
 Standard spanner
 Grease gun

4. Hazards
 Avoid skin contact with hydraulic oils by use of gloves.
 Be wary of any cuts that may be caused by running a hand carelessly across damaged wire. Use gloves.
 Ensure winch has been stopped before inspecting wire.
 When laying down the double part block on its side for lubrication, ensure the block is completely
secure as there can be a risk of it falling over.

6 Maintenance - Annex D
MACGREGOR NORWAY AS D5
 User Manual for Crane

Annex E - Hydraulic Hoses

1. General
Inspection and replacement intervals should be done according to the Periodic Inspection and Maintenance
Program.

Hydraulic hose manufacturers estimate that 80% of hose failures are attributable to external physical damage
through pulling, kinking, crushing or abrasion of the hose.

Hydraulic hose can and will age whether it is in normal service conditions or unused in storage. Hose failure is
not an indication of poor product performance, but rather natural degradation. After a while a hydraulic hose
will show sign of wear that include cracking, blisters and bubbles.

The operating conditions that a correctly installed hydraulic hose is subjected to will ultimately determine its
service life. Extreme temperatures, e.g. high daytime operating temperatures and very cold conditions when the
machine is standing at night, accelerate aging of the hose's rubber tube and cover.

External factors are:

 Environmental conditions
 Ultraviolet light
 Salt water
 Air pollutants
 Extreme temperatures
 Ozone
 Chemicals
 Electricity
 Abrasion damage

6 Maintenance - Annex E
MACGREGOR NORWAY AS E1
 User Manual for Crane

Typical examples of abrasion damage:

Abrasion caused by hoses rubbing against each other or surrounding surfaces is the most common type of
damage. Replace the hoses and avoid new abrasion and external damage, ensure all clamps are kept secure, pay
careful attention to routing whenever a replacement hose is installed and if necessary, apply inexpensive
polyethylene spiral wrap, zip tie, sleeves and guards to protect hydraulic hoses from abrasion (see photo below).

6 Maintenance - Annex E

E2 MACGREGOR NORWAY AS
 User Manual for Crane

Typical examples of ozone and bending damages:

Increased ozone, caused by

pollution, attacks bonds in
certain rubber compounds.
Tiny cracks occur primarily
where the hose is stressed; at
curves, bends and clamping
locations. These cracks allow
airborne contaminants to
invade and weaken the hose.

External heat damage can

result in hardened and
cracked hose covers. Replace
the hoses, check possible
external harmful heat sources.

2. Replacement
MacGregor recommend replacing hoses at the intervals described in the Periodic Inspection and Maintenance
Program.

Replacement of denso tape on hose connections after reinstallation is recommended to avoid corrosion.

Installation of a replaced hose at less than the minimum recommended bend radius may significantly reduce the
lifetime of the hose (see illustrations below). Particular attention must be given to prevent sharp bends at the
hose connection to the fitting (photo above).

Proper physical installation of the hose assembly requires a correctly installed port connection ensuring that no
twist or torque is transferred to the hose when the fittings are being tightened.

Bending a hydraulic hose in more than one place will result in twisting of its wire reinforcement. A twist of five
degrees can reduce the service life of a high-pressure hydraulic hose by as much as 70% and a seven degree
twist can result in a 90% reduction in service life.

Ordering of hoses must be done according to the Hose List in chapter 7.

6 Maintenance - Annex E
MACGREGOR NORWAY AS E3
 User Manual for Crane

3. Tools & Tool Safety

 Standard wrench or spanner of appropriate size
 Gloves
 Safety glasses

4. Hazards
 Ensure both the system and the specific damaged hose are devoid of pressure before attempting any
replacement. Removing hoses or tampering with damaged hoses while the system is under pressure can
result in a high pressure release of hydraulic oil.
 Clean the maintenance area before and after maintenance to avoid slippery surfaces and any
contamination.
 Remember to dispose of any damaged or unusable components in the correct manner, by taking them to
a recycling center that deals with the components in question.

6 Maintenance - Annex E

E4 MACGREGOR NORWAY AS
 User Manual for Crane

Annex F - Replacement of Hydraulic Filters

1. General
1.1. Before Disassembly
Prior to replacement of the hydraulic filters (for action intervals,
see the Periodic Inspection and Maintenance Program), it is
important to make sure that the oil level in the tank is below the
return filters mounted on the tank top. These filters have
contamination retainers which might contain some particles.
Lower the level in the tank by lifting the main jib and the knuckle
jib. This action must be taken to reduce the risk of mixing
unfiltered “dirty” oil with the clean oil in the tank.

Then, shut down the HPU for at least 15 minutes. This will release
the pressure and drain oil to the tank. When applicable, press the
emergency (local) stop button.

Make sure you have the correct filters and sealings. MacGregor Return filter with contamination
recommends replacing the O-rings each time the filters are replaced. retainer (circled)

Keep tools, working area and equipment clean.

Most of the filters are located on the HPU (inside the king). However, they can also be placed outside on the
king platform or mounted on the winches. Normally, all filters (apart from the air breathers and emergency
supply filter) have clogged filter indicators (lights) and an alarm indication in the crane control system.

1.2. After Disassembly

 When draining the filters, collect all fluid in a suitable container and dispose it in accordance with
environmental regulations.
 After disassembly, clean all parts, check for damage or wear and replace parts if necessary.
 When changing a filter element a high level of cleanliness must be maintained.
 The operational safety and life expectancy of the filter, and whether it is ready for use, depends to a
high degree on regular and careful maintenance.
 Normally there is no need for venting the filters after the replacement (except for the replenishment
filters).

6 Maintenance - Annex F
MACGREGOR NORWAY AS F1
 User Manual for Crane

Typical crane king modules with HPU and oil filters

6 Maintenance - Annex F

F2 MACGREGOR NORWAY AS
 User Manual for Crane

2. Breather Filters
Breather filters prevent contamination from the surroundings from entering
the system in connection with fluctuations of the oil level in the tank (tank
breathing).

Some filters are delivered as one unit but most commend are filters with
separate elements.

Removing the element:

1. Remove nut and washer

2. Lift off cap
3. Remove element

Fitting the element:

1. Fit new element

2. Replace cap
3. Replace washer
4. Replace nut and tighten

2.1. Access Point

Access the breather filter via crane king door, for best access use the platform inside the crane king. See 1.2
Filter Locations.

2.2. Tools & Tool Safety

 Wrench or spanner of appropriate size.
 Safety glasses

2.3. Hazards
 Clean area before and after to avoid slippery surfaces or contamination.
 After maintenance, dispose of old filter by taking it to the appropriate recycling center.

6 Maintenance - Annex F
MACGREGOR NORWAY AS F3
 User Manual for Crane

3. Offline Filter
Offline oil filtration systems with integrated circulating pumps are
ideal for controlling oil contamination levels for particles, water
and degradation products (oxidation resin/sludge, varnish). The
filters are normally mounted at the bottom of the tank and circulate
the oil in the tank.

The lifetime of the filter element depends on the operating

conditions. See the Periodic Inspection and Maintenance Program
for replacement intervals. When the pressure gauge (illustration
beside) indicates a pressure drop of 2 bar across this filter, an
alarm is generated on the operator terminal indicating that the filter
element is due for replacement.

The Offline filter is normally 3 micron nominal.

6 Maintenance - Annex F

F4 MACGREGOR NORWAY AS
 User Manual for Crane

3.1. Offline Filter Replacement

Stop the CJC filter Close valve on the oil Close valve on the oil Automatic air vent: No Open oil drain valve.
pump inlet filter outlet action Drain according to
Air vent screw: Open environmental
screw precautions

When the filter Lift off the filter Unscrew the spring nut Remove the spring and Remove the used filter
housing is drained, housing the spring guide inserts. Depose of
unscrew the top nut according to
regulations

Clean the filter bottom Put the new CJC filter Insert type B, BLA or Mount the spring guide Tighten the spring nut Replace both O-rings Replace O-ring for the Tighten the top nut Automatic air vent: No Be aware that oil
inserts in place BLAT, use insert guide carefully - make sure by hand until contact top nut with a torque of 90Nm action. spillage is a serious
between the filter there is no contact with spring guide. Air vent screw: safety risk - keep
elements between the O-ring Then tighten the Replace usit ring for clean!
and the thread spring nut 4 turns per air vent screw, and
filter insert tighten with torque of
10 Nm

6 Maintenance - Annex F
MACGREGOR NORWAY AS F5
 User Manual for Crane

4. Return Filters
These filters are normally low pressure filters.
The location are typically at the top of the
tank, but they can also be mounted as in-line
filters outside on the king platform or on the
winch itself.

Replacement of return filters as in-line

filters:

1. Close inlet and outlet ball valves (if

present)
2. Open the air bleed plug on the top of
the filter to make it easier to drain he
oil.
3. Open the drain valves and drain the
filters completely.

Removing the element:

1. Switch off the hydraulic system and release filter pressure.

2. Undo vent screw(s), remove the oil drain plug(s) and drain fluid into a container.
3. Unscrew the cover plate.
4. Remove the filter element(s) from the element spigot. Examine the element surface for dirt residues and
larger particles, these can indicate damage to the components.
5. Remove the contamination retainer by turning anti-clockwise (bayonet fitting) and clean (only type
1.0).
6. Replace or clean the filter element (only W/HC and V elements can be cleaned).
7. Clean the cover plate and housing; pay particular attention to the threads.
8. Examine the filter, especially sealing surfaces and thread for mechanical damage.
9. Check the O-rings and seals and replace if necessary.

6 Maintenance - Annex F
MACGREGOR NORWAY AS F7
 User Manual for Crane

Fitting the element:

1. Moisten the sealing surfaces and thread on the cover plate and housing, as well as the O-ring on the
cover plate and element, with clean operating fluid.
2. When fitting a new element, check that the designation corresponds to that of the old element.
3. Fit the contamination retainer onto the new or cleaned filter element by turning clockwise (only for type
1.0).
4. Place the filter element(s) carefully onto the element location spigot.
5. Screw on the cover plate fully. Then unscrew by one quarter-turn.
6. Screw in the oil drain screw(s); tighten the vent screw(s).
7. Switch on the hydraulic system and vent filter at an appropriate point in the system.
8. Check the filter for leakage.

Typical return filter

mounted separately from
the tank (in-line filter)

Inlet and outlet

ball valves

Drain valve

4.1. Access Point

Access the return filter through the crane king door, by standing on the platform inside the king. See filter
locations section 1.2.

4.2. Tools & Tool Safety

 Standard wrench or spanner of appropriate size
 Gloves
 Safety glasses

4.3. Hazards
 Avoid skin exposure to hydraulic oil.
 Clean area before and after maintenance to avoid slippery surfaces or contamination.
 Dispose of old filter appropriately by taking it to a recycling centre.

6 Maintenance - Annex F

F8 MACGREGOR NORWAY AS
 User Manual for Crane

5. Pressure Filters
High-pressure filters are installed after the pumps and other prime movers to protect critical hydraulic
components such as cylinders, motors and valves.

Removing the element:

1. Close the inlet and the outlet valve (if present). Ref. Hydraulic flow diagram.
2. Remove oil drain plug at the bottom of the bowl, collect oil in a container.
3. Unscrew bowl. (Collect fluid in a suitable container and dispose of it in accordance with environmental
regulations).
4. Remove filter element from element location spigot (examine surface of element for dirt residue and
larger particles; these can indicate damage to the components).
5. Clean bowl by using white sprite or similar.
6. Examine filter, especially sealing surfaces and threads, for mechanical damage.
7. Replace O–rings.

Fitting the element:

1. Moisten thread and sealing surfaces on the filter bowl and head, as well as the O–ring on the bowl and
element if necessary, with clean operating fluid.
2. When fitting a new element, check that the designation corresponds to that of the old element.
3. Place filter element carefully onto the element location spigot.
4. Screw in filter bowl fully.
5. Screw in oil drain plug.
6. Unscrew filter bowl by one quarter–turn.
7. IMPORTANT: Open Inlet and outlet valve
8. Clean/dry the outside of the filter bowl. After start-up of the hydraulic system again, check for any
leaks.

6 Maintenance - Annex F
MACGREGOR NORWAY AS F9
 User Manual for Crane

5.1. Access Point

Access the pressure filters though the crane king door, by standing on the platform inside the king. See filter
locations section 1.2.

5.2. Tools & Tool Safety

 Standard wrench
 Spill tray

5.3. Hazards
 Clean area before and after maintenance to avoid slippery surfaces or contamination.
 Ensure valves are closed and system depressurised before performing any maintenance. If valves are
opened while the system is pressurised, high pressure hydraulic oil will be released.

6 Maintenance - Annex F

F10 MACGREGOR NORWAY AS

 User Manual for Crane

6. Drain Filters
The drain filters are normally located at the top of the tank, but can also be mounted outside on the platform or
on the winches. Three different drain filter types can occur:

Type 1 (In-line) Type 2 (Tank mounted) Type 3 (In-line)

For replacement procedure, see For replacement procedure, For replacement procedure,
section 5 - "Pressure Filters" see section 6 - "Drain see section 4 - "Return
Filters" (see below) Filters"

Typical drain filters

Removing the element: Fitting the element:

1. Loosen cover plate bolts, turn and 1. Moisten sealing surfaces and thread on
remove the cover plate. the cover plate and housing, as well as
2. Remove filter element carefully from the O-rings on the cover plate and
element spigot. Examine element element, with clean hydraulic fluid.
surface for dirt residue and larger 2. When fitting a new element, check that
particles; these can indicate damage to the designation corresponds to that of the
the system components. old element.
3. Remove contamination retainer (if 3. Fit the contamination retainer (if present)
present) by turning anti-clockwise onto the new filter element by turning it
(bayonet fitting). clockwise.
4. Clean cover plate, housing and 4. Place filter element(s) carefully onto the
contamination retainer; pay particular element location spigot.
attention to the threads. 5. Re-fit cover plate and tighten cover plate
5. Examine filter, especially sealing bolts.
surfaces and thread, for mechanical 6. Switch on hydraulic system and Check
damage. filter for leakage.
6. Replace O-rings.

6 Maintenance - Annex F
MACGREGOR NORWAY AS F11
 User Manual for Crane

6.1. Access Point

Access the pressure filters though the crane king door, by standing on the platform inside the king. See section
1.2 Filter Locations.

6.2. Tools & Tool Safety

 Standard wrench or spanner of appropriate size.
 Gloves
 Safety glasses

6.3. Hazards
 Avoid skin exposure to hydraulic oil.
 Clean area before and after maintenance to avoid slippery surfaces or contamination.
 Dispose of old filter appropriately by taking it to a recycling centre.

6 Maintenance - Annex F

F12 MACGREGOR NORWAY AS

 User Manual for Crane

7. Replenishment Filters (Semi-Active Cranes)

Removing the element: Fitting the element:

1. Verify that the HPU is not running. 1. Use clean hydraulic fluid to moisten
2. Close the inlet valves to the sealing surfaces and threads on the cover
replenishment pumps, normally located plate and housing, as well as the O-rings
on the tank wall. on the cover plate and element.
3. Close the outlet valve (if present). 2. When fitting a new element, check that
the designation corresponds to that of the
4. Open the air bleed plug on the top of the old element.
filter to make it easier to drain the oil.
3. Place filters element(s) carefully onto the
5. Drain the replenishment pump filters element location spigot.
with the valves at the bottom of the filter
houses. 4. Screw on cover plate fully and then
unscrew by one quarter-turn.
6. Unscrew top covers.
5. Close the drain valve and air bleed plug.
7. Remove filter element(s) from element
spigot. Examine element surface for dirt 6. IMPORTANT: Open the inlet and outlet
residue and larger particles; these can valves.
indicate damage to system components.
8. Clean cover plate and housing; pay Vent the filters:
particular attention to the threads.
1. Start the HPU and let the replenishment
9. Examine filter, especially sealing pump run for one minute.
surfaces and threads, for mechanical
2. Stop the HPU
damage.
3. Release carefully air bleed plug on top of
10. Replace O-rings and check seals.
the replenishment filter and bleed of all
air.
4. Close the air plug when the oil is floating
and no more air is bleeding.
5. Clean up, start HPU and check filters for
leakages

Replenishment filters

6 Maintenance - Annex F
MACGREGOR NORWAY AS F13
 User Manual for Crane

Annex G - Oil Analysis

1. General
According to the Periodic Inspection and
Maintenance Program, the health of the
hydraulic oil in the system needs to be tested
at a regular basis. This is to be done by
taking an oil sample from the reservoir.

For cranes with the reservoir inside the king,

the oil sample is normally taken at a drain
valve located under the reservoir in the crane
foundation (photo at right).

Note: It is important for the trending of the

fluid condition that the same sample location
is used each time.

Typical drain valve for oil sample

2. Bottle Cleanliness
Because of the extreme oil cleanliness levels, even the slightest dirt originating in a sample bottle can have an
adverse effect on the precision of the particle count. It is common to represent bottle contamination levels as the
number of particles greater than ten microns per millilitre (0.01 mm).

6 Maintenance - Annex G
MACGREGOR NORWAY AS G1
 User Manual for Crane

3. How to Sample
1. The system should have normal operating temperature and flow conditions when taking an oil sample.
MacGregor recommends operating the system for at least 30 minutes with actuators cycling prior to
talking samples. (If not possible to sample when the equipment is operating, sample as soon as safely
possible after shutdown to prevent the settling of contaminants).
2. Open the sampling valve and let at least one litre pass the ball valve tube. Collect the flushed fluid in a
container.
3. Use a 100 % clean standard analysis bottle (typical 500 ml) provided by a bottle supplier. Open the
sample bottle cap, taking care not to contaminate. Hold the cap in hand or place on a clean surface, face
down.
4. Fill the sample bottle about halfway, cap and shake well to flush the internal surface. Discard the fluid.
5. Fill the sample bottle again until the fluid level is about 1 cm (½”) from the top.
6. Cap the bottle immediately and then close the sampling valve.
7. Label the sample bottle with sample details, fill out the sample form and enclose both in the supplied
plastic container for transport.

4. Visual Analysis
Looking and smelling at hydraulic fluid is the simplest way to determine the fluid's condition. Clean fluid is
amber in color. A milky, dark, or otherwise abnormal color may indicate the presence of one or more
contaminants. A milky appearance implies contamination by water. If the fluid looks milky, take immediate
action to avoid severe damage to your hydraulic system.

A marked change in the smell of the hydraulic fluid can indicate a chemical breakdown. If a distinct change in
the smell of hydraulic fluid is detected, have it chemically analyzed by a commercial lab.

5. Type of Analysis
MacGregor recommends performing a particle and water analysis according to the Periodic Inspection and
Maintenance Program, whether you are conducting onsite particle counting, or relying on a commercial lab. A
full oil analysis is also recommended to be done according to the program. The analysis may include particle
counter, water content, viscosity, oxidation, iron, silicon and copper content.

The data from the analysis must be logged.

6 Maintenance - Annex G

G2 MACGREGOR NORWAY AS
 User Manual for Crane

6. Tools & Tool Safety

 Gloves
 Safety glasses
 Standard wrench or spanner of appropriate size

7. Hazards
 Avoid skin exposure to hydraulic oil. If exposed wash area with water and soap.
 Clean area before and after sample to avoid slippery surfaces or contamination of sample.
 Ensure bottle top of sample is secure.

6 Maintenance - Annex G
MACGREGOR NORWAY AS G3
 User Manual for Crane

Annex I - Accumulator Pre-Charge Pressures

1. General
Instructions for pre-charging of both bladder and piston accumulators via an accumulator test and filling kit is
provided in this section. When checking or re-charging accumulator pressure; always use an associated test and
filling kit. Appropriate kits can be provided by MacGregor Norway.

Note: When the accumulator is installed in a system, reduce the system pressure to 0.

Pre-charge pressure table:

Acc. Pos. (qty) Dwg. ref Precharge pressure:

Main Winch
WH 59.2, 60.2, 61.2 SP2582-1-L-XA-006 50 bar
WH 55.1, 56.1, 57.1, 58.1 SP2582-1-L-XA-006 225 bar
WH 54 SP2582-1-L-XA-006 150 bar
WH 59.1, 60.1, 61.1 SP2582-1-L-XA-006 130 bar
Whip Winch
UH 11.1, 12.1, 13.1, 14.1 SP2582-1-L-XA-008 150 bar
UH 11.2, 12.2, 13.2, 14.2 SP2582-1-L-XA-008 150 bar
Slew System
SH 11, 12, 13, 14 SP2582-1-L-XA-004 6 bar

6 Maintenance - Annex I
MACGREGOR NORWAY AS I1
 User Manual for Crane

2. Charging Procedures
2.1. Bladder Accumulator
• Attach the hexagonal connector (1) to the nitrogen bottle.
• Remove the gas valve protective caps from the accumulator. Secure the swivel connector (2) on the gas
valve and tighten sufficiently to prevent gas leakage. (Use adapter (5) on the accumulator for
installation of swivel connector on gas valve). Screw the bar handle (3) in a clockwise direction to open
the accumulator gas valve.

2 1

• Slowly open the nitrogen bottle valve until the expanding bladder closes the poppet valve. Check this
closure prior to charging to desired pressure.
• Close the nitrogen bottle valve. Wait for 5 minutes, before checking the pre-charge pressure. To lower
the pressure, open the air bleed valve (4).
• The Pre-charge pressure will drop slightly when the compressed gas cools off. Therefore, pre-charge to
20% above required pressure.
• Screw the bar handle (3) in a counter clockwise direction to close the gas valve. Use the air bleed valve
(4) to expel all gas from the pre-charging assembly. Remove the swivel connector (2) . (Remove the
adapter (5) if this has been used). Carefully test the gas connections for leakage by applying soapy
water or using leak detector in and around the gas valve area when the pre-charging is complete.
• Fit the gas valve protective caps.
• Remove the hexagonal connector (1) from the nitrogen bottle.
• Check the pre-charge according to the Periodic Inspection and Maintenance Program.

6 Maintenance - Annex I

I2 MACGREGOR NORWAY AS
 User Manual for Crane

2.2. Piston Accumulator

• Attach the hexagon connector (1) to the nitrogen bottle.
• Remove the gas valve protective U-bolt and the protective cap from the accumulator. Secure the swivel
connector (2) on the gas valve and tighten sufficiently to prevent gas leakage. Screw the top hexagonal
nut on the accumulator gas valve in a counter clockwise direction until bottoming to open gas valve.
• Slowly open the nitrogen bottle valve to allow the piston to bottom the accumulator.
• Close the nitrogen bottle valve. Wait for five minutes, before checking the pre-charge pressure. To
lower the pressure, open the air bleed valve (4).
• The pre-charge pressure will drop slightly when the compressed gas cools off. Therefore, pre-charge to
20% above desired pressure.
• Screw the top hexagonal nut in a clockwise direction to close the gas valve. Use the air bleed valve (4)
to expel all gas from the pre-charging assembly. Remove the swivel connector (2). Carefully test the
gas connections for leakage by applying soapy water or using leak detector in and around the gas valve
area when pre-charge is complete.
• Fit the gas valve protective cap and the protective U-bolt.
• Remove the hexagonal connector (1) from the nitrogen bottle.

Note: Use nitrogen only! Compressed air and oxygen involve risk of explosion!

