zxc ® 03-Nov-2012 16:51

MACGREGOR Deck crane GLBE3025-2/2425GR / INSTRUCTION MANUAL


Year: 2012
Language: english
Author: MacGregor
Genre: INSTRUCTION MANUAL
Publisher: MacGregor
Series: 2/10108.01RHM
Format: PDF
Quality: OCR without errors (SECURED)
Number of pages: 540
Description: This instruction manual covers the MacGREGOR Spare parts hydraulic deck crane. We hope that it will prove a General advice how to order spare parts; spare parts valuable companion to everyone concerned with the lists and illustrations, operation of the crane or otherwise in a responsible position.
Every manual belongs to a specific crane or piece of equipment. The identification can be found on the label on the manual’s back. The manual contains nine sections. The various sections cover the following subjects:
Main Contents:
1. General
2. Technical Description
3. Function
4. Operation
5. Maintenance
6. Service
6.0 How to Order Spare Parts
6.1 Hydraulic System
6.2 Mechanical Equipment
6.3 Electrical Equipment
7 Extra Equipment
9. Spare parts manual
9.0 How to Order Spare Parts
9.1 Machinery
9.2 Pump Unit, Oil Cooler
9.3 Mechanical Equipment
9.4 Hydraulic Components
9.5 Electric Components
9.7 Extra Equipment

General

General
The fundamental and foremost rule in all work with hydraulic systems and components is absolute cleanliness.
Many components, e.g. valves and pumps, have very narrow tolerances, therefore microscopic impurities, invisible to the human eye, may have disastrous effect on the function of a hydraulic system.
The hydraulic system installation contains a cleaner with a cartridge designed to stop impurities produced within the hydraulic system during operation. Every care must be taken to prevent external impurities from entering the system when servicing or repairing it.
This also applies for components that have been removed and or to be reinstalled. Sooner or later, a component that has been replaced will be inspected in a test equipment somewhere. It is important that the component stays in the same condition as it was when it was removed, as it may otherwise be impossible to decide the real cause of a malfunction. It may also be possible that a component sent in for inspection is not defective at all, and will be returned.
Rules when working on the hydraulic system
The following fast rules shall be observed during working on the hydraulic system:
1. Carry out a rough general clean-up.
2. Protect the area where work shall be done. Use a sheet of plastic material or similar.
3. Clean well with white spirit or a similar solvent. Remember that it is not enough to clean only the parts immediately concerned, but also their surroundings from where accumulated dirt may be transferred in to the repair area. Do not forget to clean the tools to be used.