6 Maintenance - Annex I
MACGREGOR NORWAY AS I3
 User Manual for Crane

2.3. Tools & Tool Safety

• Safety glasses
• Spanner or wrench of appropriate size
• Gloves

2.4. Hazards
• Filling accumulators involves dealing with pressurised nitrogen which if handled incorrectly can result
in explosion. Experience personnel recommended.
• Check for damaged hoses, as working with damaged hoses can lead to release of pressurised gas.
• Ensure hose connections are secure.

6 Maintenance - Annex I

I4 MACGREGOR NORWAY AS
 User Manual for Crane

Annex J - Bondura Bolts

1. General
The crane is fitted with a set of Bondura bolts. These bolts are typically used for connecting the main structural
elements and to connect the hydraulic cylinders to the crane. These bolts are dimensioned according to function
and the illustration below indicates where and how the bolts are used.

Please refer to the parts list on the main assembly drawing for bolt size’ (Ø).

King – main jib bolts Main jib – knuckle jib bolts

Main jib Knuckle jib

cylinder bolts cylinder bolts

Typical example of an offshore crane

2. Re-Torque
The principle of these bolts is that a cone is fitted to each side of the conical bolt ends. These cones expand in
place when the locking plates are fitted and the locking plate bolts are torque tightened to the specified torque
value.

Please use the table below for the correct torque values according to bolt diameter (Ø).

Dimension (Ø) bolt: Plate bolt torque (Nm): Plate bolt No. and size:
140-150 500 6 X M24
160-180 500 8 X M24
200-250 500 10 X M24
260-300 600 10 X M30
320 600 10 X M30

6 Maintenance - Annex J
MACGREGOR NORWAY AS J1
 User Manual for Crane

Re-torque is to be performed at intervals stated in the Periodic Inspection and Maintenance Program. This action
is to ensure that the cones will “follow after” any potential wear, prevent ovality and keep the bolt tightly fit.

3. Cone Play Measurement

This measurement is to be performed in order to monitor potential loss of “Wedging force”.

 Tightening should be performed by alternating from one side of the bolt to the other.
 When tightening, check that the cone (locking plate) does not “tilt”.
 If tightening results in contact between the cone flange and structure i.e. distance “X” is 0, the cone
must be exchanged to an “oversize” cone. Contact MacGregor Norway AS.

Measurement “X” = 0 means no “wedging force”! Replace cone. Contact MacGregor Norway AS.

X O-ring/”marineseals”

Locking plate

Distance bushing

Bondura bolt with dual lubrication

6 Maintenance - Annex J

J2 MACGREGOR NORWAY AS
 User Manual for Crane

4. Tools & Tool Safety

 Lift or scaffolding may be required
 Sledge hammer
 Torque tool suitable for 500 Nm
 Gloves, hat and glasses

5. Hazards
 When working up high it is recommended to use a safety harness
 Caution when using heavy tools

6 Maintenance - Annex J
MACGREGOR NORWAY AS J3
 User Manual for Crane

Annex K - Slew Bearing and Foundation Bolts

1. General
See Periodic Inspection and Maintenance Program for intervals of the following:

 Bolt inspection critical areas: Elongation, threads, cracks and tension

 Inspect all slew ring bolts / nuts (bolts / nuts in place)
 Perform “knock-test” of all slew ring bolts
 Initial re-tensioning of all bolts
 Periodic re-tensioning of all bolts
 Removal and examination of individual bolts: 20 % of bolts annually*

* 20% of the bolts shall be removed and examined. The first 20% shall be taken in the most loaded sector of the
crane. If any significant defects are found during this examination another 20% are drawn. If any of this second
set is found to be defective then all bolts shall be drawn. If the first 20% are found to be acceptable the bolts can
be re-used and the next 20 % can be drawn the following year.

Manual torque wrench

When refitting, all bolts shall be tensioned according to doc. no: WI 51.

1.1. Knock-Test
It is recommended to use a ball peen hammer and do a “knock test” on each bolt. In the event that a nut should
have become loose, the lack of tension in the bolt will generate a different sound during the knock test as
compared to the fully tensioned bolts. Loose nuts indicate that bolt must be re-tensioned according to doc. no:
WI 51.

Note: The knock-test and re-tensioning can be performed every other time according to the Periodic Inspection
and Inspection Program.

6 Maintenance - Annex K
MACGREGOR NORWAY AS K1
 User Manual for Crane

2. Tools & Tool Safety

 Manual torque wrench
 Gloves, glasses and hard hat
 Ball peen hammer

3. Hazards
 A safety harness is recommended if a ladder or lift is being used for re-tensioning.

WI 51 – Bolt selection- tensioning forces - torques: See the following pages.

6 Maintenance - Annex K

K2 MACGREGOR NORWAY AS
Doc type WORK INSTRUCTION

Doc. ID Annex K - WI 51 attachment

Business Area: Document owner: Document revision:

MacGregor Norway Discipline lead mechanical 4

Business Line: Document revised by:

OFS Advanced Load Handling 25.10.2012 AFL

Bolt selection / tightening torques / bolt tensioning forces

1 Purpose/ Scope
The purpose of this procedure is to be a guide reference to ensure correct selection of bolts, and correct
tensioning for bolts and nut.

2 Responsibilities
- Discipline Lead mechanical is responsible for this instruction.
- Operator/ foreman of work are responsible for performance of actual instruction.
- QC surveyors are responsible to perform control.

3 Description

3.1 Use of bolt selection, tightening torque and hydraulic tensioning

This document applies when referenced by drawing, technical specification or other document associated with
a delivery.

The bolt selection in this document refers to how to select bolts and bolt quality in general applications (e.g.
winch assembly, gearbox assembly, etc.) and special applications (e.g. slew ring bolts and nuts)

The tightening torques in this document applies to critical bolts specifically identified by the drawing,
technical specification/requirement or other document. See section 3.4.

The bolt tensioning forces (hydraulic tensioning) apply to all crane slewing ring bolts with thread diameter
M33 or larger. See section 3.5.

Other bolts may be tightened according to mechanic’s judgment.

Bolts tightened according to mechanic’s judgment shall be firm, but avoid overtightening. This implies that
tightening torque according to mechanic’s judgment will be much less than tightening torque by torque
wrench, in order to avoid the risk of overtightening.

Page 1 of 5
Doc type WORK INSTRUCTION

Doc. ID Annex K - WI 51 attachment

3.2 Engineering notes (for Cargotec use)

Typical applications of this document are most MacGregor assemblies with bolts to be tightened with a torque
wrench / pneumatic wrench or with a hydraulic tensioning device.

The tightening torques (section 3.4) are valid for standard, full-section, uncoated carbon steel (not stainless)
fasteners lubricated with anti-seize compound, such as Loctite 8009. These tightening torques are also
generally used for hot dip zinc coated fasteners, although such fasteners would require a somewhat higher
torque to achieve maximum clamping force. Source: Tingstad table T-18, lower left-hand section.

Bolt tensioning forces (section 3.5): Source: Rothe Erde.

3.3 Bolt/nut Selection

Selection of bolts/nuts for different assemblies and applications is normally done according to material
specification list on the relevant assembly drawing. Here the bolt size, type and quality and number are
specified. In addition to this, all bolts shall conform with and be tested in accordance with a recognised
standard e.g. pertinent part of ISO 898.

In general bolts are to be delivered according to DNV “Standard for certification Lifting appliances Oct 2011,
Ch. 2, Sec. 1, D400 Formatted: Font color: Auto

Bolt connections are normally divided into three different groups; secondary, primary and essential.
1. Secondary bolts are bolts in platforms, stairs, ladders, railings, installation of cabins and cabinets etc.
Bolts in this category are to be delivered with 2.2 works certificate and it is no requirement to charpy tests.
Bolts smaller than M12 to be stainless steel A4 quality. Bolts from M12 and up to be hot dip galvanised
8.8 quality.
2. Primary bolts are transferring structural loads and are elements in the primary load carrying structure.
Bolts in this category are to be delivered with 2.2 works certificates and there it is no requirements to
charpy tests. Bolts smaller than M12 to be stainless steel A4 quality. Bolts from M12 and up to be hot dip
galvanised 8.8 quality. If the structural calculations show that an increased strength is required, 10.9
qualities may be used.
3. Essential bolts are part of a non-redundant load path and a breakage may result in a collapse or a serious
mal-function. Bolts used in slew bearings are considered as essential. Bolts in this category are to be
delivered with 2.2, 3.1 or 3.2 certificates. If installed in a slew bearing for offshore cranes, 3.2 certificates
is required. If installed in slew bearings for other cranes 3.1 is acceptable. For all other essential
connections 2.2 is required. Normally 8.8 or 10.9 qualities are used in this category. No higher than 10.9
quality is allowed. The requirements to charpy test are given in DNV “Standard for certification Lifting
appliances Oct 2011, Ch. 2, Sec. 1, Table D2. This table applies for slew ring bolts only. Bolts with
diameter less than Ø25mm has no charpy test requirements. The requirements for bolts from Ø25mm are
42J for offshore applications and 25J for other applications Test temperature (Td) is normally -20 degC for
offshore cranes and -10 degC for other cranes.

Page 2 of 5
Doc type WORK INSTRUCTION

Doc. ID Annex K - WI 51 attachment

3.4 Tightening torques

 Carbon steel (not stainless) threaded fasteners, full section.

 Lubricated with anti-seize compound (Molycote G rapid plus).

Tightening torques in N·m. Torque tolerance: ±5%.

Strength grade Strength grade

Thread 8.8 10.9 12.9** Thread 8.8 10.9 12.9**

M12 65 95 110 M33* 1 400 2 050 2 350

M14 100 150 175 M36* 1 850 2 600 3 050
M16 155 225 265 M39* 2 350 3 350 3 950
M18 220 315 370 M42* 2 950 4 200 4 900
M20 310 440 510 M45* 3 650 5 150 6 000
M22 410 590 690 M48* 4 400 6 300 7 400
M24 530 760 890 M52* 5 700 8 000 9 400
M27 780 1 100 1 300 M56* 7 000 10 000 11 700
M30 1 050 1 500 1 750

Note:
If using nord-lock washer the torque needs to be increased by 10%
*) Bolts for crane slewing rings that are M33 or larger shall be tightened using a hydraulic tensioning
device; see section 0.
**) Bolts with quality 12.9 are not to be used on MacGregor products. By any use of 12.9, technical dept.
needs to confirm this.

Page 3 of 5
Doc type WORK INSTRUCTION

Doc. ID Annex K - WI 51 attachment

3.5 Bolt tensioning forces

Bolt tension forces including tolerances for "large-clearance metric thread" – DIN 2510 – Sheet 2 – using
hydraulic tension cylinders.

Strength class to DIN/ISO 898 8.8 10.9

Yield point Rp 0.2 N/mm² 660 940

Metric Pitch Stress Core cross Tension force Theoretical Tension force at Theoretical use of
ISO-thread area section at yield point use of tension yield point tension force
DIN 13 force
As A3 F0.2 FM= 0.9·F0.2 F0.2 FM= 0.9·F0.2
mm mm² mm² kN kN kN kN

M33 3.5 668 617 440 396 627 564

M36 4 786 723 518 466 738 664

M39 4 943 873 622 559 886 797

M42 4,5 1,083 999 714 642 1,018 916

M45 4.5 1,265 1,174 834 750 1,189 1,070

M48 5 1,426 1,320 941 846 1,340 1,206

M52 5 1,707 1,590 1,126 1,013 1,604 1,443

M56 5,5 1,971 1,833 1,300 1,170 1,852 1,666

M64 6 2.599 2,426 1,715 1,543 2,443 2,198

M72 6 3,372 3,174 2,225 2,002 3,169 2,852

M80 6 4,245 4,023 2,801 2,520 3,990 3,591

M90 6 5,479 5,226 3,616 3,254 5,150 4,635

M100 6 6,858 6,575 4,526 4,073 6,446 5,801

Preload the bolts with the advisable care crosswise to the specified values. It is possible to calculate with a
tightening factor of αA of 1.2 to 1.6, depending on the tightening method, and to use the yield point of the bolt
up to 90%.
The preload of the bolt tightened first is influenced by the tightening of the other bolts so that a minimum of
two passes is required.
This will at the same time compensate for the settling produced by the smoothing out of the unloaded mating
surface during preloading (thread and nut contact surface).
As the tension force applied in this method will not only cause elongation in the shaft but also in the thread, it
is important to choose the correct thread series or thread tolerances acc. to DIN 2510. An inadequate thread
clearance may cause jamming of the nut, when the bolt is elongated. Taking into account the nut height,
consultation with the bolts manufacturer is absolutely necessary.
The bolts should be long enough to leave at least 1 · d above the nuts free for positioning the tension cylinder.

Page 4 of 5
Doc type WORK INSTRUCTION

Doc. ID Annex K - WI 51 attachment

4 References

Page 5 of 5
 User Manual for Crane

Annex L - Slew Bearing Wear Measurement

1. General
The slew bearing is always under the influence of tilting
moments. Over time this will cause uneven wear on the
raceway of the three-row roller bearing surfaces in the slew
bearing. In order to keep precise control over the wear on
the roller raceway, annual measurements are necessary.
This is done between four measuring plates, welded/bolted
onto the foundation and the lower part of the rotating part of
the slew bearing.

Note: If the measuring plates are not already fitted, it is

recommended that the crane owner take appropriate action
to fit these measuring plates to the foundation within the
first two months of crane operation. The measurements
taken and logged in the slew ring wear measurement table in

this Annex, may be carefully examined by

international societies at a later stage in conjunction
with crane re-certification.

Measuring should be done with the main jib in its

highest angle and the knuckle jib in its innermost
position (contact between jibs), ref. photo above and
illustration at left.

Measuring principle: Four measurement points are

equally spaced around the foundation (denoted 1 to 4).
Measurements are to be taken at slew positions 0o, 90 o,
180 o and 270 o and written down. Start with
measurements in slew position 0 o, then 90 o etc. The
mean value of these measurements will indicate level
of slew bearing wear.

Paint on the slew bearing is removed at the initial

measurement. Corrosion protection (Tectyl or similar)
is to be applied after the measurements are taken.

6 Maintenance - Annex L
MACGREGOR NORWAY AS L1
 User Manual for Crane

Two typical measuring point setups on the crane pedestal

6 Maintenance - Annex L

L2 MACGREGOR NORWAY AS
 User Manual for Crane

Typical three –row roller bearing

In order to have comparable measurements it is important that the measurements are done in the exact same
slew positions and with the jibs in the same geometric position. The operator panel in the crane cabin shows
both jib and slew positions. These positions can be used for future reference.

The following table is to be used for recording measurements at the intervals specified in the Periodic Inspection
and Maintenance Program following the initial measurement. The accuracy of the measuring instrument is to be
minimum ±0.01mm.

Depth micrometer

6 Maintenance - Annex L
MACGREGOR NORWAY AS L3
 User Manual for Crane

The photo below shows measurement at one of the four measurement points on the crane pedestal. The
maximum allowable deviation is:

Permitted increase in slack*

Crane Axial reduction Tilt forward and
measurement back
1077 2.00 2.60
1301 2.00 2.60
1400 2.00 2.60
1610 2.00 2.60
1800 2.60 3.20
1891 2.60 3.20
2201 2.60 3.20
2398 3.30 4.00
2806 3.30 4.00
3293 3.30 4.00
3568 1.20 2.00
3990 1.60 2.80
4240 1.60 2.80
4841 1.60 2.80
5150 2.00 4.20
6800 2.00 4.20

If the wear is found to have increased significantly, the time intervals between measurements should be
shortened. If the wear exceeds the given limit, consult MacGregor Marine Service.

*Deviations in flatness are measured in accordance with DIN EN ISO 1101 on the contact surfaces
**The value for increase in slack is a measurement of how much the hardened layers of the bearing are worn

6 Maintenance - Annex L

L4 MACGREGOR NORWAY AS
 User Manual for Crane

1.1. Slew Bearing Measurement Table

Delivery
Date: Date: Date: Date: Date:
date

Running
hours

Measuring Slew 1 Dev. 2 Dev. 3 Dev. 4 Dev. 5 Dev.

Basic
point position

1 0

2 0

3 0

4 0

Measuring Slew 1 Dev. 2 Dev. 3 Dev. 4 Dev. 5 Dev.

Basic
point position

1 90

2 90

3 90

4 90

Measuring Slew 1 Dev. 2 Dev. 3 Dev. 4 Dev. 5 Dev.

Basic
point position

1 180

2 180

3 180

4 180

Measuring Slew 1 Dev. 2 Dev. 3 Dev. 4 Dev. 5 Dev.

Basic
point position

1 270

2 270

3 270

4 270

6 Maintenance - Annex L
MACGREGOR NORWAY AS L5
 User Manual for Crane

1.2. Slew Bearing Seal

The black rubber seal for the slew
bearing (photo at right) is a separate
component mounted to the slew bearing.

See Periodic Inspection and

Maintenance Program for inspection
intervals of the slew bearing seal.

For correct operation, the seals must be

free from dirt. When cleaning the unit,
prevent the cleaner from contacting the
seals or from entering the raceways
system. If any of the seals are found to
be damaged, they must be replaced. Re-
lubricate the unit after this inspection.

1.3. Raceway Grease Samples

When annual wear measurements are taken, it is recommended
to take raceway grease samples for lab analysis as well. Thus
it is possible to determine the raceway wear rate and the actual
condition of the raceway system. Analysis and evaluation are
to be carried out by an authorized company. The original
sample results data are to be stored onboard the vessel.

1.3.1. Grease sampling:

Locate the two sampling ports (2 x180o) on the outside of the
slew bearing. Remove the blanking bolts and collect grease
samples while rotating the slew bearing. Use the table below
for recording the sample results. A grease sampling kit (photo
at right) specifically produced for the sampling action can be
provided by MacGregor Norway AS.

6 Maintenance - Annex L

L6 MACGREGOR NORWAY AS
 User Manual for Crane

1.3.2. Slew raceway grease sample log

Sample No. 1 Sample No. 2 Sample No. 3 Sample No. 4 To be continued

Tester:

Signature:

Date:

Grease
sample
result

6 Maintenance - Annex L
MACGREGOR NORWAY AS L7
 User Manual for Crane

2. Tools & Tool Safety

 Depth micrometer
 Glasses, gloves and hard hats
 Lift or ladder

3. Hazards
 In order to measure correctly paint may need to be removed.
 For any necessary paint removal for correct measurements, use a paint removal chemical or paint
removal sand paper.
 Ensure adequate protection is used for working with paint removal.
 Use Tectyl rust preventative after measuring to prevent rust.

6 Maintenance - Annex L

L8 MACGREGOR NORWAY AS
 User Manual for Crane

Annex M - Wire Sheave Wear Measurement

1. General
Note: From early 2011, some cranes were equipped with tempered steel sheaves. For these cranes, the wire
sheave groove wear measurement is not applicable.

Obtaining good measurements of wire sheave groove wear will help the crane owner to apply appropriate
sheave maintenance actions in addition to providing relevant input to the crane maintenance schedule.

The wire sheave grooves include a two to three mm induction hardened layer beyond which the hardness
gradually decreases. The abrasion that the grooves are subject to can be monitored and understood by use of a
sliding gauge for measuring the depth of the groove. Measurements are taken to a tenth of a millimeter. Based
on the original inspection date, wear measurement trend analysis can be used to influence the measuring
schedule itself so that it continues to accurately indicate the health and future useful lifetime of the sheaves.

Requirements for the wear measurement:

 Vessel shore side.

 Follow normal crane maintenance safety instructions.
 Two personnel required: one certified crane operator and one maintenance worker.
 2-way communications are established between crane operator and maintenance worker.

1.1. Groove Measuring

There are normally eight wire sheaves to be measured (four
for the main winch and four for the whip winch wire). The
measurement shall be taken at the same reference position on
the wire sheave every time. This is to avoid "false" wear
indications. The reference position is normally marked on the
wire sheave flange by means of a sign plate (shown here by
an arrow).

Each wire sheave is individually numbered according to their

position on the crane (ref. drawing for the main winch wire
sheaves later in this section).

Note: It is imperative that maintenance workers verify that

the crane control system key switch in the cabin is in the OFF
position prior to approaching the wire sheaves.

Wire sheave marking sign

6 Maintenance - Annex M
MACGREGOR NORWAY AS M1
 User Manual for Crane

Wire measurement procedure

Wire measurement procedure

1 Operate the crane (rotate wire sheaves) to make the measuring point indicators on the wire
sheaves clearly visible and accessible.

2 Locate the mark (photo at previous page) which exactly indicates where the measurement should
be taken.

3 Perform depth measurement by means of a steel rule and a sliding gauge (or equivalent) to
measure the distance from top of flange to bottom of groove (photo below).

4 Record the measurement/deviation in the "wire sheaves log", an example of which is provided on
next page.

5 Repeat procedure for all wire sheaves.

Groove depth measurement

1.2. Scheduled Maintenance

Due to the characteristics of wire sheave groove wear, it is recommended that the measuring frequency
according to the Periodic Inspection and Maintenance Program. Thereafter it will be at the crane owner's
discretion to adjust the maintenance schedule based on the previous depth measurements and the crane owner's
inherent technical experience and expertise.

6 Maintenance - Annex M

M2 MACGREGOR NORWAY AS
 User Manual for Crane

1.3. Wire Sheaves Log

Measurements to be taken No. 5 sheave No. 6 sheave
No. 1 sheave No. 2 sheave No. 3 sheave No. 4 sheave
according to the Periodic Inspection (King) (Wire spooler)
and Maintenance Program.
main whip main whip main whip main whip main whip main whip
winch winch winch winch winch winch winch winch winch winch winch winch
Initial measurement:
Date: Measurement:
Deviation:
Date: Measurement:
Deviation:
Date: Measurement:
Deviation:
Date: Measurement:
Deviation:
Date: Measurement:
Deviation:
Date: Measurement:
Deviation:
Date: Measurement:
Deviation:

*Note: The table provided in this page is standardized. The amount of sheaves may differ from crane to crane.

The initial measurement value in the table above is the value for the first measurement taken for each individual wire sheave. If, upon receipt of this procedure,
the values are not already stated measurements should be carried out and logged in conjunction with the cranes’ Harbor Acceptance Test or equivalent.

6 Maintenance - Annex M
MACGREGOR NORWAY AS M1
 User Manual for Crane

Wire sheave numbering sequence for the main winch wire

2. Tools & Tool Safety

 Lift or ladder to achieve appropriate height
 Gloves, glasses and hardhats
 Slide calliper

3. Hazards
 Ensure to clean the area before measuring to achieve accurate results
 If a lift or ladder is used it is advised to use a safety harness.

6 Maintenance - Annex M
MACGREGOR NORWAY AS
 User Manual for Crane

Annex N - General Electrical System

1. Control Cabinets (CC) and Junction Boxes (JB)

The crane has numerous electrical cabinets installed in different locations in the system. In addition, several
junction boxes (JB) is located outside the king. These must be checked regularly for moisture and corrosion.
Check Cortec VCI due date and replace according to Periodic Inspection and Maintenance Program.

The following must be done on all cabinets and JB:

 Open and check that the doors gaskets are in good condition (apply Vaseline, silicone, or similar if dry).
 Check regularly for water ingress, corrosion, damage, loose glands, and ambient conditions in excess of
the specifications.

Tighten all cable terminal Tighten all cabinet Check and clean the
connections and fuses bushings drain plug (if applicable)

VCI device
plate at JB
(see photo
Tighten all cable
below)
terminal connections
and fuses

Electrical Junction box

cabinet.

VCI device plate at JB

6 Maintenance - Annex N
MACGREGOR NORWAY AS N1
 User Manual for Crane

2. Tools & Tool Safety

 None required.

3. Hazards
 Ensure power is turned off before accessing electrical cabinet or junction box. This is in order to avoid
electrocution. Working with live wires is extremely dangerous!

6 Maintenance - Annex N

N2 MACGREGOR NORWAY AS
 User Manual for Crane

Annex O - Motion Reference Unit (MRU)

1. Inspection
A visual inspection of the MRU through the Trend Screen display is to be done according to the Periodic
Inspection and Maintenance Program. This is to verify that the MRU is working properly, and that is does not
require any immediate recalibration.

On the operator terminal, go to the Trend picture via the Menu button and set MRU Heave Velocity and MRU
Heave Position to trend pens. Verify that the MRU Heave Velocity signal varies around zero and has no offset.
Also verify that MRU Heave Velocity is zero when the MRU Heave Position changes direction. If there seems
to be an offset on the MRU Heave Velocity signal, the MRU must be recalibrated.

6 Maintenance - Annex O
MACGREGOR NORWAY AS O1
 User Manual for Crane

2. Recalibration
Two MRU types are used on active heave compensated cranes, either
MRU type Z or type H. The replacement procedure is the same for both.

The recalibration intervals for these are found in the Periodic Inspection
and Maintenance Program.

When the MRU needs to be recalibrated, MacGregor Norway

Kristiansand must be informed. A recalibrated MRU will be shipped out
to the vessel. When it arrives, replace the old MRU with the recalibrated one and ship the old MRU back to
MacGregor Norway.

During the MRU replacement, the vessel should be alongside the quay since the MRU must not
experience any movement during the initialization period.

The replacement procedure is rather simple and can be done by an electrician:

 Shut down the crane.

 Unscrew the cable connected to the old MRU, placed in the CC-300 cabinet in the crane pedestal (an
alarm will then be shown at the operator terminal, stating "MRU error").
 While holding the MRU, unscrew the four hexagonal socket cap screws (5mm) on top of the MRU
housing.
 Remove the MRU from its housing, and note which direction the R+- arrow (photo below) is pointing.
 Install the new, calibrated MRU with the R+- arrow pointing in the same direction as the old one.
 Tighten the four hexagonal socket cap screws.
 Screw on the cable to the bottom of the MRU.
 Wait for approximately five to ten minutes while the MRU initialization sequence runs.

During the initialization period (approximately

five to ten minutes) after an MRU replacement,
an alarm stating "MRU failure" will be shown
on the operator terminal. As soon as the
initialization is completed, the alarm will
disappear.

The old MRU must immediately be returned to

MacGregor Norway.

Required tools:

 Allen key - 5 mm.

6 Maintenance - Annex O

O2 MACGREGOR NORWAY AS
 User Manual for Crane

Annex P - Pressure Transmitters

1. Inspection
1.1. General
The pressure transmitters have been calibrated to a certain pressure range, and send a 4-20 mA signal,
corresponding to the calibrated range to an analogue input channel in the PLC system.

However, to secure correct pressure readings, an inspection of the most "essential" pressure transmitters must to
be done. MacGregor Norway recommend to do this according to the Periodic Inspection and Maintenance
Program and followed up by a recalibration (often replacement) if needed.

The transmitters on active boost cranes which must be checked are listed in the table below, while those for
semi-active cranes are listed on the following page. In the tables, the name of the transmitter, its tag number and
maximum allowed deviation is provided.

Active Boost

For active boost cranes, the following pressure transmitters are evaluated to be "essential" and must be checked
frequently:

Pressure transmitter Tag no.: Max. allowed deviation

Main winch motor displacement pressure 1 -PT204A (or -PT204) 0.5 bar

Main winch motor displacement pressure 2 -PT204B (or -PT205) 0.5 bar

LS pressure A -PT219A (or -PT219) 2.0 bar

LS pressure B -PT219B (or -PT220) 2.0 bar

Main pump regulator pressure -PT203 2.0 bar

6 Maintenance - Annex P
MACGREGOR NORWAY AS P1
 User Manual for Crane

Semi-Active

For semi-active cranes, the following pressure transmitters are evaluated to be "essential" and must be checked
frequently:

Pressure transmitter Tag no.: Max. allowed deviation

Displacement:

Motor disp passive left 1 -PT240 0.5 bar

Motor disp passive left 2 -PT241 0.5 bar

Motor disp passive right -PT242 0.5 bar

Motor disp act motor 1 -PT243 0.5 bar

Motor disp act motor 2 -PT244 0.5 bar

* Whip winch displacement pressure (* if whip winch AHC) -PT260 0.5 bar

Other:

Replenishment pressure -PT203 2.0 bar

Servo pressure -PT202 2.0 bar

LS pressure A -PT216 2.0 bar

LS pressure B -PT217 2.0 bar

Main winch passive motor B pressure -PT208 2.0 bar

LP/HP accumulator high pressure A -PT211 2.0 bar

LP/HP accumulator high pressure B -PT212 2.0 bar

LP/HP accumulator low pressure A -PT213 2.0 bar

LP/HP accumulator low pressure B -PT214 2.0 bar

Main pump A/B pressure -PTxxx 2.0 bar

Recommended tools:

 Hand pump.
 T-joint (2x).
 Calibrated pressure transmitter (0-60 bar).
 Calibrated pressure transmitter (0-400 bar).
 Calibrated pressure transmitter (0-460 bar) for main pump transmitters.
 Portable data recorder / measurement device.

6 Maintenance - Annex P

P2 MACGREGOR NORWAY AS
 User Manual for Crane

1.2. Inspection Process

MacGregor Norway recommends the following method for checking the pressure transmitters:

 Portable data recorder and a hand pump.

1.2.1. Portable Data Recorder & Hand Pump

When possible, the transmitter that is being tested should be removed from its location (see section 2 -
"Replacement" for removal description) and connected together with a calibrated transmitter. The two
transmitters are then connected to a measurement device and applied pressure upon by means of a hand pump
(see illustration below).

After the transmitter is unplugged from the crane, testing is done in the following order:

1. Connect the hand pump to a T-joint.

2. Connect the transmitter that is being tested on one side.
3. Connect a calibrated transmitter on the other side.
4. Connect the two transmitters to the applicable port on the measurement device via an additional T-joint.
5. Apply pressure and compare the two transmitters.

Note: The pressure should be applied step by step between 5-10 bar. If the deviation exceeds the maximum
allowed value, the transmitter must be changed. The consequence of having too high deviation will differ from
transmitter to transmitter. Please contact MacGregor Norway for advice!

Transmitter to be tested

Hand pump
Calibrated transmitter
Measurement device

6 Maintenance - Annex P
MACGREGOR NORWAY AS P3
 User Manual for Crane

2. Replacement
Replacement of pressure transmitters is done in the following order:

 Stop the HPU.

 Verify that there is no pressure where the pressure transmitter is fitted. (There will be pressure in the
system, but it is important to bleed off the pressure
where the pressure transmitter is located).
 Remove the old pressure transmitter.
 Install the new pressure transmitter.
 Verify that it is properly fitted / tightened.
 Install the electric cable to the transmitter (use
Vaseline in the plug).
 Turn on the power to the crane.

Required tools:

 Wrench/spanner - 27 mm.

3. Tools & Tool Safety

 Hand pump.
 T-joint (2x).
 Calibrated pressure transmitter (0-60 bar).
 Calibrated pressure transmitter (0-400 bar).
 Calibrated pressure transmitter (0-460 bar) for main pump transmitters.
 Portable data recorder / measurement device.
 Wrench/spanner - 27 mm.

4. Hazards
 Ensure system is depressurised.
 Clean area after maintenance to avoid slippery surfaces.
 Use drip tray.

6 Maintenance - Annex P

P4 MACGREGOR NORWAY AS
 User Manual for Crane

Annex Q - Encoders

1. General
All pulse encoders must be inspected and checked for proper
function, damage and corrosion according to the Periodic
Inspection and Maintenance Program. They are located the
following places:

 Main jib (2x)

 Knuckle jib (2x)
 Main winch
 Whip winch
 Slew pinion
 Spooling device (if applicable) Jib angle encoder

Slew rotation Winch rotation encoder (main winch)

encoder

6 Maintenance - Annex Q
MACGREGOR NORWAY AS Q1
 User Manual for Crane

2. Maintenance
Inspection of a pulse encoder is done in the following order:

 Unplug and remove the encoder.

 Disassemble it by unscrewing the two crosshead
screws.
 Verify that there is no moisture and/or corrosion
inside the encoder.
 Verify that the O-ring is not damaged and that it
is in its slot when re-assembling the encoder.
The O-ring must be lubricated with Vaseline.
 Before re-assembling the encoder, lubricate the
flange with a thin layer of Vaseline.
 Verify that the encoder shaft is in the centre of
the flexible coupling (bottom photo next page).
This prevents bias to the shaft.
The flexible coupling (if applicable) should be
retightened as these have a tendency to loosen.
 Re-plug the cables and verify that the connections are tight.
 Verify that the crane is in exactly the correct position (normally parked position) before resetting the
encoder.
 Reset the encoder via the Setup screen ("Encoder reset") on the operator terminal.

Required tools:

 Small screw driver.

 Spanner/wrench - 15 mm.
 Allen key - 4 mm.

6 Maintenance - Annex Q

Q2 MACGREGOR NORWAY AS
 User Manual for Crane

3. Replacement
If a pulse encoder is damaged, it must be replaced. Replacement is a simple procedure which may be undertaken
by an electrician.

 Unplug and remove the old encoder.

 Disassemble it by unscrewing the two
crosshead screws and check the address
dip switch combination (Profibus
address) for the old encoder (circled in
the photo at right).
 Disassemble the new encoder.
 Make sure that the address dip switch
combination in the new pulse encoder is
identical to the old one so the control
system identifies the encoder correctly.
 Verify that the O-ring is in its slot when
re-assembling the encoder. The O-ring
must be lubricated with Vaseline.
 Before reassembling the encoder,
lubricate the flange with a thin layer of
Vaseline.
 Verify that the encoder shaft is in the
centre of the flexible coupling (photo
below). This prevents bias to the shaft.
The flexible coupling (if applicable)
should be retightened as these have a
tendency to loosen.
 Re-plug the cables and verify that the connections are tight.
 Verify that the crane is in exactly the correct position (normally parked position) before resetting the
encoder.
 Reset the encoder via the Setup screen ("Encoder reset") on the operator terminal.

Required tools:

 Small screw driver.

 Spanner/wrench - 15 mm.
 Allen key - 4 mm.

Encoder with flexible coupling attached

(the plastic type coupling used for slew
only)

6 Maintenance - Annex Q
MACGREGOR NORWAY AS Q3
 User Manual for Crane

Annex S - Decommissioning

1. General
This annex describes the process of decommissioning a crane. The process is defined as removing a crane from
service making it redundant. The crane can then be reused, sold for parts or recycled. This is general guide
stating the basic requirements for removing a crane from service. Decommissioning is the responsibility of the
equipment owner. In the event of the crane being stored for a long period of time, refer to section 3 “Storage”
and Chapter 4: Handling, Preservation and Installation - “WI 58 Handling, Storage, and Preservation Marine.”

2. Decommissioning

Pre-Decommissioning Survey: A pre-decommissioning survey is recommended in order to identify targeted actions

and to create the most effective methods for removal of components/cabling/oil etc.

Classification: As the decommissioning commences, objects should be identified as either scrap

(SCRAP) or objects that can be reused (REUSE).

Remove Components:  Control panels

 Operator chairs
 Lights
 PLC Systems
 Screens

Disconnect any Electrical  Electrical cabinets

Cabling:  Junction boxes
 If removing crane from platform, ensure power supply cords are disconnected.

Note: Ensure electric power has been turned off.

Drain any Oil: Refer to Annex T “Disposal of Waste”

 Hydraulic oil from tank.
 Gearbox oil.

Other Waste Disposal: Refer to Annex T “Disposal of Waste”

 Batteries
 Electrical components

Cleaning and Preparation:  Clean all surfaces.

 Clean inside of oil tank.
 Remove any possibly environmentally harmful or dangerous liquids (Annex T).

6 Maintenance - Annex S
CARGOTEC NORWAY AS S1
 User Manual for Crane

3. Storage
This is a general guide. The following points refer to steps that may be taken with reference to moving a crane
into storage. For an in depth description of this procedure, refer to Chapter 4: Handling, Preservation and
Installation - “WI 58 Handling, Storage, and Preservation Marine.”

Disconnection: Disconnect slip ring.

Disconnect electrical connections (including power supply).

Preservation: Exterior
Interior
Oil

Lifting/transport: Packing
Unpacking

Storage: Heat electrical motors.

Heat inside the cabin.

6 Maintenance - Annex S

S2 CARGOTEC NORWAY AS
 User Manual for Crane

Annex T - Disposal of Waste

1. General
Any used material including oil needs to be disposed of in the correct manner according to the regulations set
out by the national authorities.

2. Hydraulic Oil
 Drain the hydraulic oil from the main tank.
 Transfer the hydraulic oil to an approved storage container that can be sealed.
 Ensure the container is clean before filling it with oil to avoid contamination.
 Secure the lid tightly ensuring there is no chance of oil spilling out.
 Find the closest recycling center and check to make sure they accept used hydraulic oil.
 Take the used oil to recycling center for disposal.

Note: Improper disposal of oil is a crime. Do not mix hydraulic oil with other chemicals for recycling, check to
ensure any transmission fluid is ok to be stored and recycled with hydraulic oil.

3. Lubricating Oil
Lubricating oil collected during maintenance will usually be collected by use of a drip tray. With this oil it is
important to remember:

 Store lubrication oil in an approved container.

 When the container is full, safely dispose by taking it to a certified recycling center appropriate for
dealing with this type of oil.
 Generally gear box oil and oil in the crane king foundation will remain in place if the crane is
decommissioned or resold, unless there is a specific reason for its removal.

4. Batteries
 Generally located in the CC100 cabinet.
 Also located outside the crane cabin and inside the crane king are emergency backup batteries.
 Be sure to dispose of batteries in the correct manner by taking them to a recycle center appropriate for
dealing with batteries.

5. Crane Electronics
 Common electrical components that may need to be disposed of include light bulbs and tubes.
 Ensure they are taken to a recycling center capable of dealing with these materials.

6 Maintenance - Annex T
CARGOTEC NORWAY AS Q1
 User Manual for Crane

Annex Z - Maintenance Log

Periodic Maintenance Program
Maintenance Log

Crane type: MacGregor Offshore Crane ID Number: SP______

System Maintenance Date Comments Sign. Date Comments Sign. Date Comments Sign
Action
1
2
3
HYDRAULIC

4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

6 Maintenance - Annex Z

MacGregor NORWAY AS Z1
 User Manual for Crane

Periodic Maintenance Program

Maintenance Log

Crane type: MacGregor Offshore Crane ID Number: SP______

System Maintenance Date Comments Sign. Date Comments Sign. Date Comments Sign
Action
20
MECHANICAL

21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38

6 Maintenance - Annex Z

MacGregor NORWAY AS Z2
 User Manual for Crane

Periodic Maintenance Program

Maintenance Log

Crane type: MacGregor Offshore Crane ID Number: SP______

System Maintenance Date Comments Sign. Date Comments Sign. Date Comments Sign
Action
39
ELECTRICAL

40
41
42
43
44
45
46
47
48
49

6 Maintenance - Annex Z

MacGregor NORWAY AS Z3
 User Manual for Crane

Annex V – Retensioning and Control of Slew

Bearing Bolts

Revision Description Date Author Checked by

0 First Issue 24.08.2015 JSR ONO

This document and all information and data herein or herewith is the confidential and proprietary property of MacGregor Norway AS and is not to be used,
reproduced or disclosed in whole or in part by or to anyone without the written confirmation from MacGregor Norway AS.

© MacGregor Norway AS
www.macgregor.com

6 Maintenance - Annex V
MACGREGOR NORWAY AS V1
 User Manual for Crane

Annex V – Retensioning and Control of Slew

Bearing Bolts

1. Tool List
 Safety glasses
 Gloves
 Hardhat
 Work overalls
 Steel capped boots
 Tensioning tool
 Molycoat G-Rapid Plus
 Tectyl spray Tensioning Tool
 Denso tape / plastic cap

2. Check/retensioning/control of bolts
 All slew bearing bolts shall be checked according to maintenance schedule in the user manual
by performing knock test, retensioning or removing bolt for check by third part.

 Before knock test is performed, remove plastic cap or denso tape on all bolts to be tested.
End of bolt to be degreased. Test is performed by knocking on end of bolts to hear if sound in
the bolts is equal. If not, retensioning is to be performed.

 Before retensioning is performed, remove plastic cap or denso tape on all bolts to be
retensioned. Bolts, nuts and threads to be properly degreased and threads lubricated with
Molycote G-Rapid Plus. How to retension bolts is described in chapter three.

 Before control of bolts is performed, remove plastic cap or denso tape on all bolts to be sent
for control by third part. Bolts could also be changed instead of controlled. Bolts, nuts and
threads to be properly degreased and threads lubricated with Molycote G-Rapid Plus before
removing bolt. How to remove bolts is described in chapter three.

6 Maintenance - Annex V

V2 MACGREGOR NORWAY AS
 User Manual for Crane

3. Preparation for Tensioning/Loosening of bolts

1. Select the correct tensioning tool. Picture showing in this instruction is the recommended tool
Macgregor have designed for their products. This tensioner is designed and stamped with
2275 bar as the correct tension.
2. If other tension tools are used make sure that value from schedule is followed.(see below)

Strength class to DIN/ISO 898 8.8 10.9

Yield point Rp 0.2 N/mm² 660 940

Metric Pitch Stress Core cross Tension force Theoretical Tension force Theoretical
ISO- area section at yield point use of at yield point use of
thread tension tension force
DIN 13 As A3 F0.2 force F0.2 FM= 0.9·F0.2
mm mm² mm² kN FM= 0.9·F0.2 kN kN
kN
M30 3,5 561 370 333 527 453,88
M33 3.5 668 617 440 396 627 564
M36 4 786 723 518 466 738 664
M39 4 943 873 622 559 886 797
M42 4,5 1,083 999 714 642 1,018 916
M45 4.5 1,265 1,174 834 750 1,189 1,070
M48 5 1,426 1,320 941 846 1,340 1,206
M52 5 1,707 1,590 1,126 1,013 1,604 1,443
M56 5,5 1,971 1,833 1,300 1,170 1,852 1,666
M64 6 2.599 2,426 1,715 1,543 2,443 2,198
M72 6 3,372 3,174 2,225 2,002 3,169 2,852
M80 6 4,245 4,023 2,801 2,520 3,990 3,591
M90 6 5,479 5,226 3,616 3,254 5,150 4,635
M100 6 6,858 6,575 4,526 4,073 6,446 5,801

3. Select the side of the bolt that will be tightened or removed. On this side, it is very important to
keep A 1x bolt dia.(min.0,8 x dia.) with threads outside nut for tensioning tool. Tool grip and
tension indicator to be added to length. This according to recommended Macgregor tension
tool.

Figure 1 1x bolt dia. (min 0,8 x bolt dia.)

A

6 Maintenance - Annex V
MACGREGOR NORWAY AS V3
 User Manual for Crane

Tightening of the bolts:

1. All bolts are tightened in two rounds.

2. First round torque should be 70% (100% is 2275 bar on Macgregor recommended tool. If
other tool, follow schedule above). Follow recommended tightening order (Figure 2).
3. Repeat procedure with 100% torque.
4. When retightening 100% one time.

Preservation:

1. Check the threads on each bolt.

2. Lubricated plastic caps or denso tape need to be put around the bolts to protect them from
damage and corrosion.

Note: Ensure all safety guidelines are followed when using a tensioning tool. It is important that the
person handling the tensioning tool is qualified to do so.

Figure 2: Tensioning order for slew bearing bolts.

4. Safety Considerations
 It is recommended that any personnel handling a tensioning tool be qualified and have the
necessary experience to do so.
 Personnel are advised to keep their head or face clear when tensioning the bolts.

6 Maintenance - Annex V

V4 MACGREGOR NORWAY AS
 User Manual for Crane

5. Tracking of Bolts According to Maintenance

Schedule
1. It is recommended to keep tracking of all bolts that have been checked / changed during the
period of five years according to maintenance schedule. Example of this is colour codes on
bolts.
2. Below is schedule that can be copied for this use. Colours in schedule to be marked on bolts
that are controlled/retightened/changed.

SP_________ SLEW BEARING INNER

RING / OUTER RING
HMC_______

1 CONTROL 2 CONTROL 3 CONTROL 4 CONTROL 5 CONTROL

PERFORMED PERFORMED PERFORMED PERFORMED PERFORMED
DATE: DATE: DATE: DATE: DATE:

NAME_____ NAME_____ NAME_____ NAME_____ NAME_____

NAME_____ NAME_____ NAME_____ NAME_____ NAME_____
NAME_____ NAME_____ NAME_____ NAME_____ NAME_____
NAME_____ NAME_____ NAME_____ NAME_____ NAME_____
NAME_____ NAME_____ NAME_____ NAME_____ NAME_____

6 Maintenance - Annex V
MACGREGOR NORWAY AS V5
 User Manual for Crane

7 Component Parts List

Table of Contents
1. Overview ..........................................................................................................................................1
2. Component Parts List Hydraulics .....................................................................................................2
3. Hydraulic Hose List ..........................................................................................................................3
4. Component Parts List Electro...........................................................................................................4
5. Ordering Spare Parts .......................................................................................................................5

7 Component Parts List

MACGREGOR NORWAY AS
 User Manual for Crane

1. Overview
Included in this chapter are the component parts list for the hydraulic and electrical system (see following
pages). The parts lists for crane mechanical are incorporated on the crane assembly drawings as follows:

Crane main assembly: 21271718

Main Winch Mechanical Assembly: 21270974

Whip Winch Mechanical Assembly: 21270973

Main Jib Assembly: 21271722

King main assembly:

21271727

Foundation main assembly: 21274216

Knuckle jib main assembly: 21271759

7 Component Parts List

MACGREGOR NORWAY AS 1
 User Manual for Crane

2. Component Parts List Hydraulics

7 Component Parts List

MACGREGOR NORWAY AS 2
 Page 1 of 5
Lines 9/4/2015
MacGregor Norway AS 2:16 PM

Item number Product name Item group

2582-1-07HYD HYDRAULIC COMPONENTS SW
2582-1-07HYD
Item number Position Product name Item type Group Qty Per series Unit Line type Weight Notes

SP25821LXA000 HYD FLOW DIAGRAM Item SW 1.0000 1 pcs Item 0.00

SP25821LXA000
Item number Position Product name Item type Group Qty Per series Unit Line type Weight Notes

11108503 HYDRAULIC TAG SET Item SW 1.0000 1 pcs Item 0.00

SP25821LXA001 HYD FLOW DIAGRAM Item SW 1.0000 1 pcs Item 0.00
SP25821LXA001
Item number Position Product name Item type Group Qty Per series Unit Line type Weight Notes

11023435 MH01 BUTTERFLY VALVE Item HV 3.0000 1 pcs Item 11.40

11001589 MH02 RUBBER COMPENSATOR Item HL 3.0000 1 pcs Item 7.80
10002853 MH03 BALL VALVE Item HV 1.0000 1 pcs Item 0.50
10000425 MH04 BALL VALVE Item HV 6.0000 1 pcs Item 1.32
10006257 MH05 BUTTERFLY VALVE Item HV 1.0000 1 pcs Item 1.95
10001471 MH06 TEST COUPLING,MANOMETER Item Item 1.0000 1 pcs Item 0.08
11015247 MH07 SCREW PUMP UNIT Item HW 1.0000 1 pcs Item 80.00
10001461 MH08 TEST COUPLING Item Item 6.0000 1 pcs Item 0.48
10000500 MH09 CHECK VALVE Item HV 1.0000 1 pcs Item 3.98
11005260 MH11 BALL VALVE Item Item 1.0000 1 pcs Item 0.22
10005789 MH12 THERMOMETER Item HW 1.0000 1 pcs Item 0.28
10006111 MH13 BREATHER FILTER Item CB 4.0000 1 pcs Item 6.00
11001960 MH14 RETURN FILTER Item CR 2.0000 1 pcs Item 66.40
1177171 MH15 FILTER ELEMENT Item CR 2.0000 1 pcs Item 11.80
11001963 MH16 FILTER Item CR 2.0000 1 pcs Item 41.20
11002656 MH17 FILTER ELEMENT Item CR 2.0000 1 pcs Item 3.20
11003576 MH18 FILTER Item CR 1.0000 1 pcs Item 4.50
11003577 MH19 FILTER ELEMENT Item CR 1.0000 1 pcs Item 0.80
11007429 MH20 LEVEL/TEMP. INSTRUMENT Item EH 1.0000 1 pcs Item 1.50
11022045 MH21 OIL COOLER Item IA 4.0000 1 pcs Item 920.00
11019856 MH22 BALL VALVE Item HV 8.0000 1 pcs Item 1.20
11003578 MH23 FILTER Item CR 1.0000 1 pcs Item 0.00
11005260 MH24 BALL VALVE Item Item 1.0000 1 pcs Item 0.22
10000721 MH25 QUICK DISCONNECT COUPLING MALE Item HL 1.0000 1 pcs Item 0.19
10000722 MH26 QUICK DISCONNECT COUPLING FEMALE Item HL 1.0000 1 pcs Item 0.47
11005260 MH27 BALL VALVE Item Item 5.0000 1 pcs Item 1.10
10001472 MH29 PRESSURE GAUGE Item Item 1.0000 1 pcs Item 0.21
11108581 MH30 LEVEL GAUGE Item SW 1.0000 1 pcs Item 17.00
11108585 MH32 CHECK VALVE Item SW 1.0000 1 pcs Item 4.10
10002853 MH33 BALL VALVE Item HV 1.0000 1 pcs Item 0.50
10009881 MH35 FILTER ELEMENT Item CR 4.0000 1 pcs Item 14.00
SP25821LXA002 HYD FLOW DIAGRAM Item SW 1.0000 1 pcs Item 0.00
 Page 2 of 5
Lines 9/4/2015
MacGregor Norway AS 2:16 PM

SP25821LXA002
Item number Position Product name Item type Group Qty Per series Unit Line type Weight Notes

11020012 MH50 HYDRAULIC PUMP Item HP 3.0000 1 pcs Item 525.00

11004380 MH51 CHECK VALVE Item HV 3.0000 1 pcs Item 3.00
11015042 MH52 PUMP/MOTOR Item HM 1.0000 1 pcs Item 490.00
10005411 MH53 PRESSURE RELIEF VALVE Item HV 1.0000 1 pcs Item 3.58
10001461 MH54 TEST COUPLING Item Item 6.0000 1 pcs Item 0.48
10002011 MH55 CHECK VALVE Item HV 1.0000 1 pcs Item 0.92
10000423 MH56 BALL VALVE Item HV 1.0000 1 pcs Item 0.12
10001472 MH57 PRESSURE GAUGE Item Item 1.0000 1 pcs Item 0.21
10005908 MH58 BALL VALVE Item HV 3.0000 1 pcs Item 17.40
10006115 MH59 SAE 6000 PSI MALE THREADED FLANGE COMPLETE Item Item 6.0000 1 pcs Item 15.00
10000421 MH60 RESTRICTOR VALVE HS 06 Item HV 4.0000 1 pcs Item 1.40
10000530 MH62 SHUTTLE VALVE Item HV 1.0000 1 pcs Item 0.20
10000428 MH63 BALL VALVE Item HV 3.0000 1 pcs Item 1.50
11108402 MH64 MAIN CONTROL VALVE Item SW 1.0000 1 pcs Item 0.00
11015955 MH65 PUMP BLOCK Item HV 1.0000 1 pcs Item 7.00
10000431 MH66 BALL VALVE Item HV 1.0000 1 pcs Item 2.30
10000420 MH67 RESTRICTOR VALVE HS 04 Item HV 1.0000 1 pcs Item 0.20
11003748 MH68 FILTER,HIGH PRESSURE Item CP 3.0000 1 pcs Item 90.00
10007055 MH69 FILTER ELEMENT Item CP 3.0000 1 pcs Item 3.90
10005654 MH70 PRESSURE RELIEF VALVE Item HV 3.0000 1 pcs Item 4.53
10006113 MH71 VALVE HOUSING Item HV 3.0000 1 pcs Item 39.00
10006248 MH72 CHECK VALVE Item HV 1.0000 1 pcs Item 0.50
10000421 MH73 RESTRICTOR VALVE HS 06 Item HV 1.0000 1 pcs Item 0.35
21433507 MH74 PUMP BLOCK Item HL 1 pcs Item 0.00
10001471 MH75 TEST COUPLING,MANOMETER Item Item 4.0000 1 pcs Item 0.32
SP25821LXA003 HYD FLOW DIAGRAM Item SW 1.0000 1 pcs Item 0.00
SP25821LXA003
Item number Position Product name Item type Group Qty Per series Unit Line type Weight Notes

11106025 JH01 MAIN JIB CYLINDER Item HC 1.0000 1 pcs Item 5,781.00
11106026 JH02 MAIN JIB CYLINDER Item HC 1.0000 1 pcs Item 5,790.00
11106027 JH03 KNUCKLE JIB CYLINDER Item HC 1.0000 1 pcs Item 2,745.00
11106028 JH04 KNUCKLE JIB CYLINDER Item HC 1.0000 1 pcs Item 2,744.70
10002639 JH06 PRESSURE RELIEF VALVE Item HV 1.0000 1 pcs Item 14.06
11108655 JH07 CYLINDER VALVE BLOCK Item HV 1 pcs Item 0.00
10001461 JH08 TEST COUPLING Item Item 6.0000 1 pcs Item 0.48
11108654 JH09 CYLINDER VALVE BLOCK Item HV 1 pcs Item 0.00
11002999 JH10 CARTRIDGE VALVE Item HV 1 pcs Item 0.00
11108672 JH12 CYLINDER VALVE BLOCK Item HV 1 pcs Item 0.00
11108671 JH13 CYLINDER VALVE BLOCK Item HV 1 pcs Item 0.00
10009274 JH14 BALANCE VALVE Item HV 1 pcs Item 0.00
10007645 JH15 PRESSURE RELIEF VALVE Item HV 1 pcs Item 0.00
11108656 JH16 CYLINDER VALVE BLOCK Item HV 1 pcs Item 0.00
 Page 3 of 5
Lines 9/4/2015
MacGregor Norway AS 2:16 PM

11015597 JH17 BALANCE VALVE CARTRIDGE Item HV 1 pcs Item 0.00

SP25821LXA004 HYD FLOW DIAGRAM Item SW 1.0000 1 pcs Item 0.00
SP25821LXA004
Item number Position Product name Item type Group Qty Per series Unit Line type Weight Notes

11003244 SG01 SLEW GEAR Item PT 5.0000 1 pcs Item 2,400.00

10009558 SG03 ADAPTER SET SAE-C Item PH 5.0000 1 pcs Item 17.50
10009709 SG04 OIL TANK Item HW 5.0000 1 pcs Item 1.00
10001321 SH01 HYDRAULIC MOTOR Item HM 5.0000 1 pcs Item 88.00
11105827 SH02 VALVE BLOCK Item HV 4.0000 1 pcs Item 59.60
11105826 SH03 VALVE BLOCK Item HV 1.0000 1 pcs Item 14.90
10000530 SH04 SHUTTLE VALVE Item HV 1.0000 1 pcs Item 0.20
10000418 SH05 RESTRICTOR CHECK VALVE HST 04 Item HV 1.0000 1 pcs Item 0.22
10001471 SH06 TEST COUPLING,MANOMETER Item Item 1.0000 1 pcs Item 0.08
11000741 SH10 VALVE BLOCK Item HV 1.0000 1 pcs Item 20.00
10002392 SH11 ACCUMULATOR Item HA 1.0000 1 pcs Item 72.00
10002393 SH12 CLAMP Item HA 2.0000 1 pcs Item 2.20
10001438 SH13 DAMPER RING Item HA 1.0000 1 pcs Item 0.25
10007386 SH14 REDUCER Item HA 1.0000 1 pcs Item 0.75
10000430 SH17 BALL VALVE Item HV 1.0000 1 pcs Item 1.60
11105880 SH18 SOLENOID VALVE Item HV 1.0000 1 pcs Item 1.89
10003737 SH19 SUBPLATE Item HV 1.0000 1 pcs Item 1.32
10001461 SH20 TEST COUPLING Item Item 1.0000 1 pcs Item 0.08
SP25821LXA005 HYD FLOW DIAGRAM Item SW 1.0000 1 pcs Item 0.00
SP25821LXA005
Item number Position Product name Item type Group Qty Per series Unit Line type Weight Notes

11106081 TG01 TUGGER WINCH Item SW 1.0000 1 pcs Item 215.00

11106082 TG02 TUGGER WINCH Item SW 1.0000 1 pcs Item 215.00
11007407 TH01 PROPORTIONAL VALVE Item HV 1.0000 1 pcs Item 62.44
11000838 TH02 DIRECTIONAL VALVE Item HV 1.0000 1 pcs Item 8.63
10005379 TH03 DIRECTIONAL VALVE Item HV 1.0000 1 pcs Item 1.50
11009315 TH04 PRESSURE RELIEF VALVE CPL Item HV 2.0000 1 pcs Item 3.56
10004011 TH06 DIRECTIONAL VALVE Item HV 2.0000 1 pcs Item 3.40
10008852 TH07 PRESSURE REDUCING VALVE Item HV 1.0000 1 pcs Item 0.15
10008853 TH08 VALVE HOUSING Item HV 1.0000 1 pcs Item 0.83
10001321 TH09 HYDRAULIC MOTOR Item HM 2.0000 1 pcs Item 35.20
10009900 TH10 VALVE BLOCK Item HV 2.0000 1 pcs Item 46.00
10000530 TH11 SHUTTLE VALVE Item HV 4.0000 1 pcs Item 0.80
10000633 TH12 RESTRICTOR CHECK VALVE HST 06 Item HV 2.0000 1 pcs Item 0.74
10001461 TH15 TEST COUPLING Item Item 1.0000 1 pcs Item 0.08
11012106 TT20 HYDRAULIC CYLIND ER Item HC 2.0000 1 pcs Item 26.40
10000523 TT21 BALANCE VALVE Item HV 2.0000 1 pcs Item 2.70
SP25821LXA006 HYD FLOW DIAGRAM Item SW 1.0000 1 pcs Item 0.00
SP25821LXA006
Item number Position Product name Item type Group Qty Per series Unit Line type Weight Notes
 Page 4 of 5
Lines 9/4/2015
MacGregor Norway AS 2:16 PM

11105421 WH50 AHC VALVE BLOCK Item HV 1.0000 1 pcs Item 872.30
10004047 WH52 CONNECTOR PLUG Item EC 2.0000 1 pcs Item 0.10
10004047 WH53 CONNECTOR PLUG Item EC 1.0000 1 pcs Item 0.05
11004028 WH54 MANIFOLD Item SW 1.0000 1 pcs Item 0.00
10001435 WH55 BLADDER ACCUMULATOR Item HA 10.0000 1 pcs Item 950.00
10002393 WH56 CLAMP Item HA 20.0000 1 pcs Item 22.00
10001438 WH57 DAMPER RING Item HA 10.0000 1 pcs Item 2.50
10007386 WH58 REDUCER Item HA 10.0000 1 pcs Item 7.50
10002515 WH59 BLADDER ACCUMULATOR Item HA 2.0000 1 pcs Item 30.00
10002773 WH60 CLAMP Item HA 4.0000 1 pcs Item 4.80
10000676 WH61 REDUCER Item HA 2.0000 1 pcs Item 0.44
10000431 WH62 BALL VALVE Item HV 1.0000 1 pcs Item 2.30
10002029 WH63 PRESSURE REDUCING VALVE Item HV 1.0000 1 pcs Item 0.85
10001461 WH64 TEST COUPLING Item Item 1.0000 1 pcs Item 0.08
10001471 WH65 TEST COUPLING,MANOMETER Item Item 1.0000 1 pcs Item 0.08
10001594 WH98 PRESSURE RELIEF VALVE Item HV 1.0000 1 pcs Item 1.56
SP25821LXA007 HYD FLOW DIAGRAM Item SW 1.0000 1 pcs Item 0.00
SP25821LXA007
Item number Position Product name Item type Group Qty Per series Unit Line type Weight Notes

11106033 WG01 WINCH GEAR Item PH 7.0000 1 pcs Item 2,275.00

11105882 WH01 HYDRAULIC MOTOR Item HM 6.0000 1 pcs Item 660.00
11003300 WH02 MOTOR VALVE BLOCK Item HV 6.0000 1 pcs Item 398.40
11003301 WH03 MOTOR VALVE BLOCK Item HV 1.0000 1 pcs Item 108.00
11005579 WH04 WINCH MANIFOLD Item SW 1.0000 1 pcs Item 0.00
10000418 WH05 RESTRICTOR CHECK VALVE HST 04 Item HV 1.0000 1 pcs Item 0.22
10001461 WH06 TEST COUPLING Item Item 4.0000 1 pcs Item 0.32
11007438 WH07 MANIFOLD Item SW 1.0000 1 pcs Item 0.00
10002245 WH09 SEQUENCE VALVE Item HV 1.0000 1 pcs Item 0.64
10006247 WH10 CHECK VALVE Item HV 1.0000 1 pcs Item 0.17
10007029 WH11 PRESSURE REDUCING VALVE Item HV 1.0000 1 pcs Item 0.05
10004716 WH12 VALVE HOUSING Item HV 1.0000 1 pcs Item 0.87
11105881 WH14 MOTOR WITH SPEED SENSOR Item HM 1.0000 1 pcs Item 110.00
10001471 WH15 TEST COUPLING,MANOMETER Item Item 2.0000 1 pcs Item 0.16
SP25821LXA008 HYD FLOW DIAGRAM Item SW 1.0000 1 pcs Item 0.00
SP25821LXA008
Item number Position Product name Item type Group Qty Per series Unit Line type Weight Notes

11003058 UG01 WINCH GEAR Item PH 1.0000 1 pcs Item 542.00

11003668 UG02 WINCH GEAR Item PH 1.0000 1 pcs Item 380.00
11005265 UG03 ADAPTER SET Item HW 2.0000 1 pcs Item 14.00
11009173 UH01 HYDRAULIC MOTOR Item HM 2.0000 1 pcs Item 64.00
11015860 UH02 VALVE BLOCK Item HV 1.0000 1 pcs Item 45.00
11015861 UH03 VALVE BLOCK Item HV 1.0000 1 pcs Item 45.00
11002087 UH04 VALVE BLOCK Item HV 1.0000 1 pcs Item 110.00
10000530 UH05 SHUTTLE VALVE Item HV 2.0000 1 pcs Item 0.40
 Page 5 of 5
Lines 9/4/2015
MacGregor Norway AS 2:16 PM

11002436 UH06 RELIEF VALVE Item HV 1.0000 1 pcs Item 0.20

11002437 UH07 VALVE HOUSING INC CHECK VALVE Item HV 1.0000 1 pcs Item 1.30
10002265 UH08 BALL VALVE Item HV 2.0000 1 pcs Item 0.80
10002245 UH10 SEQUENCE VALVE Item HV 1.0000 1 pcs Item 0.64
11022030 UH11 BLADDER ACCUMULATOR PRECHARGED Item HA 2.0000 1 pcs Item 220.00
10002393 UH12 CLAMP Item HA 4.0000 1 pcs Item 4.40
10001438 UH13 DAMPER RING Item HA 2.0000 1 pcs Item 0.50
10001437 UH14 CONSOLE Item HA 2.0000 1 pcs Item 2.80
10000430 UH16 BALL VALVE Item HV 1.0000 1 pcs Item 1.60
10001461 UH18 TEST COUPLING Item Item 2.0000 1 pcs Item 0.16
10001471 UH19 TEST COUPLING,MANOMETER Item Item 3.0000 1 pcs Item 0.24
10005379 UH22 DIRECTIONAL VALVE Item HV 2.0000 1 pcs Item 3.00
10003737 UH23 SUBPLATE Item HV 2.0000 1 pcs Item 2.64
10000494 UH24 CHECK VALVE Item HV 1.0000 1 pcs Item 0.10
11009984 UH25 CABINET Item EQ 1.0000 1 pcs Item 26.00
10007029 UH36 PRESSURE REDUCING VALVE Item HV 1.0000 1 pcs Item 0.05
10004716 UH37 VALVE HOUSING Item HV 1.0000 1 pcs Item 0.87
10001594 UH51 PRESSURE RELIEF VALVE Item HV 1.0000 1 pcs Item 1.56
11009315 UH52 PRESSURE RELIEF VALVE CPL Item HV 1.0000 1 pcs Item 1.78
10004011 UH54 DIRECTIONAL VALVE Item HV 2.0000 1 pcs Item 3.40
 User Manual for Crane

3. Hydraulic Hose List

7 Component Parts List

MACGREGOR NORWAY AS 3
HOSE LISTS
Project no. : SP2582-1 Project no. : SP2582-1
Revision Code : 1 Revision Code : 1
Date : 10-Jul-2015 Date : 13-Jul-2015
Created By : LNA Created By : LNA
Drawing no. : SP2582-1-L-XA-001 Drawing no. : SP2582-1-L-XA-002
System : TANK SYSTEM System : PUMP SYSTEM

Hose No. Total Length Hose No. Total Length

mm mm
6 2634,4 203 1350,2
7 1734,4 204 1470,2
8 3134,4 212 1075,8
9 1934,4 213 645,9
10 984,4 214 1095,9
11 2134,4 215 955,9
12 984,4 216 731,9
13 2234,4 217 1306,7
28 1726,7 222 2212,1
29 1626,7 223 1812,1
32 1060,8 224 1562,1
33 800,8 228 969,7
34 560,8 230 998,9
35 760,8 2001 695,9
36 960,8 2002 675,9
37 2760,2 3001 1728,7
38 1648,9 4001 1728,7
46 1948,9 4002 1678,7
48 1150,2 4003 1455,9
49 999,2 4007 1410,7

Project no. : SP2582-1 Project no. : SP2582-1

Revision Code : 1 Revision Code : 1
Date : 10-Jul-2015 Date : 13-Jul-2015
Created By : LNA Created By : LNA
Drawing no. : SP2582-1-L-XA-003 Drawing no. : SP2582-1-L-XA-006
System : JIB SYSTEM System : MAIN WINCH AHC BLOCK

Hose No. Total Length Hose No. Total Length

mm mm
3101 1915,00 1302 2370,8
3102 2116,3 1307 1777,9
3103 1612,1 1308 2177,9
3104 1765,00 1357 1782,1
3105 2148,8 1361 2718,2
3106 1612,1 1366 2718,2
3301 1856,2 1368 2432,2
3302 1928,8 1370 1865,4
3303 1928,8 1371 1765,4
3304 1856,2 1372 1632,2
3305 1831,4
3306 1831,4
3307 2042,00
3308 2010,7
3309 2010,7
Project no. : SP2582-1 Project no. : SP2582-1
Revision Code : 1 Revision Code : 1
Date : 13-Jul-2015 Date : 13-Jul-2015
Created By : LNA Created By : LNA
Drawing no. : SP2582-1-L-XA-005 Drawing no. : SP2582-1-L-XA-004
System : TUGGER WINCH System : SLEW SYSTEM

Hose No. Total Length Hose No. Total Length

mm mm
2301 570,8 4101 960,8
2302 2869,7 4102 1260,8
2303 2062,1 4103 960,8
2304 2112,1 4104 1160,8
2307 2969,7 4105 560,8
2309 3062,1 4106 1176,4
2310 3012,1 4107 976,4
2311 3072,1 4108 969,7
2312 2565,00 4109 769,7
2313 2565,00 4110 976,4
2314 1404,2 4111 1442,7
2315 1364,2 4112 1392,7
2318 1862,1 4113 1531,4
2319 1862,1 4114 1342,7
2320 570,8 4115 961,4
2321 2869,7 4116 1211,4
2322 2062,1 4117 1201,4
2323 2112,1 4118 951,4
2326 2989,7 4119 792,7
2327 2182,1 4120 652,7
2328 3099,8 4121 1469,7
2329 3079,8 4122 1369,7
2330 3132,1 4123 1169,7
2331 2565,00 4124 1269,7
2332 2565,00 4125 1269,7
2333 1843,00 4130 1367,6
2335 1673,00 4131 1360,8
2336 1862,1 4132 1110,8
2337 1862,1 4133 1260,8
2338 669,7 4134 667,6
2339 889,7 4135 1412,1
2344 1200,8 4136 670,8
2357 326,4 4137 1262,1
2360 1562,1 4138 1262,1
2361 2190,8 4139 1362,1
2362 2092,1 4141 569,9
2363 2330,8 4142 1829,7
2364 2422,1 4149 1662,1
2365 1019,7 4150 2370,8
2366 899,7 4151 2362,1
2367 1050,8 4152 2162,1
2368 950,8 4153 1962,1
2369 1922,1
Project no. : SP2582-1
Revision Code : 1
Date : 13-Jul-2015
Created By : LNA
Drawing no. : SP2582-1-L-XA-007
System : MAIN WINCH MOTORS & BLOCKS

Hose No. Total Length

mm 1194 1369,7
1101 759,9 1195 1126,4
1102 759,9 1196 1126,4
1103 2559,9 1201 5210,7
1104 764,9 1202 3110,7
1105 809,9 1203 3510,7
1106 759,9 1204 2810,7
1107 759,9 1205 2310,7
1111 2748,9 1206 2893,3
1112 2748,9 1207 3223,3
1113 1898,9 1211 5210,7
1114 1498,9 1212 4110,7
1115 1848,9 1213 3460,7
1116 2198,9 1214 2710,7
1117 2748,9 1215 2410,7
1121 710,8 1216 2493,3
1122 710,8 1217 3043,3
1123 960,8 1221 2518,2
1125 560,8 1222 2518,2
1126 710,8 1224 2465,7
1127 710,8 1225 3070,8
1131 4359,8 1226 2370,8
1132 2409,8 1227 3367,6
1133 2420,8 1228 2770,8
1134 1970,8 1229 2670,8
1135 2570,8 1230 2062,1
1136 1112,1 1231 1462,1
1141 1312,1 1232 2676,4
1142 1362,1 1251 3626,9
1143 2062,1 1252 3326,9
1144 1212,1 1253 2626,9
1145 1312,1 1254 2626,9
1146 1212,1 1255 2626,9
1151 1062,1 1256 3326,9
1152 1112,1 1257 4126,9
1153 2462,1
1154 1020,8
1155 1112,1
1156 1112,1
1161 1012,1
1162 1062,1
1163 2462,1
1165 962,1
1166 1112,1
1167 1162,1
1171 1069,7
1172 1069,7
1173 2058,6
1174 1158,6
1175 1069,7
1176 1069,7
1181 1262,1
1182 1262,1
1183 2312,1
1185 1312,1
1186 1312,1
1187 1312,1
1191 1126,4
1192 1126,4
1193 2219,7
Project no. : SP2582-1
Revision Code : 1
Date : 13-Jul-2015
Created By : LNA
Drawing no. : SP2582-1-L-XA-008
System : WHIP WINCH MOTORS & BLOCKS

Hose No. Total Length

mm
2102 1751,3
2104 2062,1
2105 1319,7
2107 1269,7
2108 1020,8
2109 590,8
2112 1202,1
2113 1783,3
2114 1312,1
2115 1109,7
2116 1329,8
2117 1516,4
2118 1276,4
2124 1359,8
2126 3412,1
2127 1169,7
2128 1912,1
2129 1393,3
2130 1099,7
2131 1362,1
2132 1362,1
2133 1309,8
2137 1010,7
2138 2032,2
2139 959,8
2140 1916,4
2141 1270,8
2142 2076,4
2145 2018,2
2146 2018,2
2148 2010,8
2150 1308,4
2151 2142,7
2152 2070,8
2153 2010,8
2154 1986,4
2156 1149,7
2157 1092,1
2159 1122,1
2160 1980,8
2161 1062,1
 User Manual for Crane

4. Component Parts List Electro

7 Component Parts List

MACGREGOR NORWAY AS 4
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
-AT01 ULTRASONIC WIND SENSOR W. HEATER Wind Speed Sensor 11105549 /202.A5
=MAIN WINCH -ES01 MULTI PURPOSE FIXTURE IP68 RED AVI-Light 11014904 /253.A4

A =MAIN JIB -ES02 MULTI PURPOSE FIXTURE IP68 RED AVI-Light 11014904 /253.A6 A
=KNUCKLE JIB -ES03 FLOODLIGHT 500W/230VAC/IP67 Floodlight 11001748 /253.A8
=KNUCKLE JIB -ES04 FLOODLIGHT 500W/230VAC/IP67 Floodlight 11001748 /253.B8

B B

C C

D D

E E

F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 700
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: 701

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=CRANE KING -ES05 ARMATURE 2x18W 60Hz 2x18W 11002378 /253.C3
=CRANE KING -ES06 ARMATURE 2x18W BATTERY 1.5h 2x18W 11008467 /253.C3

A =CRANE PEDESTAL -ES07 ARMATURE 2x18W 60Hz 2x18W 11002378 /253.A3 A

=CRANE PEDESTAL -ES08 ARMATURE 2x18W BATTERY 1.5h 2x18W 11008467 /253.A2
=CRANE KING -ES09 ARMATURE 2x18W BATTERY 1.5h 2x18W 11008467 /253.C4
=MAIN JIB -ES21 FLOODLIGHT 230V-RX7-60HZ Floodlight Whip Winch 11012091 /253.D6
=MAIN WINCH -ES22 FLOODLIGHT 230V-RX7-60HZ Floodlight Main Winch 11012091 /253.C4
=CRANE CABIN -HB001 17" LCD TOUCH SCREEN LCD Touch screen 11108990 /208.A6
SVING/TILTBAR SORT 11011943
=ON BRIDGE -HB002 19 INCH MULTI DISPLAY LCD Touch screen 11014821 /410.E4
RACK ADAPTER FRAME/PLATE 11012217
SVING/TILTBAR SORT 11011943
B B
=CRANE KING -LS201 LEVEL SWITCH Level Switch Oil Draintank 11011952
=CRANE KING -M61 AXIAL FAN King Floor 11017100 /252.E7
FAN COVER 11014360
=CRANE KING -PT201 PRESSURE TRANSMITTER 0-0,5 BAR Oil Level HPU Tank 11013580
=CRANE KING -PT202 PRESSURE TRANSMITTER 0-400 BAR Mainline pressure 11008341
=CRANE KING -PT203 PRESSURE TRANSMITTER 0-400 BAR Main pump regulator pressure 11008341
=MAIN JIB -PT205 PRESSURE TRANSMITTER 0-400 BAR WW MOPS Pilot pressure 11008341
=MAIN JIB -PT207 PRESSURE TRANSMITTER 0-400 BAR WW Accumulator pressure 11008341
=MAIN JIB -PT210 PRESSURE TRANSMITTER 0-400 BAR WW Brake pressure 11008341
=CRANE KING -PT250 PRESSURE TRANSMITTER 0-400 BAR Slew Brake Pressure 11008341
C C
=MAIN WINCH -PT204A PRESSURE TRANSM. 0-60 BAR MW Motor displacement pressure 111008340
=MAIN WINCH -PT206A PRESSURE TRANSMITTER 0-400 BAR MW Accumulator pressure 11008341
=MAIN WINCH -PT208A PRESSURE TRANSMITTER 0-400 BAR MW Brake pressure 1 11008341
=CRANE KING -PT219A PRESSURE TRANSMITTER 0-400 BAR LS Pressure A 11008341
=CRANE KING -PT219B PRESSURE TRANSMITTER 0-400 BAR LS Pressure B 11008341
=MAIN WINCH -RC101 COMPACT CAMERA COLOUR CCC102 Main Winch 11011792 /412.E1
=MAIN JIB -RC102 COMPACT CAMERA COLOUR CCC102 Whipline Winch 11011792 /412.E2
=MAIN JIB -RC103 COMPACT CAMERA COLOUR CCC102 Tugger Winch 11011792 /412.E3
=CRANE CABIN -RC105 COMPACT LCD7" MONITOR 11014355
=CRANE CABIN -RC115 COMPACT LCD 7" UNI AFRS232 MONITOR CCTV Monitor Jib End 11012345 /202.F3
D D
=CRANE KING -S01 SWITCH 2 POL 11002377 /253.C3
UNIVERSAL SEAL 11002379
UNIVERSAL SEAL 11002379
=CRANE PEDESTAL -S02 SWITCH 2 POL 11002377 /253.A3
UNIVERSAL SEAL 11002379
UNIVERSAL SEAL 11002379
=CRANE KING -TT201 TEMP.TRANSMITTER Oil Temp HPU Tank 11013798
=ON BRIDGE -U63 XGA LINE RECEIVER XGA LINE RECEIVER 11011865 /410.E3
=CRANE CABIN -UA101 2 SOUND WARNING HORN 24V Bullshorn 11011844 /405.D5
=KNUCKLE JIB -WT201 LOADCELL 1100kN Ø220 11109285
E E
=KNUCKLE JIB -WT202 LOADCELL Ø130 200kN 11107582
=CRANE KING -XS10 SOCKET OUTLET Socket Outlet 11002376 /253.C3
UNIVERSAL SEAL 11002379
=KNUCKLE JIB -ZS209 PROX NC Ø18mm 2-part sensor 11012238 /202.D8
=KNUCKLE JIB -ZS241 PROX NC Ø18mm MW Upper hook stop 11012238 /202.A8
=KNUCKLE JIB -ZS242 PROX NC Ø18mm MW Upper hook stop 11012238 /202.B8
=CRANE KING -ZT201 MULTITURN ENCODER Slew position 11001752 /202.A3
=MAIN JIB -ZT202 SINGLETURN ENCODER Main Jib position 11001753 /202.B5
=MAIN JIB -ZT203 SINGLETURN ENCODER Main Jib position 11001753 /202.A5
F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 701
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: 702

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=MAIN WINCH -ZT204 MULTITURN ENCODER Main Winch position 11001752 /202.A5
=MAIN JIB -ZT205 MULTITURN ENCODER Whip Winch position 11001752 /202.B6

A =MAIN JIB -ZT206 SINGLETURN ENCODER Knuckle Jib position 11001753 /202.C7 A
=MAIN JIB -ZT207 SINGLETURN ENCODER Knuckle Jib position 11001753 /202.A7
=CRANE KING -ZT208 MULTITURN ENCODER Slew position 11001752 /202.A3

B B

C C

D D

E E

F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 702
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: 703

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=CRANE CABIN +CC100 -A35.1 POWER SUPPLY 230/24 10A 230VAC/24VDC 11013597 /403.D2
=CRANE CABIN +CC100 -A35.2 UPS MODULE 24V/6A 11009669 /403.D3

A =CRANE CABIN +CC100 -A35.3 BATTERY MODULE 7Ah Battery module 11009675 /403.E2 A
=CRANE CABIN +CC100 -D01.0 PROFIBUS CONNECTOR 90deg 10007473 /444.E1
=CRANE CABIN +CC100 -D01.1 PLC CPU PN/DP 11012118 /414.B1
BACKPLATE 480mm 11005740
MEMORY CARD 2MB 11011614
PROFIBUS CONNECTOR 90deg FOR PC-CONN 10006834
=CRANE CABIN +CC100 -D02 IM SENTRALRACK 11007679 /414.B2
=CRANE CABIN +CC100 -D03 DIGITAL INPUT MODULE16DI 11002445 /414.B3
FRONT CONNECTOR 20pin 11002450
=CRANE CABIN +CC100 -D04 DIGITAL INPUT MODULE 32DI 10005726 /414.B4
B B
FRONT CONNECTOR 40pin 11002451
ny komponent
=CRANE CABIN +CC100 -D05 DIGITAL OUTPUT MODULE 16DO 11002446 /414.E1
FRONT CONNECTOR 20pin 11002450
ny komponent
=CRANE CABIN +CC100 -D06 DIGITAL OUTPUT MODULE 16DO 11002446 /414.E3
FRONT CONNECTOR 20pin 11002450
ny komponent
=CRANE CABIN +CC100 -D07 DIGITAL OUTPUT MODULE 16DO 11002446 /414.E4
FRONT CONNECTOR 20pin 11002450
C C
ny komponent
=CRANE CABIN +CC100 -D08 ANALOG INPUT MODULE 8AI ANALOG INPUT MODULE 8AI 11000573 /414.E6
FRONT CONNECTOR 20pin 11002450
ny komponent
=CRANE CABIN +CC100 -D09 ANALOG INPUT MODULE 8AI ANALOG INPUT MODULE 8AI 11000573 /415.C1
FRONT CONNECTOR 20pin 11002450
=CRANE CABIN +CC100 -D10 ANALOG INPUT MODULE 8AI ANALOG INPUT MODULE 8AI 11000573 /415.C3
FRONT CONNECTOR 20pin 11002450
=CRANE CABIN +CC100 -D11 IM EXTENSION MODULE 11007680 /415.C4
=CRANE CABIN +CC100 -D12 ANALOG INPUT MODULE 8AI ANALOG INPUT MODULE 8AI 11000573 /415.C5
D D
FRONT CONNECTOR 20pin 11002450
=CRANE CABIN +CC100 -D13 ANALOG INPUT MODULE 8AO 11005840 /415.E1
FRONT CONNECTOR 40pin 11002451
=CRANE CABIN +CC100 -D14 ANALOG INPUT MODULE 8AO 11005840 /416.B1
FRONT CONNECTOR 40pin 11002451
=CRANE CABIN +CC100 -D15 ANALOG INPUT MODULE 8AO 11005840 /416.B5
FRONT CONNECTOR 40pin 11002451
=CRANE CABIN +CC100 -D16 COUNTER MODULE 11012940 /416.E1
FRONT CONNECTOR 20pin 11002450
=CRANE CABIN +CC100 -D18 COMM.PROCESSOR 11105599 /416.E4
E E
=CRANE CABIN +CC100 -D50 BOX PC WITH VESA MOUNTING BRACKET 11109257 /410.B3
=CRANE CABIN +CC100 -D50.3 UPS 750VA RS232/USB 11107042 /403.C3
=CRANE CABIN +CC100 -D100 RS 485 REPEATER 11002271 /444.D1
=CRANE CABIN +CC100 -E21 UNI SWITCH CCTV 11011838 /412.A4
=CRANE CABIN +CC100 -F01 CIRCUIT BREAKER 32A 3pol C 32A 11052039 /502.D1
=CRANE CABIN +CC100 -F02 CIRCUIT BREAKER 10A 2p C Socket -XS01 10A 11002500 /502.D2
=CRANE CABIN +CC100 -F03 CIRCUIT BREAKER 10A 2p C Spare 10A 11002500 /502.D2
=CRANE CABIN +CC100 -F04 CIRCUIT BREAKER 10A 2p C Power Supply -G01, -G02 10A 11002500 /403.A1
=CRANE CABIN +CC100 -F05 CIRCUIT BREAKER 10A 2p C Power Supply MOPS 10A 11002500 /403.D1
F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 703
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +CC100 704

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=CRANE CABIN +CC100 -F06 CIRCUIT BREAKER 10A 2p C Power Supply -G01, -G02 10A 11002500 /403.C1
=CRANE CABIN +CC100 -F07 CIRCUIT BREAKER 10A 2p C 10A 11002500 /403.D1

A =CRANE CABIN +CC100 -F08 CIRCUIT BREAKER 20A 1p C 24VDC Distribution -XP20 20A 11008692 /403.A7 A
=CRANE CABIN +CC100 -F09 CIRCUIT BREAKER 20A 1p C 24VDC Distribution -XP20 20A 11008692 /403.A3
=CRANE CABIN +CC100 -F10 CIRCUIT BREAKER 10A 1pol C 12VDC Distribution -X121 10A 11005776 /403.B2
=CRANE CABIN +CC100 -F11 FUSE TERMINAL BLOCK 4mm² [1] (1) 10A 11014814 /403.D2
=CRANE CABIN +CC100 -G01 POWER SUPPLY 40A 230/24V 11012723 /403.A2
=CRANE CABIN +CC100 -G02 POWER SUPPLY 40A 230/24V 11012723 /403.B2
=CRANE CABIN +CC100 -HS101 SWITCH 20A 3P Control System ON/OFF 11011859 /404.E1
=CRANE CABIN +CC100 -K01 RELAY 24VDC 1xNOC ON RAIL 10008121 /423.B2
=CRANE CABIN +CC100 -K02 RELAY 24VDC 1xNOC ON RAIL 10008121 /423.B2
=CRANE CABIN +CC100 -K03 RELAY 24VDC 1xNOC ON RAIL 10008121 /423.B3
B B
=CRANE CABIN +CC100 -K04 RELAY 24VDC 1xNOC ON RAIL 10008121 /423.B4
=CRANE CABIN +CC100 -K05 RELAY 24VDC 1xNOC ON RAIL 10008121 /423.B5
=CRANE CABIN +CC100 -K06 RELAY 24VDC 1xNOC ON RAIL 10008121 /423.B6
=CRANE CABIN +CC100 -K07 RELAY 24VDC 1xNOC ON RAIL 10008121 /423.B7
=CRANE CABIN +CC100 -K08 RELAY 24VDC 1xNOC ON RAIL 10008121 /423.B8
=CRANE CABIN +CC100 -K09 RELAY 24VDC 1xNOC ON RAIL 10008121 /428.B2
=CRANE CABIN +CC100 -K10 RELAY 24VDC 1xNOC ON RAIL 10008121 /428.B3
=CRANE CABIN +CC100 -K11 RELAY 24VDC 1xNOC ON RAIL 10008121 /428.B4
=CRANE CABIN +CC100 -K12 RELAY 24VDC 1xNOC ON RAIL 10008121 /424.C1
=CRANE CABIN +CC100 -K13 RELAY 24VDC 1xNOC ON RAIL 10008121 /424.C7
C C
=CRANE CABIN +CC100 -K14 RELAY 24VDC 1xNOC ON RAIL 10008121 /424.C8
=CRANE CABIN +CC100 -K15 RELAY 24VDC 1xNOC ON RAIL 10008121 /425.C2
=CRANE CABIN +CC100 -K16 RELAY 24VDC 1xNOC ON RAIL 10008121 /425.C2
=CRANE CABIN +CC100 -K17 RELAY 24VDC 1xNOC ON RAIL 10008121 /425.C3
=CRANE CABIN +CC100 -K18 RELAY 24VDC 1xNOC ON RAIL 10008121 /425.C4
=CRANE CABIN +CC100 -K19 RELAY 24VDC 1xNOC ON RAIL 10008121 /425.C5
=CRANE CABIN +CC100 -K20 RELAY 24VDC 1xNOC ON RAIL 10008121 /425.C6
=CRANE CABIN +CC100 -K21 RELAY 24VDC 1xNOC ON RAIL 10008121 /425.C6
=CRANE CABIN +CC100 -K22 RELAY 24VDC 1xNOC ON RAIL 10008121 /425.C7
=CRANE CABIN +CC100 -K23 RELAY 24VDC 1xNOC ON RAIL 10008121
D D
=CRANE CABIN +CC100 -K24 RELAY 24VDC 1xNOC ON RAIL 10008121
=CRANE CABIN +CC100 -K25 RELAY 24VDC 1xNOC ON RAIL 10008121
=CRANE CABIN +CC100 -K26 RELAY 24VDC 1xNOC ON RAIL 10008121
=CRANE CABIN +CC100 -K27 RELAY 24VDC 1xNOC ON RAIL 10008121
=CRANE CABIN +CC100 -K28 RELAY 24VDC 1xNOC ON RAIL 10008121 /424.C6
=CRANE CABIN +CC100 -K30 RELAY 24VDC 2xNOC ON RAIL 10008122
=CRANE CABIN +CC100 -K31 RELAY 24VDC 2xNOC ON RAIL 10008122
=CRANE CABIN +CC100 -K32 RELAY 24VDC 2xNOC ON RAIL 10008122
=CRANE CABIN +CC100 -K33 RELAY 24VDC 2xNOC ON RAIL 10008122
=CRANE CABIN +CC100 -K34 RELAY 24VDC 2xNOC ON RAIL 10008122
E E
=CRANE CABIN +CC100 -K35 RELAY 24VDC 2xNOC ON RAIL 10008122
=CRANE CABIN +CC100 -K36 RELAY 24VDC 2xNOC ON RAIL 10008122 /427.B2
=CRANE CABIN +CC100 -K37 RELAY 24VDC 2xNOC ON RAIL 10008122 /427.B2
=CRANE CABIN +CC100 -K38 RELAY 24VDC 2xNOC ON RAIL 10008122 /427.B3
=CRANE CABIN +CC100 -K39 RELAY 24VDC 2xNOC ON RAIL 10008122 /427.B4
=CRANE CABIN +CC100 -K40 RELAY 24VDC 2xNOC ON RAIL 10008122 /427.B5
=CRANE CABIN +CC100 -K41 RELAY 24VDC 2xNOC ON RAIL 10008122 /427.B6
=CRANE CABIN +CC100 -K42 RELAY 24VDC 2xNOC ON RAIL 10008122 /427.B7
=CRANE CABIN +CC100 -K43 RELAY 24VDC 2xNOC ON RAIL 10008122 /413.E6
F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 704
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +CC100 705

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=CRANE CABIN +CC100 -K44 RELAY 24VDC 1NO+1NC 11013903 /403.C7
=CRANE CABIN +CC100 -K51 4 CHANGEOVER RELAY 24VDC COIL 11052050 /405.E1

A 4 CHANGEOVER RELAY, SOCKET 11012052 A

=CRANE CABIN +CC100 -K52 4 CHANGEOVER RELAY 24VDC COIL 11052050 /405.E3
4 CHANGEOVER RELAY, SOCKET 11012052
=CRANE CABIN +CC100 -K53 4 CHANGEOVER RELAY 24VDC COIL 11052050 /405.E3
4 CHANGEOVER RELAY, SOCKET 11012052
=CRANE CABIN +CC100 -K90 SAFETY RELAY 11011853 /404.D2
=CRANE CABIN +CC100 -K91 CONTACTOR DC OPERATED 11013821 /404.E4
=CRANE CABIN +CC100 -K92 CONTACTOR DC OPERATED 11013821 /404.E5

=CRANE CABIN +CC100 -U40 VALVE CONTROLLER 10005060 /433.C1

B B
11-PIN SOCKET FOR VALVE CONTROLLER 10008130
HOLDING SPRING FOR VALVE CONTROLLER 11001114
=CRANE CABIN +CC100 -U41 VALVE CONTROLLER 10005060 /433.C2
11-PIN SOCKET FOR VALVE CONTROLLER 10008130
HOLDING SPRING FOR VALVE CONTROLLER 11001114
=CRANE CABIN +CC100 -U42 VALVE CONTROLLER 10005060 /433.C4
11-PIN SOCKET FOR VALVE CONTROLLER 10008130
HOLDING SPRING FOR VALVE CONTROLLER 11001114
=CRANE CABIN +CC100 -U43 VALVE CONTROLLER 10005061 /433.C5
11-PIN SOCKET FOR VALVE CONTROLLER 10008130
C C
HOLDING SPRING FOR VALVE CONTROLLER 11001114
=CRANE CABIN +CC100 -U44 VALVE CONTROLLER 10005061 /433.C6
11-PIN SOCKET FOR VALVE CONTROLLER 10008130
HOLDING SPRING FOR VALVE CONTROLLER 11001114
=CRANE CABIN +CC100 -U45 VALVE CONTROLLER 10005061 /433.C7
11-PIN SOCKET FOR VALVE CONTROLLER 10008130
HOLDING SPRING FOR VALVE CONTROLLER 11001114
=CRANE CABIN +CC100 -U46 VALVE CONTROLLER 10005061 /434.C1
11-PIN SOCKET FOR VALVE CONTROLLER 10008130
HOLDING SPRING FOR VALVE CONTROLLER 11001114
D D
=CRANE CABIN +CC100 -U47 VALVE CONTROLLER 10005061 /434.C2
11-PIN SOCKET FOR VALVE CONTROLLER 10008130
HOLDING SPRING FOR VALVE CONTROLLER 11001114
=CRANE CABIN +CC100 -U48 VALVE CONTROLLER 10005061 /434.C4
11-PIN SOCKET FOR VALVE CONTROLLER 10008130
HOLDING SPRING FOR VALVE CONTROLLER 11001114
=CRANE CABIN +CC100 -U49 VALVE CONTROLLER 10005061 /434.C5
11-PIN SOCKET FOR VALVE CONTROLLER 10008130
HOLDING SPRING FOR VALVE CONTROLLER 11001114
=CRANE CABIN +CC100 -U50 VALVE CONTROLLER 10005060 /434.C6
E E
11-PIN SOCKET FOR VALVE CONTROLLER 10008130
HOLDING SPRING FOR VALVE CONTROLLER 11001114
=CRANE CABIN +CC100 -U51 VALVE CONTROLLER 10005061 /436.C2
11-PIN SOCKET FOR VALVE CONTROLLER 10008130
HOLDING SPRING FOR VALVE CONTROLLER 11001114
=CRANE CABIN +CC100 -U52 VALVE CONTROLLER 10005061 /437.C1
11-PIN SOCKET FOR VALVE CONTROLLER 10008130
HOLDING SPRING FOR VALVE CONTROLLER 11001114
=CRANE CABIN +CC100 -U61 ETHERNET SWITCH SWITCH 8 ports 11014174 /410.B5
F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 705
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +CC100 706

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=CRANE CABIN +CC100 -U66 EXTENDER XGA 1:3 VGA Extender 11012665 /410.B1
=CRANE CABIN +CC100 -U101 4Ch 0-20mA REPEATER EExi 11011773 /421.D1

A =CRANE CABIN +CC100 -U102 4Ch 0-20mA REPEATER EExi 11011773 /421.D4 A
=CRANE CABIN +CC100 -U103 ETHERNET SECURITY ROUTER Remote Acc Router 11014193 /410.B6
=CRANE CABIN +CC100 -X1 TERMINAL BLOCK 2.5mm² [1-341] (341) Terminal 2,5 mm² 11105962 /403.C7
FUSE 11107024 /425.C3
=CRANE CABIN +CC100 -X2 TERMINAL BLOCK 2.5mm² [1-18] (18) Terminal 2.5 mm² 11105958 /421.D2
=CRANE CABIN +CC100 -X3 TERMINAL BLOCK 2.5mm² [1-25] (25) Terminal 2.5 mm² 11105958 /412.C5
=CRANE CABIN +CC100 -X10 TERMINAL BLOCK 16mm² [1-6] (6) Terminal 16mm² /502.D1
TERMINAL BLOCK 2.5mm² [7-18] (12) Terminal 2.5 mm² 11105958 /502.D2
=CRANE CABIN +CC100 -X12 Terminal 0,14 - 2,5 mm² [1-11] (11) Terminal 2,5 mm² /413.B1
=CRANE CABIN +CC100 -X13 TERMINAL BLOCK 2.5mm² [1-14] (14) Terminal 2.5 mm² 11105958 /404.A3
B B
=CRANE CABIN +CC100 -X14 TERMINAL BLOCK 2.5mm² [1-6] (6) Terminal 2.5 mm² 11105958 /405.A1
=CRANE CABIN +CC100 -X21 BNC-V75 CONNECTOR INP 75 Ω [0] (1) BNC-connector 11008740 /208.C4
=CRANE CABIN +CC100 -X22 BNC-V75 CONNECTOR INP 75 Ω [0] (1) BNC-connector 11008740 /208.C4
=CRANE CABIN +CC100 -X121 FUSE TERMINAL BLOCK 4mm² [1-2] (2) Terminal 2.5 mm² 11014814 /403.B2
=CRANE CABIN +CC100 -X301 DOUBLE TERM.BLOCK W. DIODE PTTB 2,5-DIO/U-O 11105975 /423.D2
=CRANE CABIN +CC100 -X303 CAT5 ETHERNET PATCH PANEL w/SHIELD 11009080 /402.B5
=CRANE CABIN +CC100 -X304 CAT5 ETHERNET PATCH PANEL w/SHIELD 11009080 /402.B3
+CC100 -X305 CAT5 ETHERNET PATCH PANEL w/SHIELD 11009080 /402.B8
=CRANE CABIN +CC100 -X307 DIODE EEX(e) [4] (1) 11007976 /403.A3
=CRANE CABIN +CC100 -XB Terminal 0,14 - 2,5 mm² [1-28] (28) Terminal 2,5 mm² 11105958 /401.B2
C C
=CRANE CABIN +CC100 -XC Terminal 0,14 - 2,5 mm² [1-3] (3) Terminal 2,5 mm² 11105958 /402.B2
=CRANE CABIN +CC100 -XP20 FUSE TERMINAL BLOCK 4mm² [1-13] (13) 11105958 /404.A6
=CRANE CABIN +CC100 -XP22 FUSE TERMINAL BLOCK 4mm² [1-6] (6) 11105958 /404.A8
=CRANE CABIN +CC100 -XP23 FUSE TERMINAL BLOCK 4mm² [1-6] (6) 11105958 /404.E8
=CRANE CABIN +CC100 -XP25 TERMINAL BLOCK 2.5mm² [1-42] (42) Terminal 2.5 mm² 11105958 /403.C5
FUSE TERMINAL BLOCK 4mm² [1-20] (20) /403.A5
=CRANE CABIN +CC100 -XP40 TERMINAL BLOCK 2.5mm² [2-4] (3) Terminal 2.5 mm² 11105958 /405.A5
=CRANE CABIN +CC100 -XS01 SOCKET OUTLET, 250V AC, 10/16A, DIN 11008782 /253.E1

D D

E E

F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 706
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +CC100 707

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=CRANE KING +CC200 -CC200 WALL ENCLOSURE 1000x800x300 800x1000x300mm 11012341
=CRANE KING +CC200 -D200 S7 RS 485 REPEATER 11002271 /445.B2

A =CRANE KING +CC200 -D201 S7 RS 485 REPEATER 11002271 /445.B4 A

=CRANE KING +CC200 -F01 CIRCUIT BREAKER 10A 2p C Power Supply -G01 10A 11002500 /440.A3
=CRANE KING +CC200 -F02 CIRCUIT BREAKER 10A 1pol C 24VDC Distribution 10A 11005776 /440.A4
=CRANE KING +CC200 -G01 SITOP POWER SUPPLY 10A 230VAC/24VDC 11013597 /440.A3
=CRANE KING +CC200 -H1 LAMP HVITE 11002525 /440.A3
=CRANE KING +CC200 -K40 RELAY 24VDC 2NO+2NC 11013892 /440.D5
=CRANE KING +CC200 -S1 COMPLETE CHANGE-OVER-SWITCH EMERGENCY MODE SELECTOR 11002535
ADAPTER 11002517
CONTACT ELEMENT 1NO 11002518
CONTACT ELEMENT 1NC 11002524
B B
LABELMOUNT 50mm 11001858
=CRANE KING +CC200 -X1 TERMINAL BLOCK 2.5mm² [1-175] (175) Terminal 2.5 mm² 11105958 /440.B5
=CRANE KING +CC200 -X2 FUSE TERMINAL BLOCK 4mm² [1-27] (27) Terminal 2.5 mm² 11105962 /440.B6
=CRANE KING +CC200 -X2 FUSE 11107024 /440.B6
=CRANE KING +CC200 -X12 Terminal 0,14 - 2,5 mm² [1-12] (12) Terminal 2,5 mm² 11105958 /441.E1
=CRANE KING +CC200 -X40 SOCKET 200-250V 50-60Hz 16A BLUE 16A /440.A1
=CRANE KING +CC200 -X40 PLUG 200-250V 50-60Hz 16A BLUE 16A /440.A1

C C

D D

E E

F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 707
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +CC200 708

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=CRANE PEDESTAL +CC300 -CC300 WALL ENCLOSURE 800x600x300mm 11011894
=CRANE PEDESTAL +CC300 -D01 PROFIBUS CONNECTOR 90deg FOR PC-CONN 10006834 /448.C2

A INTERFACE MODULE 10008297 /448.D3 A

BACKPLATE 480mm 11005740
=CRANE PEDESTAL +CC300 -D02 DIGITAL INPUT MODULE 16DI 11002445 /448.D3
FRONT CONNECTOR 20pin 11002450
=CRANE PEDESTAL +CC300 -D03 DIGITAL OUTPUT MODULE 16DO 11002446 /448.D5
FRONT CONNECTOR 20pin 11002450
=CRANE PEDESTAL +CC300 -F01 CIRCUIT BREAKER, 6A 2p B Power Supply -G01 6A 11006370 /447.C3
=CRANE PEDESTAL +CC300 -F02 CIRCUIT BREAKER, 6A 2p B 6A 11006370 /447.D3
=CRANE PEDESTAL +CC300 -F03 CIRCUIT BREAKER 10A 1pol C 10A 11005776 /447.C6
=CRANE PEDESTAL +CC300 -G01 POWER SUPPLY 230/24 10A 230VAC/24VDC 11013597 /447.C4
B B
=CRANE PEDESTAL +CC300 -G02 POWER SUPPLY 10A 230VAC/24VDC 11013597 /447.D4
=CRANE PEDESTAL +CC300 -K1 OPTOCOUPLER 11006978 /449.D7
=CRANE PEDESTAL +CC300 -K2 RELAY 24VDC 1xNOC ON RAIL 10008121 /451.C2
=CRANE PEDESTAL +CC300 -K3 RELAY 24VDC 1xNOC ON RAIL 10008121 /451.C3
=CRANE PEDESTAL +CC300 -K4 RELAY 24VDC 1xNOC ON RAIL 10008121 /451.C3
=CRANE PEDESTAL +CC300 -K5 RELAY 24VDC 1xNOC ON RAIL 10008121 /451.C4
=CRANE PEDESTAL +CC300 -K6 RELAY 24VDC 1xNOC ON RAIL 10008121 /451.C5
=CRANE PEDESTAL +CC300 -K7 RELAY 24VDC 1xNOC ON RAIL 10008121 /451.C6
=CRANE PEDESTAL +CC300 -K8 RELAY 24VDC 1xNOC ON RAIL 10008121 /451.C7
=CRANE PEDESTAL +CC300 -K9 RELAY 24VDC 1xNOC ON RAIL 10008121 /451.C7
C C
=CRANE PEDESTAL +CC300 -K10 RELAY 24VDC 1xNOC ON RAIL 10008121 /452.C2
=CRANE PEDESTAL +CC300 -K11 RELAY 24VDC 1xNOC ON RAIL 10008121 /452.C3
=CRANE PEDESTAL +CC300 -K12 RELAY 24VDC 1xNOC ON RAIL 10008121 /452.C3
=CRANE PEDESTAL +CC300 -K13 RELAY 24VDC 1xNOC ON RAIL 10008121 /452.C4
=CRANE PEDESTAL +CC300 -U65 ETHERNETSWITCH Switch for Remote Access 11013551 /201.B3
=CRANE PEDESTAL +CC300 -X1 TERMINAL BLOCK 2.5mm² [1-57] (57) Terminal 2.5 mm² 11105958 /449.C2
=CRANE PEDESTAL +CC300 -X30 CAT5 ETHERNET PATCH PANEL w/SHIELD 11009080 /449.D4
=CRANE PEDESTAL +CC300 -X101 TERMINAL BLOCK 2.5mm² [1-6] (6) Terminal 2.5 mm² 11105958 /447.C7
=CRANE PEDESTAL +CC300 -X201 TERMINAL BLOCK 2.5mm² [1-6] (6) Terminal 2.5 mm² 11105958 /447.D7
=CRANE PEDESTAL +CC300 -X307 DIODE EEX(e) [4] (1) 11007976 /447.C5
D D
=CRANE PEDESTAL +CC300 -XA Terminal 0,14 - 2,5 mm² [1-2] (2) Terminal 2,5 mm² 11105958 /447.C3
=CRANE PEDESTAL +CC300 -ZT001 MRU 11107029 /208.E1
MRU CABLE 11107031
MRU BRACKET 11107030

E E

F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 708
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +CC300 709

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=CRANE KING +ES400 -D01.1 NTERFACE MODULE 11011695 /454.B1
BACKPLATE 480mm 11005740

A =CRANE KING +ES400 -D01.2 REPEATER PLUG 11015926 /445.C6 A

=CRANE KING +ES400 -D02 DIGITAL INPUT MODULE 32DI 11011698 /454.B2
FRONT CONNECTOR 40pin 11002451
=CRANE KING +ES400 -D03 DIGITAL INPUT MODULE 32DI 11011698 /454.B5
FRONT CONNECTOR 40pin 11002451
=CRANE KING +ES400 -D04 DIGITAL OUTPUT MODULE 32DO 11011699 /454.D5
FRONT CONNECTOR 40pin 11002451
+ES400 -E01 FAN AND FILTER UNIT Ventilation Fan 11013758 /507.C5
OUTLET FILTER RAL 7035 11013759
FINE FILTER MAT 11013760
B B
=CRANE KING +ES400 -ES400 CABINET 1580x1930x600 (WHD) 11026051
=CRANE KING +ES400 -F01 CIRCUIT BREAKER 63A 3P 230VAC Main Fuse 63A 11052176 /504.B1
=CRANE KING +ES400 -F02 CIRCUIT BREAKER 40A 3pol C 230VAC To +CC100 40A 11002499 /504.B2
=CRANE KING +ES400 -F03 CIRCUIT BREAKER 16A 3pol C -M50 Cooling Fan Motor 16A 11006057 /504.B3
=CRANE KING +ES400 -F04 CIRCUIT BREAKER 10A 2p C Floodlight Main Jib, MW, WW, TW 10A 11002500 /504.B4
=CRANE KING +ES400 -F05 CIRCUIT BREAKER 10A 2p C Socket -XS10, Light in King & Pedestal 10A 11002500 /505.B2
=CRANE KING +ES400 -F06 CIRCUIT BREAKER 10A 2p C 10A 11002500 /505.B5
=CRANE KING +ES400 -F07 CIRCUIT BREAKER 10A 2p C Spare 10A 11002500 /505.B7
=CRANE KING +ES400 -F08 CIRCUIT BREAKER 10A 2p C Motor Heating, Em.Pump Heating 10A 11002500 /506.B2
=CRANE KING +ES400 -F09 CIRCUIT BREAKER 6A 2p C Cooler Fan -M61 6A 11008711 /506.B3
C C
=CRANE KING +ES400 -F10 CIRCUIT BREAKER 10A 2p C Main Pump 1, -M01 10A 11002500 /506.B4
=CRANE KING +ES400 -F11 CIRCUIT BREAKER 10A 2p C Main Pump 2, -M02 10A 11002500 /506.B4
=CRANE KING +ES400 -F12 CIRCUIT BREAKER 10A 2p C Main Pump 3, -M03 10A 11002500 /506.B5
=CRANE KING +ES400 -F14 CIRCUIT BREAKER 10A 2p C Earth Fault Monitoring, Circ.Pump -M10 10A 11002500 /506.B6
=CRANE KING +ES400 -F15 CIRCUIT BREAKER 20A 2p C 230VAC UPS Main Fuse 20A 11012042 /507.B1
=CRANE KING +ES400 -F16 CIRCUIT BREAKER 16A 2p C 230VAC UPS To +CC100 16A 11008610 /507.B2
=CRANE KING +ES400 -F17 CIRCUIT BREAKER 10A 2p C 230VAC UPS Spare 10A 11002500 /507.B3
=CRANE KING +ES400 -F18 CIRCUIT BREAKER 10A 2p C 230VAC UPS To +CC300 10A 11002500 /507.B4
=CRANE KING +ES400 -F19 CIRCUIT BREAKER 6A 2p C 230VAC UPS To +ES400 (PLC, Vent.Fan) 6A 11008711 /507.B5
=CRANE KING +ES400 -F20 CIRCUIT BREAKER 6A 2p C 6A 11008711 /507.B6
D D
=CRANE KING +ES400 -F21 CIRCUIT BREAKER 6A 2p C 230VAC UPS AVI-light 6A 11008711 /507.B7
=CRANE KING +ES400 -F22 CIRCUIT BREAKER 10A 1pol C 24VDC Distribution -X20 10A 11005776 /454.C3
=CRANE KING +ES400 -G1 SITOP POWER SUPPLY 10A 230VAC/24VDC 11013597 /454.C1
=CRANE KING +ES400 -G2 SITOP POWER SUPPLY 10A 230VAC/24VDC 11013597 /454.D1
=CRANE KING +ES400 -H31 LAMP FRONT BLUE Oil Heater On 11003174 /527.D3
ADAPTER 11002517
LABELMOUNT 50mm 11001858
LED ELEMENT WHITE 85-264VAC FRONT FIX 11003178
=CRANE KING +ES400 -H32 LAMP FRONT BLUE Oil Heater On 11003174 /527.D5
ADAPTER 11002517
E E
LABELMOUNT 50mm 11001858
LED ELEMENT WHITE 85-264VAC FRONT FIX 11003178
=CRANE KING +ES400 -HS117 EMERGENCY STOP COMPLETE 11007971
=CRANE KING +ES400 -K01 CONTACTOR 400 A, 3-PHASE AC 400A 11008786 /513.E7
=CRANE KING +ES400 -K02 CONTACTOR 400 A, 3-PHASE AC 400A 11008786 /513.E6
=CRANE KING +ES400 -K03 CONTACTOR, 250A AC 250A 11012030 /513.E6
=CRANE KING +ES400 -K04 CONTACTOR 400 A, 3-PHASE AC 400A 11008786 /514.E7
=CRANE KING +ES400 -K05 CONTACTOR 400 A, 3-PHASE AC 400A 11008786 /514.E6
=CRANE KING +ES400 -K06 CONTACTOR, 250A AC 250A 11012030 /514.E6
F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 709
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +ES400 710

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=CRANE KING +ES400 -K07 CONTACTOR 400 A, 3-PHASE AC 400A 11008786 /515.E7
=CRANE KING +ES400 -K08 CONTACTOR 400 A, 3-PHASE AC 400A 11008786 /515.E6

A =CRANE KING +ES400 -K09 CONTACTOR, 250A AC 250A 11012030 /515.E6 A

=CRANE KING +ES400 -K13 AUXILLIARY CONTACTS 2NO2NC 11008772 /517.E7
230VAC CONTACTOR INC. 1NO 17A 11012832 /517.E7
=CRANE KING +ES400 -K14 AUXILLIARY CONTACTS 2NO2NC 11008772 /518.E7
CONTACTOR 230VAC 3PHASE 9A 1NO 9A 11008769 /518.E7
=CRANE KING +ES400 -K15 CONTACTOR 230VAC 3PHASE 9A 1NO 9A 11008769 /519.E7
AUXILLIARY CONTACTS 2NO2NC 11008772 /519.E7
=CRANE KING +ES400 -K16 CONTACTOR 230VAC 3PHASE 9A 1NO 9A 11008769 /520.E7
AUXILLIARY CONTACTS 2NO2NC 11008772 /520.E7
=CRANE KING +ES400 -K17 CONTACTOR 230VAC 3PHASE 9A 1NO 9A 11008769 /521.E7
B B
AUXILLIARY CONTACTS 2NO2NC 11008772 /521.E7
=CRANE KING +ES400 -K18 CONTACTOR 230VAC 3PHASE 9A 1NO 9A 11008769 /522.E7
AUXILLIARY CONTACTS 2NO2NC 11008772 /522.E7
=CRANE KING +ES400 -K24 1 CHANGEOVER RELAY 24VDC COIL Autostart 10009705 /463.E1
1 CHANGE-OVER RELAY, SOCKET 11012033
=CRANE KING +ES400 -K25 1 CHANGEOVER RELAY 24VDC COIL Autostart 10009705 /463.E2
1 CHANGE-OVER RELAY, SOCKET 11012033
=CRANE KING +ES400 -K26 1 CHANGEOVER RELAY 24VDC COIL Autostart 10009705 /463.E3
1 CHANGE-OVER RELAY, SOCKET 11012033
=CRANE KING +ES400 -K27 1 CHANGEOVER RELAY 24VDC COIL Autostart 10009705 /463.E4
C C
1 CHANGE-OVER RELAY, SOCKET 11012033
=CRANE KING +ES400 -K28 1 CHANGEOVER RELAY 24VDC COIL Autostart 10009705 /463.E5
1 CHANGE-OVER RELAY, SOCKET 11012033
=CRANE KING +ES400 -K29 1 CHANGEOVER RELAY 24VDC COIL Autostart 10009705 /463.E6
1 CHANGE-OVER RELAY, SOCKET 11012033
=CRANE KING +ES400 -K30 1 CHANGEOVER RELAY 24VDC COIL Autostart 10009705 /463.E7
1 CHANGE-OVER RELAY, SOCKET 11012033
=CRANE KING +ES400 -K31 1 CHANGEOVER RELAY 24VDC COIL Autostart 10009705 /463.E8
1 CHANGE-OVER RELAY, SOCKET 11012033
=CRANE KING +ES400 -K32 1 CHANGEOVER RELAY 24VDC COIL Autostart 10009705 /464.E1
D D
1 CHANGE-OVER RELAY, SOCKET 11012033
=CRANE KING +ES400 -K33 1 CHANGEOVER RELAY 24VDC COIL Autostart 10009705 /464.E2
1 CHANGE-OVER RELAY, SOCKET 11012033
=CRANE KING +ES400 -K34 1 CHANGEOVER RELAY 24VDC COIL Autostart 10009705 /464.E3
1 CHANGE-OVER RELAY, SOCKET 11012033
=CRANE KING +ES400 -K35 1 CHANGEOVER RELAY 24VDC COIL 10009705 /464.E4
1 CHANGE-OVER RELAY, SOCKET 11012033
=CRANE KING +ES400 -K36 1 CHANGEOVER RELAY 24VDC COIL 10009705 /464.E5
1 CHANGE-OVER RELAY, SOCKET 11012033
=CRANE KING +ES400 -K37 TIME RELAY 3-60s 50ms DELAY 11006373 /513.E7
E E
=CRANE KING +ES400 -K38 TIME RELAY 3-60s 50ms DELAY 11006373 /514.E7
=CRANE KING +ES400 -K39 TIME RELAY 3-60s 50ms DELAY 11006373 /515.E7
=CRANE KING +ES400 -K41 4 CHANGEOVER RELAY 24VDC COIL 11052050 /464.E6
4 CHANGEOVER RELAY, SOCKET 11012052
=CRANE KING +ES400 -K42 4 CHANGEOVER RELAY 24VDC COIL 11052050 /464.E7
4 CHANGEOVER RELAY, SOCKET 11012052
=CRANE KING +ES400 -K43 1 CHANGEOVER RELAY 24VDC COIL Autostart 10009705 /465.E1
1 CHANGE-OVER RELAY, SOCKET 11012033
=CRANE KING +ES400 -K44 4 CHANGEOVER RELAY 24VDC COIL 11052050 /465.E2
F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 710
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +ES400 711

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=CRANE KING +ES400 -K44 4 CHANGEOVER RELAY, SOCKET 11012052
=CRANE KING +ES400 -K45 4 CHANGEOVER RELAY 24VDC COIL 11052050 /465.E3

A 4 CHANGEOVER RELAY, SOCKET 11012052 A

=CRANE KING +ES400 -K46 4 CHANGEOVER RELAY 24VDC COIL 11052050 /465.E4
4 CHANGEOVER RELAY, SOCKET 11012052
=CRANE KING +ES400 -K47 1 CHANGEOVER RELAY 24VDC COIL 17A 10009705 /465.E5
1 CHANGE-OVER RELAY, SOCKET 11012033
=CRANE KING +ES400 -K48 1 CHANGEOVER RELAY 24VDC COIL 17A 10009705 /465.E6
1 CHANGE-OVER RELAY, SOCKET 11012033
=CRANE KING +ES400 -K49 1 CHANGEOVER RELAY 24VDC COIL 17A 10009705 /465.E7
1 CHANGE-OVER RELAY, SOCKET 11012033
=CRANE KING +ES400 -K50 1 CHANGEOVER RELAY 24VDC COIL 17A 10009705 /465.E8
B B
1 CHANGE-OVER RELAY, SOCKET 11012033
=CRANE KING +ES400 -K51 1 CHANGEOVER RELAY 24VDC COIL 10009705 /466.E1
1 CHANGE-OVER RELAY, SOCKET 11012033
=CRANE KING +ES400 -K52 1 CHANGEOVER RELAY 24VDC COIL 10009705 /466.E2
1 CHANGE-OVER RELAY, SOCKET 11012033
=CRANE KING +ES400 -K55 CONTACTOR 230VAC 3PHASE 9A 1NO 9A 11008769
=CRANE KING +ES400 -K56 CONTACTOR 230VAC 3PHASE 9A 1NO 9A 11008769
=CRANE KING +ES400 -K91 4 CHANGEOVER RELAY 24VDC COIL Em.stop 11052050 /467.C7
4 CHANGEOVER RELAY, SOCKET 11012052
=CRANE KING +ES400 -K92 4 CHANGEOVER RELAY 24VDC COIL Em.stop 11052050 /467.C7
C C
4 CHANGEOVER RELAY, SOCKET 11012052
=CRANE KING +ES400 -K93 4 CHANGEOVER RELAY 24VDC COIL Em.stop 11052050 /467.C8
4 CHANGEOVER RELAY, SOCKET 11012052
=CRANE KING +ES400 -K94 4 CHANGEOVER RELAY 24VDC COIL Em.stop 11052050 /467.C8
4 CHANGEOVER RELAY, SOCKET 11012052
=CRANE KING +ES400 -K95 CONTACTOR 230VAC 3PHASE 9A 1NO 9A 11008769 /526.D4
=CRANE KING +ES400 -P01 OVERLOAD RELAY Therm. 11006314 /513.C5
=CRANE KING +ES400 -P02 OVERLOAD RELAY Therm. 11006314 /514.C5
=CRANE KING +ES400 -P03 OVERLOAD RELAY Therm. 11006314 /515.C5
=CRANE KING +ES400 -P05 OVERLOAD RELAY Therm. 11006314 /517.C5
D D
=CRANE KING +ES400 -P07 OVERLOAD RELAY Therm. 11006314 /519.C5
=CRANE KING +ES400 -P08 OVERLOAD RELAY Therm. 11006314 /520.C5
=CRANE KING +ES400 -P09 OVERLOAD RELAY Therm. 11006314 /521.C5
=CRANE KING +ES400 -P10 OVERLOAD RELAY Therm. 11006314 /522.C5
=CRANE KING +ES400 -P21 A-METER, PANEL MOUNTED, 40-300A 11007570 /513.B3
IP65 FRONT PROTECTION 48x48 11013692
=CRANE KING +ES400 -P22 A-METER, PANEL MOUNTED, 40-300A 11007570 /514.B3
IP65 FRONT PROTECTION 48x48 11013692
=CRANE KING +ES400 -P23 A-METER, PANEL MOUNTED, 40-300A 11007570 /515.B3
IP65 FRONT PROTECTION 48x48 11013692
E E
=CRANE KING +ES400 -P25 A-METER, PANEL MOUNTED, 0-15A 11007570 /517.D3
IP65 FRONT PROTECTION 48x48 11013692
=CRANE KING +ES400 -P31 HOUR COUNTER 230V 60Hz 11012684 /513.D8
=CRANE KING +ES400 -P32 HOUR COUNTER 230V 60Hz 11012684 /514.D8
=CRANE KING +ES400 -P33 HOUR COUNTER 230V 60Hz 11012684 /515.D8
=CRANE KING +ES400 -Q01 CIRCUIT BREAKER 3P -M01 HPU Main Pump 1 300A 11012670 /513.C1
COVER SCREW TERMINAL 11012860
COVER SCREW TERMINAL 11012860
=CRANE KING +ES400 -Q02 CIRCUIT BREAKER 3P -M02 HPU Main Pump 2 300A 11012670 /514.C1
F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 711
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +ES400 712

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=CRANE KING +ES400 -Q02 COVER SCREW TERMINAL 11012860
COVER SCREW TERMINAL 11012860

A A
=CRANE KING +ES400 -Q03 CIRCUIT BREAKER 3P -M03 HPU Main Pump 3 300A 11012670 /515.C1
COVER SCREW TERMINAL 11012860
COVER SCREW TERMINAL 11012860

=CRANE KING +ES400 -Q05 AUX.SWITCH 1NO 1NC MOUNT RIGHT SIDE 11011648 /517.B6
MOTOR PROTECTIVE CIRCUIT BREAKER 16A -M10 Circulation Pump 12A 11012633 /517.A2
=CRANE KING +ES400 -Q06 AUX.SWITCH 1NO 1NC MOUNT RIGHT SIDE 11011648 /518.B6
MOTOR PROTECTIVE CIRCUIT BREAKER -M11 CJC Filter 1,0A 11003506 /518.C2
=CRANE KING +ES400 -Q07 AUX.SWITCH 1NO 1NC MOUNT RIGHT SIDE 11011648 /519.B6
B B
MOTOR PROTECTIVE CIRCUIT BREAKER 6.3A -M20 Oil Cooler 1 4,0A 11007530 /519.C2
=CRANE KING +ES400 -Q08 AUX.SWITCH 1NO 1NC MOUNT RIGHT SIDE 11011648 /520.B6
MOTOR PROTECTIVE CIRCUIT BREAKER 6.3A -M21 Oil Cooler 2 4,0A 11007530 /520.A2
=CRANE KING +ES400 -Q09 AUX.SWITCH 1NO 1NC MOUNT RIGHT SIDE 11011648 /521.B6
MOTOR PROTECTIVE CIRCUIT BREAKER 6.3A -M22 Oil Cooler 3 4,0A 11007530 /521.B2
=CRANE KING +ES400 -Q10 AUX.SWITCH 1NO 1NC MOUNT RIGHT SIDE 11011648 /522.B6
MOTOR PROTECTIVE CIRCUIT BREAKER 6.3A -M23 Oil Cooler 4 4,0A 11007530 /522.A2
=CRANE KING +ES400 -Q14 MOTOR PROTECTIVE CIRCUIT BREAKER 2.5A 2.0A 11008468 /527.C2
AUX.SWITCH 1NO 1NC MOUNT RIGHT SIDE 11011648 /527.C2
=CRANE KING +ES400 -Q15 AUX.SWITCH 1NO 1NC MOUNT RIGHT SIDE 11011648 /527.C5
C C
MOTOR PROTECTIVE CIRCUIT BREAKER 2.5A 2.0A 11008468 /527.C4
=CRANE KING +ES400 -Q16 MOTOR PROTECTIVE CIRCUIT BREAKER -U01 Monitoring Relay 1 0,7A 11012520 /517.B2
=CRANE KING +ES400 -Q17 MOTOR PROTECTIVE CIRCUIT BREAKER -U02 Monitoring Relay 2 0,7A 11012520 /518.B2
=CRANE KING +ES400 -Q18 MOTOR PROTECTIVE CIRCUIT BREAKER -U03 Monitoring Relay 3 0,7A 11012520 /521.B2
=CRANE KING +ES400 -Q50 AUX.SWITCH 1NO 1NC MOUNT RIGHT SIDE Motor trip 11011648 /526.C3
MOTOR PROTECTIVE CIRCUIT BREAKER -M61 Cooling Fan 2,5A 11011647 /526.C1
=CRANE KING +ES400 -S01 3-POS SWITCH Local 11008446
ADAPTER 11002517
CONTACT ELEMENT 1NO 11002518 /513.A8
=CRANE KING +ES400 -S02 PUSHBUTTON WITH LAMP 11012044 /513.E8
D D
=CRANE KING +ES400 -S03 SWITCH 2-POS MAINTAINED W/IND.LIGHT BLUE 11012043
ADAPTER 11002517
LED ELEMENT BLUE 85-264VAC FRONT FIX 11003177
CONTACT ELEMENT 1NO 11002518
LABELMOUNT 50mm 11001858
CONTACT ELEMENT 1NO 11002518
=CRANE KING +ES400 -S04 3-POS SWITCH Local 11008446
ADAPTER 11002517
CONTACT ELEMENT 1NO 11002518 /514.A8
=CRANE KING +ES400 -S05 PUSHBUTTON WITH LAMP Start 11012044 /514.E8
E E
=CRANE KING +ES400 -S06 SWITCH 2-POS MAINTAINED W/IND.LIGHT BLUE 11012043
ADAPTER 11002517
LED ELEMENT BLUE 85-264VAC FRONT FIX 11003177
CONTACT ELEMENT 1NO 11002518
LABELMOUNT 50mm 11001858
CONTACT ELEMENT 1NO 11002518
=CRANE KING +ES400 -S07 3-POS SWITCH Local 11008446
ADAPTER 11002517
CONTACT ELEMENT 1NO 11002518 /515.A8
F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 712
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +ES400 713

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=CRANE KING +ES400 -S08 PUSHBUTTON WITH LAMP Start 11012044 /515.E8
=CRANE KING +ES400 -S09 SWITCH 2-POS MAINTAINED W/IND.LIGHT BLUE 11012043

A ADAPTER 11002517 A
LED ELEMENT BLUE 85-264VAC FRONT FIX 11003177
CONTACT ELEMENT 1NO 11002518
LABELMOUNT 50mm 11001858
CONTACT ELEMENT 1NO 11002518
=CRANE KING +ES400 -S13 CONTACT ELEMENT 1NO 11002518 /517.A8
3-POS SWITCH Local 11008446
ADAPTER 11002517
=CRANE KING +ES400 -S14 PUSHBUTTON WITH LAMP 11012044 /517.E7
=CRANE KING +ES400 -S15 SWITCH 2-POS MAINTAINED W/IND.LIGHT BLUE 11012043
B B
ADAPTER 11002517
LED ELEMENT BLUE 85-264VAC FRONT FIX 11003177
CONTACT ELEMENT 1NO 11002518
LABELMOUNT 50mm 11001858
CONTACT ELEMENT 1NO 11002518
=CRANE KING +ES400 -S16 CONTACT ELEMENT 1NO 11002518 /518.A8
3-POS SWITCH Local 11008446
ADAPTER 11002517
=CRANE KING +ES400 -S17 PUSHBUTTON WITH LAMP Start 11012044 /518.E7
=CRANE KING +ES400 -S19 CONTACT ELEMENT 1NO 11002518 /519.A8
C C
3-POS SWITCH Local 11008446
ADAPTER 11002517
=CRANE KING +ES400 -S20 PUSHBUTTON WITH LAMP Start 11012044 /519.E7
=CRANE KING +ES400 -S21 SWITCH 2-POS MAINTAINED W/IND.LIGHT BLUE 11012043
ADAPTER 11002517
LED ELEMENT BLUE 85-264VAC FRONT FIX 11003177
CONTACT ELEMENT 1NO 11002518
LABELMOUNT 50mm 11001858
CONTACT ELEMENT 1NO 11002518
=CRANE KING +ES400 -S22 CONTACT ELEMENT 1NO 11002518 /520.A8
D D
3-POS SWITCH Local 11008446
ADAPTER 11002517
=CRANE KING +ES400 -S23 PUSHBUTTON WITH LAMP Start 11012044 /520.E7
=CRANE KING +ES400 -S24 SWITCH 2-POS MAINTAINED W/IND.LIGHT BLUE 11012043
ADAPTER 11002517
LED ELEMENT BLUE 85-264VAC FRONT FIX 11003177
CONTACT ELEMENT 1NO 11002518
LABELMOUNT 50mm 11001858
CONTACT ELEMENT 1NO 11002518
=CRANE KING +ES400 -S25 CONTACT ELEMENT 1NO 11002518 /521.A8
E E
3-POS SWITCH Local 11008446
ADAPTER 11002517
=CRANE KING +ES400 -S26 PUSHBUTTON WITH LAMP Start 11012044 /521.E7
=CRANE KING +ES400 -S27 SWITCH 2-POS MAINTAINED W/IND.LIGHT BLUE 11012043
ADAPTER 11002517
LED ELEMENT BLUE 85-264VAC FRONT FIX 11003177
CONTACT ELEMENT 1NO 11002518
LABELMOUNT 50mm 11001858
CONTACT ELEMENT 1NO 11002518
F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 713
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +ES400 714

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=CRANE KING +ES400 -S28 CONTACT ELEMENT 1NO 11002518 /522.A8
3-POS SWITCH Local 11008446

A ADAPTER 11002517 A
=CRANE KING +ES400 -S29 PUSHBUTTON WITH LAMP Start 11012044 /522.E7
=CRANE KING +ES400 -S30 SWITCH 2-POS MAINTAINED W/IND.LIGHT BLUE 11012043
ADAPTER 11002517
LED ELEMENT BLUE 85-264VAC FRONT FIX 11003177
CONTACT ELEMENT 1NO 11002518
LABELMOUNT 50mm 11001858
CONTACT ELEMENT 1NO 11002518
=CRANE KING +ES400 -T01 EARTH FAULT TRANSFORMER 11012046 /513.B1
=CRANE KING +ES400 -T02 EARTH FAULT TRANSFORMER 11012046 /514.B1
B B
=CRANE KING +ES400 -T03 EARTH FAULT TRANSFORMER 11012046 /515.B1
=CRANE KING +ES400 -T05 CURRENT TRANSFORMER 11012047 /504.A1
=CRANE KING +ES400 -T06 CURRENT TRANSFORMER 500/5 500/5A 11012048 /513.B2
=CRANE KING +ES400 -T07 CURRENT TRANSFORMER 500/5 500/5A 11012048 /514.B2
=CRANE KING +ES400 -T08 CURRENT TRANSFORMER 500/5 500/5A 11012048 /515.B2
=CRANE KING +ES400 -T10 TRANSFORMER 50/5A 11007574 /517.D2
=CRANE KING +ES400 -TS01 ENCLOSURE INTERNAL THERMOSTAT t > 30°C 11012620 /507.C5
=CRANE KING +ES400 -U01 3-PHASE MONITORING RELAY 600-690V Power 11008752 /517.B1
=CRANE KING +ES400 -U02 3-PHASE MONITORING RELAY 600-690V Power 11008752 /518.B1
=CRANE KING +ES400 -U03 3-PHASE MONITORING RELAY 600-690V Power 11008752 /521.B1
C C
=CRANE KING +ES400 -U27 EARTH FAULT MONITORING 11012049 /503.C2
=CRANE KING +ES400 -X1 TERMINAL BLOCK 2.5mm² [1-45] (45) Terminal 2.5 mm² 11105962 /459.B8
FUSE 11107024 /467.D2
=CRANE KING +ES400 -X6 TERMINAL BLOCK 2.5mm² [1-24] (24) Terminal 2.5 mm² 11105958 /513.E3
=CRANE KING +ES400 -X10 TERMINAL BLOCK 2.5mm² [4-35] (32) Terminal 2.5 mm² 11105958 /507.C3
TERMINAL BLOCK 4mm² [36-41] (6) Terminal 4 mm² 11105965 /509.B7
TERMINAL BLOCK 6mm² [1-3] (3) Terminal 6 mm² 11105973 /504.C2
=CRANE KING +ES400 -X16 TERMINAL BLOCK 2.5mm² [1-24] (24) Terminal 2.5 mm² 11105958 /513.D5
=CRANE KING +ES400 -X20 TERMINAL BLOCK 2.5mm² [1-11] (11) Terminal 2.5 mm² 11105958 /454.C4
=CRANE KING +ES400 -X25 TERMINAL BLOCK 2.5mm² [1-7] (7) Terminal 2.5 mm² 11105958 /454.E4
D D
=CRANE KING +ES400 -X69 TERMINAL BLOCK 4mm² [1-35] (35) Terminal 4 mm² 11012427 /517.D2
=CRANE KING +ES400 -X307 DIODE EEX(e) [4] (1) 11007976 /454.C2
=CRANE KING +ES400 -XA Terminal 0,14 - 2,5 mm² [1-23] (23) Terminal 2,5 mm² /507.C1
=CRANE KING +ES400 -XT TERMINAL BLOCK 2.5mm² [1-5] (5) Terminal 2.5 mm² 11105958 /503.B2
=CRANE KING +ES400 -XX1. TERMINAL BLOCK 2.5mm² [1-7,10-16] (14) Terminal 2.5 mm² 11105958 /513.D7
=CRANE KING +ES400 -XX2. TERMINAL BLOCK 2.5mm² [1-7,10-16] (14) Terminal 2.5 mm² 11105958 /514.D7
=CRANE KING +ES400 -XX3 TERMINAL BLOCK 2.5mm² [1-7,10-16] (14) Terminal 2.5 mm² 11105958 /515.D7

E E

F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 714
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +ES400 715

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=CRANE KING +ES404 -ES404 WALL ENCLOSURE 500x400x210 500x400x210mm 11105764 /202.D2
=CRANE KING +ES404 -F1 FUSE TERMINAL BLOCK 4mm² [1] (1) 2A 11014814 /511.B1

A =CRANE KING +ES404 -F2 FUSE TERMINAL BLOCK 4mm² [1] (1) 2A 11014814 /511.B2 A
=CRANE KING +ES404 -H02 SWITCH 2-POS MAINTAINED W/IND.LIGHT BLUE 11012043
ADAPTER 11002517
LED ELEMENT BLUE 85-264VAC FRONT FIX 11003177
CONTACT ELEMENT 1NO 11002518
LABELMOUNT 50mm 11001858
CONTACT ELEMENT 1NO 11002518
=CRANE KING +ES404 -HS116 EMERGENCY STOP COMPLETE 11007972
PROTECTION CAGE 11002623
=CRANE KING +ES404 -K01 CONTACTOR AUXILLARY CONTACTS 2NO2NC 11006311 /510.E7
B B
CONTACTOR 95A, 3-phase 95A 11006310 /510.E7
=CRANE KING +ES404 -K02 1 CHANGEOVER RELAY 24VDC COIL Autostart 10009705 /510.C5
1 CHANGE-OVER RELAY, SOCKET 11012033
=CRANE KING +ES404 -K91 1 CHANGEOVER RELAY 24VDC COIL Em.stop 10009705 /511.C6
1 CHANGE-OVER RELAY, SOCKET 11012033
=CRANE KING +ES404 -Q01 AUX.SWITCH 1NO 1NC MOUNT RIGHT SIDE 11011648 /510.C6
CIRCUIT BREAKER 3P 690VAC Power Supply 85A 11013782 /510.B1
=CRANE KING +ES404 -Q02 MOTOR PROTECTIVE CIRCUIT BREAKER 6.3A 230VAC Power Supply 5,0A 11007530 /510.D5
=CRANE KING +ES404 -S01 PUSHBUTTON WITH LAMP Start 11012044 /510.E8
=CRANE KING +ES404 -S03 CONTACT ELEMENT 1NO 11002518
C C
3-POS SWITCH Local 11008446 /510.E8
ADAPTER 11002517
=CRANE KING +ES404 -T1 TRANSFORMER 1PH 400VA 11013506 /510.D5
=CRANE KING +ES404 -X1 TERMINAL BLOCK 2.5mm² [1-6] (6) Terminal 2.5 mm² 11105958 /510.B3
=CRANE KING +ES404 -X6 TERMINAL BLOCK 2.5mm² [1-2] (2) Terminal 2.5 mm² 11105958 /510.D3
=CRANE KING +ES404 -X10 TERMINAL BLOCK 2.5mm² [1-4] (4) Terminal 2.5 mm² 11105958 /511.B1
=CRANE KING +ES404 -X13 TERMINAL BLOCK 2.5mm² [1-12] (12) Terminal 2.5 mm² 11105958 /511.D4
=CRANE KING +ES404 -X60 PLUG 440V 60Hz 125A (MALE) 125A /511.B1
=CRANE KING +ES404 -X60 SOCKET 440V 60Hz 125A (FEMALE) 125A /511.D4

D D

E E

F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 715
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +ES404 716

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=CRANE PEDESTAL +ES407 -ES407 WALL ENCLOSURE 300x300x210mm 11107262
=CRANE PEDESTAL +ES407 -F1 MOTOR PROTECTIVE CIRCUIT BREAKER 16A 14A 11012633 /512.B3

A AUX.SWITCH 1NO 1NC MOUNT RIGHT SIDE 11011648 /512.B7 A

=CRANE PEDESTAL +ES407 -K01 230VAC CONTACTOR INC. 1NO 17A 11012832
=CRANE PEDESTAL +ES407 -K03 TEMP.SENSOR 11012053
=CRANE PEDESTAL +ES407 -K04 CHANGEOVER RELAY 230VAC COIL 11012051
4 CHANGEOVER RELAY, SOCKET 11012052
=CRANE PEDESTAL +ES407 -M60 Motor 3-wire Air ventilation /101.C2
=CRANE PEDESTAL +ES407 -S1 SWITCH 2-POS MAINTAINED W/IND.LIGHT BLUE 11012043
ADAPTER 11002517
LED ELEMENT BLUE 85-264VAC FRONT FIX 11003177
CONTACT ELEMENT 1NO 11002518
B B
LABELMOUNT 50mm 11001858
=CRANE PEDESTAL +ES407 -X1 TERMINAL BLOCK 2.5mm² [1-3] (3) Terminal 2.5 mm² 11105958 /512.D1

=CRANE PEDESTAL +ES407 -X2 FUSE TERMINAL BLOCK 4mm² [1-2] (2) 11105962 /512.A4
FUSE 11107024 /512.A4

C C

D D

E E

F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 716
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +ES407 717

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=CRANE CABIN +CABIN -ME1 SINGLE INLET CENT. FAN Cabin Defrosting Fan 11107195 /253.D3
=CRANE CABIN +CABIN -R1 AIR DUCT HEATER IP44 CabinHeater Left 11107196 /502.E3

A =CRANE CABIN +CABIN -R2 AIR DUCT HEATER IP44 CabinHeater Right 11107196 /502.E4 A

B B

C C

D D

E E

F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 717
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +Cabin 718

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=MAIN WINCH +JB201 -JB201 JUNCTION BOX 570x570x150EExE INCL FIXED HOLE 11019658
MOUNTING BRACKETS 11003043

A =MAIN WINCH +JB201 -X1 TERMINAL BLOCK 2.5mm² [1-83] (83) Terminal 2.5 mm² 10009482 /429.B1 A
=MAIN WINCH +JB201 -X2 Terminal 0,14 - 2,5 mm² [1-8] (8) Terminal 2,5 mm² /445.E5

B B

C C

D D

E E

F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 718
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +JB201 719

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=MAIN JIB +JB202 -JB202 JUNCTION BOX 570x570x150EExE INCL FIXED HOLE 11014433
=MAIN JIB +JB202 -X1 TERMINAL BLOCK 2.5mm² [1-67] (67) Terminal 2.5 mm² 10009482 /431.C5

A Terminal [0] (1) Terminal 2,5 mm² /207.B5 A

=MAIN JIB +JB202 -X2 TERMINAL BLOCK 2.5mm² [1-33] (33) Terminal 2.5 mm² 10009482 /446.C1
=MAIN JIB +JB202 -X3 TERMINAL BLOCK 2.5mm² [1-18] (18) Terminal 2.5 mm² 10009482 /421.D2

B B

C C

D D

E E

F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 719
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +JB202 720

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=MAIN JIB +JB203 -JB203 JUNCTION BOX 400x200x150EExE INCL FIXED HOLE 11019660
=MAIN JIB +JB203 -X1 Terminal 0,14 - 2,5 mm² [15-26] (12) Terminal 2,5 mm² /435.B1

A TERMINAL BLOCK 2.5mm² [1-14] (14) Terminal 2.5 mm² 10009482 /431.B5 A
=MAIN JIB +JB203 -X2 TERMINAL BLOCK 2.5mm² [1-18] (18) Terminal 2.5 mm² 10009482 /421.C2

B B

C C

D D

E E

F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 720
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +JB203 721

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=KNUCKLE JIB +JB204 -JB204 JUNCTION BOX 200x200x150EExE INCL FIXED HOLE 11019661
=KNUCKLE JIB +JB204 -X1 TERMINAL BLOCK 2.5mm² [1-18] (18) Terminal 2.5 mm² 10009482 /421.B2

A A

B B

C C

D D

E E

F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 721
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +JB204 722

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=MAIN WINCH +JB205 -JB205 JUNCTION BOX 120x100x90mm 11014000
=MAIN WINCH +JB205 -X1 TERMINAL BLOCK 2.5mm² [1-5] (5) Terminal 2.5 mm² 10009482 /438.B1

A A

B B

C C

D D

E E

F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 722
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +JB205 723

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=MAIN WINCH +JB206 -JB206 JUNCTION BOX 120x100x90mm 11014000

A A

B B

C C

D D

E E

F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 723
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +JB206 724

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=MAIN WINCH +JB401 -JB401 JUNCTION BOX 150x150x100EExE INCL FIXED HOLE 11019662
=MAIN WINCH +JB401 -X10 Terminal 0,14 - 2,5 mm² [1-2] (2) Terminal 2,5 mm² /507.C8

A A

B B

C C

D D

E E

F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 724
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +JB401 725

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=MAIN JIB +JB402 -JB402 JUNCTION BOX 150x150x100EExE INCL FIXED HOLE 11019663
=MAIN JIB +JB402 -X10 Terminal 0,14 - 2,5 mm² [1-6] (6) Terminal 2,5 mm² /507.D8

A A

B B

C C

D D

E E

F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 725
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +JB402 726

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=MAIN JIB +JB403 -JB403 JUNCTION BOX 150x150x100EExE INCL FIXED HOLE 11019664
=MAIN JIB +JB403 -X10 Terminal 0,14 - 2,5 mm² [1-2] (2) Terminal 2,5 mm² /504.D4

A A

B B

C C

D D

E E

F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 726
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +JB403 727

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=KNUCKLE JIB +JB404 -JB404 JUNCTION BOX 150x150x100EExE INCL FIXED HOLE 11019665
=KNUCKLE JIB +JB404 -X10 TERMINAL BLOCK 2.5mm² [1-4] (4) Terminal 2.5 mm² 10009482 /504.E4

A A

B B

C C

D D

E E

F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 727
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +JB404 728

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=CRANE PEDESTAL +JB450 -JB450 SLIPRING 11052238 /501.E4
/201.D4

A A
=CRANE PEDESTAL +JB450 -X303 CAT5 ETHERNET PATCH PANEL w/SHIELD 11009080 /402.E5
=CRANE PEDESTAL +JB450 -X304 CAT5 ETHERNET PATCH PANEL w/SHIELD 11009080 /402.E3
=CRANE PEDESTAL +JB450 -X305 CAT5 ETHERNET PATCH PANEL w/SHIELD 11009080 /402.E8

B B

C C

D D

E E

F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 728
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +JB450 729

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=CRANE CABIN +OP103 -D101 INTERFACE MODULE 11009035 /444.B1
PROFIBUS CONNECTOR 90deg FOR PC-CONN 10006834

A =CRANE CABIN +OP103 -D102 POWER MODULE 11002261 /444.B1 A

TERMINAL MODULE 11002265
=CRANE CABIN +OP103 -D105 DIGITAL INPUT MODULE 4DI 11002262 /444.B2
TERMINAL MODULE 11003219
=CRANE CABIN +OP103 -D106 DIGITAL INPUT MODULE 4DI 11002262 /444.B3
TERMINAL MODULE 11003219
=CRANE CABIN +OP103 -D107 DIGITAL INPUT MODULE 4DI 11002262 /444.B5
TERMINAL MODULE 11003219
=CRANE CABIN +OP103 -D108 DIGITAL OURPUT MODULE 4DO 11002263 /444.B7
TERMINAL MODULE 11003219
B B
=CRANE CABIN +OP103 -HC101 3-WAY JOYSTICK LEFT 11013600 /208.B5
CONTACTMODULE 11013601
=CRANE CABIN +OP103 -HC102 3-WAY JOYSTICK LEFT 11013600 /208.B5
CONTACTMODULE 11013601
=CRANE CABIN +OP103 -HCV101.1 JOYSTICK PROFIBUS 11052157 /208.A5
=CRANE CABIN +OP103 -HCV101.2 PROFIBUS CONNECTOR 90deg 10007473 /444.E4
=CRANE CABIN +OP103 -HCV101.3 15 PINS D-SUB SCREW 11052160 /444.D5
=CRANE CABIN +OP103 -HS104 PUSHBUTTON 2NO W. PROT.COVER MOPS 11012422 /405.C1
=CRANE CABIN +OP103 -HS105 PUSHBUTTON 2NO W. PROT.COVER MOPS 11012422 /405.C3
=CRANE CABIN +OP103 -HSB101 ILLUM. PUSHBUTTON GREEN TUGGER 11014041 /442.A1
C C
ADAPTER 11002517
CONTACT ELEMENT 1NO 11002518
LED ELEMENT, FRONT WHITE 11013508
LABELMOUNT 50mm 11001858
=CRANE CABIN +OP103 -HSB102 ILLUM. PUSHBUTTON GREEN TUGGER 1 CT 11014041 /442.A2
ADAPTER 11002517
CONTACT ELEMENT 1NO 11002518
LED ELEMENT, FRONT WHITE 11013508
LABELMOUNT 50mm 11001858
=CRANE CABIN +OP103 -HSB103 ILLUM. PUSHBUTTON GREEN TUGGER 2 CT 11014041 /442.A3
D D
ADAPTER 11002517
CONTACT ELEMENT 1NO 11002518
LED ELEMENT, FRONT WHITE 11013508
LABELMOUNT 50mm 11001858
=CRANE CABIN +OP103 -X1 TERMINAL BLOCK 2.5mm² [1-31] (31) Terminal 2.5 mm² 11105958 /444.C5
=CRANE CABIN +OP103 -X14 TERMINAL BLOCK 2.5mm² [1-6] (6) Terminal 2.5 mm² 11105958 /405.C3

E E

F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 729
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +OP103 730

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=CRANE CABIN +OP104 -H106 LAMP FRONT YELLOW PERSONNEL LIFT 11002533 /443.E1
ADAPTER 11002517

A LABELMOUNT 50mm 11001858 A

LED ELEMENT, FRONT WHITE 11013508
=CRANE CABIN +OP104 -HCV102.1 JOYSTICK PROFIBUS 11052157 /208.C5
=CRANE CABIN +OP104 -HCV102.2 PROFIBUS CONNECTOR 90deg 10007473 /444.E7
=CRANE CABIN +OP104 -HCV102.3 15 PINS D-SUB SCREW 11052160 /444.D7
=CRANE CABIN +OP104 -HS102 IP65 EMERGENCY STOP BUTTON 1NO/NC Em.Stop 10009488 /404.B4
METAL GUARD RED 11002101
CONTACT BLOCK 1NC 11001106

=CRANE CABIN +OP104 -HS103 SWITCH 2-POS MAINTAINED W/IND.LIGHT BLUE CTRL ENABLE 11012043 /443.A2

B ADAPTER 11002517 B
CONTACT ELEMENT 1NO 11002518
LABELMOUNT 50mm 11001858
CONTACT ELEMENT 1NO 11002518
=CRANE CABIN +OP104 -HS106 KEY SWITCH 60deg 2pos Key switch 11007973 /443.A1
=CRANE CABIN +OP104 -HS110 PUSH BUTTON BLUE 2NO AHC/AT/CT 11012821 /443.A3
ADAPTER 11002517
LABELMOUNT 50mm 11001858
CONTACT ELEMENT 1NO 11002518
CONTACT ELEMENT 1NO 11002518

C =CRANE CABIN +OP104 -X1 TERMINAL BLOCK 2.5mm² [1-29] (29) Terminal 2.5 mm² 11105958 /444.C7 C

D D

E E

F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 730
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +OP104 731

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=CRANE CABIN +OP105 -C01 REGULATOR 230VAC 50Hz 11107189 /502.B3
+OP105 -C2 BACKPLATE 160mm 10007189

A =CRANE CABIN +OP105 -C02 REGULATOR 230VAC 50Hz 11107189 /502.B3 A

+OP105 -C3 BACKPLATE 160mm 10007189
=CRANE CABIN +OP105 -C03 REGULATOR 230VAC 50Hz 11107189 /502.B4
=CRANE CABIN +OP105 -F01 CIRCUIT BREAKER 32A 3pol C 230VAC Main Fuse 32A 11052039 /502.A1
=CRANE CABIN +OP105 -F02 CIRCUIT BREAKER 20A 3pol C Cabin Heater 20A 11012677 /502.A3
=CRANE CABIN +OP105 -F03 CIRCUIT BREAKER 16A 2p C Socket -XS02, Air Cond. Unit 16A 11008610 /502.A4
=CRANE CABIN +OP105 -F04 CIRCUIT BREAKER 16A 2p C Socket -XS03, Cabin Light 16A 11008610 /502.A5
=CRANE CABIN +OP105 -F05 CIRCUIT BREAKER 10A 2p C Power Supply 24VDC, 12VDC 10A 11002500 /502.A8
=CRANE CABIN +OP105 -F06 CIRCUIT BREAKER 10A 2p C 10A 11002500 /406.D3
=CRANE CABIN +OP105 -F10 CIRCUIT BREAKER 10A 1pol C 12VDC Distribution 10A 11005776 /406.D4
B B
=CRANE CABIN +OP105 -F11 CIRCUIT BREAKER 32A 1pol C 24VDC Distribution 32A 11012784 /406.C4
=CRANE CABIN +OP105 -F12 CIRCUIT BREAKER 6A 1p C Defrosting Fans (-ME1, -ME2), Map Light 6A 11002503 /407.B2
=CRANE CABIN +OP105 -F13 CIRCUIT BREAKER 4A 1p C Defrosting Fans (-ME1, -ME2), Map Light 4A 11002502 /407.B5
=CRANE CABIN +OP105 -F14 CIRCUIT BREAKER 10A 1pol C Washer Pumps (-P1, -P2) 10A 11005776 /407.B6
=CRANE CABIN +OP105 -F15 CIRCUIT BREAKER 6A 1p C Left Wiper Motor, -MD1 6A 11002503 /408.B2
=CRANE CABIN +OP105 -F16 CIRCUIT BREAKER 10A 1pol C Front Wiper Motor, -MD2 10A 11005776 /408.B5
=CRANE CABIN +OP105 -F17 CIRCUIT BREAKER 6A 1p C Right Wiper Motor, -MD3 6A 11002503 /408.B6
=CRANE CABIN +OP105 -F18 CIRCUIT BREAKER 4A 1p C Roof Wiper Motor, -MD4 4A 11002502 /408.B8
=CRANE CABIN +OP105 -G01 SITOP POWER SUPPLY 40A 230/24V 11012723 /406.C3
=CRANE CABIN +OP105 -G02 POWER SUPPLY 230V/3-50VDC 120W 230VAC / 3-50VDC 11007477 /406.D3
C C

=CRANE CABIN +OP105 -HS100 COMPLETE CHANGE-OVER-SWITCH Heater 11002535

ADAPTER 11002517
CONTACT ELEMENT 1NO 11002518
CONTACT ELEMENT 1NC 11002524
LABELMOUNT 50mm 11001858
=CRANE CABIN +OP105 -HS101 COMPLETE CHANGE-OVER-SWITCH DEFROSTING FAN 11002535
ADAPTER 11002517
CONTACT ELEMENT 1NO 11002518
CONTACT ELEMENT 1NC 11002524
D D
LABELMOUNT 50mm 11001858
=CRANE CABIN +OP105 -HS111 COMPLETE 3POS SWITCH LEFT WIPER /408.B2
ADAPTER 11002517
CONTACT ELEMENT 1NO 11002518
CONTACT ELEMENT 1NO 11002518
CONTACT ELEMENT 1NC 11002524
CONTACT ELEMENT 1NC 11002524

LABELMOUNT 50mm 11001858

=CRANE CABIN +OP105 -HS112 COMPLETE 3POS SWITCH FRONT WIPER /408.B5
E E
ADAPTER 11002517
CONTACT ELEMENT 1NO 11002518
CONTACT ELEMENT 1NO 11002518
CONTACT ELEMENT 1NC 11002524
CONTACT ELEMENT 1NC 11002524

LABELMOUNT 50mm 11001858

=CRANE CABIN +OP105 -HS113 COMPLETE 3POS SWITCH RIGHT WIPER /408.B7
ADAPTER 11002517
F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 731
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +OP105 732

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=CRANE CABIN +OP105 -HS113 CONTACT ELEMENT 1NO 11002518
CONTACT ELEMENT 1NO 11002518

A CONTACT ELEMENT 1NC 11002524 A

CONTACT ELEMENT 1NC 11002524

LABELMOUNT 50mm 11001858

=CRANE CABIN +OP105 -HS114 COMPLETE CHANGE-OVER-SWITCH ROOF WIPER 11002535 /408.B8
ADAPTER 11002517
CONTACT ELEMENT 1NO 11002518
CONTACT ELEMENT 1NC 11002524
LABELMOUNT 50mm 11001858
=CRANE CABIN +OP105 -JU101 UHF/VHF/FM/CD KOMPLETT UHF/VHF/FM/CD UHF/VHF/FM/CD Complete 11012178 /208.E5
B B
=CRANE CABIN +OP105 -K02 CONTACTOR DC OPERATED 11013821 /407.C5
=CRANE CABIN +OP105 -K03 4 CHANGEOVER RELAY 24VDC COIL 11052050
4 CHANGEOVER RELAY, SOCKET 11012052
=CRANE CABIN +OP105 -K04 4 CHANGEOVER RELAY 24VDC COIL 11052050
4 CHANGEOVER RELAY, SOCKET 11012052
=CRANE CABIN +OP105 -K05 IMPULSE RELAY 2NO 11013822
=CRANE CABIN +OP105 -MD1 Terminal 0,14 - 2,5 mm² [3,14] (2) Terminal 2,5 mm² /408.E2
=CRANE CABIN +OP105 -MD2 Terminal 0,14 - 2,5 mm² [3,19] (2) Terminal 2,5 mm² /408.E5
=CRANE CABIN +OP105 -MD3 Terminal 0,14 - 2,5 mm² [3,24] (2) Terminal 2,5 mm² /408.E6
=CRANE CABIN +OP105 -MD4 Terminal 0,14 - 2,5 mm² [3,31] (2) Terminal 2,5 mm² /408.E8
C C
=CRANE CABIN +OP105 -PB2 PUSH BUTTON BLACK 2NO CABIN 11002521
ADAPTER 11002517
LABELMOUNT 50mm 11001858
CONTACT ELEMENT 1NO 11002518
=CRANE CABIN +OP105 -PB3 PUSH BUTTON BLACK 2NO WASHER 11002521
ADAPTER 11002517
LABELMOUNT 50mm 11001858
CONTACT ELEMENT 1NO 11002518
=CRANE CABIN +OP105 -PB4 PUSH BUTTON BLACK 2NO WASHER 11002521
ADAPTER 11002517
D D
LABELMOUNT 50mm 11001858
CONTACT ELEMENT 1NO 11002518
=CRANE CABIN +OP105 -T1 ROOM CONTROLLER Heater Thermostat 11107194 /407.E3
=CRANE CABIN +OP105 -UA102 BUZZER 18-30V ACDC Buzzer 11002529 /208.D5
=CRANE CABIN +OP105 -X1 Terminal 0,14 - 2,5 mm² [33-38,40-43] (10) Terminal 2,5 mm² 11105958 /424.D7
TERMINAL BLOCK 2.5mm² [1-32,39] (33) Terminal 2.5 mm² 11105958 /424.D5
=CRANE CABIN +OP105 -X2 TERMINAL BLOCK 2.5mm² [1-10] (10) Terminal 2.5 mm² 11105958 /409.A3
=CRANE CABIN +OP105 -X3 TERMINAL BLOCK 2.5mm² [1-9] (9) Terminal 2.5 mm² 11105958 /407.D2
=CRANE CABIN +OP105 -X10 TERMINAL BLOCK 35mm² [1-3] (3) Terminal 35mm² /502.C1
FUSE TERMINAL BLOCK 4mm² [4-21] (18) 11105958 /502.C7
E E

F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 732
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +OP105 733

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
This document and all data disclosed herein and herewith are the confidential and
proprietary property of Cargotec and are not to be used, reproduced or disclosed HLA Location Device Name Description Techn. data Part No. Sheet
in whole or in part by or to anyone without written permission of Cargotec.
=CRANE KING +OP206 -G03 +/-10VDC POWER SUPPLY 11011909 /441.B6
=CRANE KING +OP206 -H01 JOYSTICK Joystick Outside Cabinet 11011903 /205.E6

A =CRANE KING +OP206 -K01 1 CHANGEOVER RELAY 24VDC COIL 10009705 A

1 CHANGE-OVER RELAY, SOCKET 11012033
=CRANE KING +OP206 -K02 RELAY 24VDC 2xNOC ON RAIL 10008122
=CRANE KING +OP206 -K03 RELAY 24VDC 1xNOC ON RAIL 10008121
=CRANE KING +OP206 -K05 RELAY 24VDC 2xNOC ON RAIL 10008122
=CRANE KING +OP206 -K06 RELAY 24VDC 2xNOC ON RAIL 10008122
=CRANE KING +OP206 -K07 RELAY 24VDC 2xNOC ON RAIL 10008122
+OP206 -OP206 PORTABLE CTRL STATION 11012000 /205.E6
+OP206 -S01 EMERGENCY STOP COMPLETE STOP 11014761
=CRANE KING +OP206 -S02 COMPLETE CHANGE-OVER-SWITCH MainWinch/WhipWinch Select 11002535
B B
ADAPTER 11002517
CONTACT ELEMENT 1NO 11002518
CONTACT ELEMENT 1NC 11002524
LABELMOUNT 50mm 11001858
=CRANE KING +OP206 -S03 COMPLETE CHANGE-OVER-SWITCH Winch&KnJib/MainJib&Slew Select 11002535
ADAPTER 11002517
CONTACT ELEMENT 1NO 11002518
CONTACT ELEMENT 1NC 11002524
LABELMOUNT 50mm 11001858
=CRANE KING +OP206 -X12 Terminal 0,14 - 2,5 mm² [1-12] (12) Terminal 2,5 mm² /441.D1
C C
=CRANE KING +OP206 -XP1 CHASSISSTIFT 14P 11011828

PROTECTION CAP 11011831

=CRANE KING +OP206 -XP2 MIL-C5015_ KABELYLSD 11011829
PROTECTION CAP 11011832

D D

E E

F F
Drawn by Dwg. No.
Marigest S.r.l. Date 27.05.2015 Part list SP2582-1 733
SP2582-1 HLA: Sheet rev. Next sheet
1 Issued for Information 27.05.2015 AEI ENA Project rev. 1 1
Rev. Description Date Modified by Approved HMC 3293 LKO 250-30 AHC Loc: +OP206 1

1 2 3 4 5 6 7 8
 User Manual for Crane

5. Ordering Spare Parts

Direct all enquiries regarding service and spare parts to:

MacGregor Norway AS
Andøyfaret 15
N-4623 Kristiansand
NORWAY

Phone: +47 91 68 60 00
Fax: +47 38 01 87 01

krs.spareparts@MacGregor.com
krs.service@MacGregor.com

Or look up your nearest MacGregor Marine Service station:

www.MacGregor.com

Remember to refer to the actual equipment machine number for exact definition of components and service
advice.

IMPORTANT NOTICE:

During the warranty period, all necessary spare parts must be supplied by MacGregor. The use of spare parts
supplied by other suppliers violates and forfeits the warranty.

7 Component Parts List

MACGREGOR NORWAY AS 5
 User Manual for Crane

8 Drawings & Data Sheets

See User Manual volume 2.

8 Drawings & Data Sheets

MACGREGOR NORWAY AS 1
 User Manual for Crane

Blank page.

8 Drawings & Data Sheets

2 MACGREGOR NORWAY AS
 User Manual for Crane

9 Statements and Certificates

Table of Contents
1. Declaration of Conformity .................................................................................................................1
2. DNV Approval Letter ........................................................................................................................3
3. Hydraulic Motor ................................................................................................................................5
4. Hydraulic Pump................................................................................................................................7
5. Accumulator .....................................................................................................................................9
6. Main Winch Wire ............................................................................................................................11
7. Main Winch Hook ...........................................................................................................................13
8. Whip Winch Wire ...........................................................................................................................16
9. Whip Winch Hook ..........................................................................................................................18
10. Main & Knuckle Jib Cylinders .......................................................................................................20
11. Slew Bearing ................................................................................................................................22

9 Statements and Certificates

MACGREGOR NORWAY AS
 User Manual for Crane

Blank page.

9 Statements and Certificates

MACGREGOR NORWAY AS
 User Manual for Crane

1. Declaration of Conformity

9 Statements and Certificates

MACGREGOR NORWAY AS 1
 User Manual for Crane

Blank page.

9 Statements and Certificates

2 MACGREGOR NORWAY AS
 User Manual for Crane

2. DNV Approval Letter

9 Statements and Certificates

MACGREGOR NORWAY AS 3
 User Manual for Crane

Blank page.

9 Statements and Certificates

4 MACGREGOR NORWAY AS
 User Manual for Crane

3. Hydraulic Motor

9 Statements and Certificates

MACGREGOR NORWAY AS 5
 User Manual for Crane

Blank page.

9 Statements and Certificates

6 MACGREGOR NORWAY AS
 User Manual for Crane

4. Hydraulic Pump

9 Statements and Certificates

MACGREGOR NORWAY AS 7
 User Manual for Crane

Blank page.

9 Statements and Certificates

8 MACGREGOR NORWAY AS
 User Manual for Crane

5. Accumulator

9 Statements and Certificates

MACGREGOR NORWAY AS 9
 User Manual for Crane

Blank page.

9 Statements and Certificates

10 MACGREGOR NORWAY AS
 User Manual for Crane

6. Main Winch Wire

9 Statements and Certificates

MACGREGOR NORWAY AS 11
 User Manual for Crane

Blank page.

9 Statements and Certificates

12 MACGREGOR NORWAY AS
 User Manual for Crane

7. Main Winch Hook

9 Statements and Certificates

MACGREGOR NORWAY AS 13
 User Manual for Crane

Blank page.

9 Statements and Certificates

14 MACGREGOR NORWAY AS
 User Manual for Crane

Blank page.

9 Statements and Certificates

MACGREGOR NORWAY AS 15
 User Manual for Crane

8. Whip Winch Wire

9 Statements and Certificates

16 MACGREGOR NORWAY AS
 User Manual for Crane

Blank page.

9 Statements and Certificates

MACGREGOR NORWAY AS 17
 User Manual for Crane

9. Whip Winch Hook

9 Statements and Certificates

18 MACGREGOR NORWAY AS
 User Manual for Crane

Blank page.

9 Statements and Certificates

MACGREGOR NORWAY AS 19
 User Manual for Crane

10. Main & Knuckle Jib Cylinders

9 Statements and Certificates

20 MACGREGOR NORWAY AS
 User Manual for Crane

Blank page.

9 Statements and Certificates

MACGREGOR NORWAY AS 21
 User Manual for Crane

11. Slew Bearing

9 Statements and Certificates

22 MACGREGOR NORWAY AS
 User Manual for Crane

Blank page.

9 Statements and Certificates

MACGREGOR NORWAY AS 23
User Manual for Crane

10 Other

10 Other
MACGREGOR NORWAY AS 1
 User Manual for Crane

Blank page.

10 Other

2 MACGREGOR NORWAY AS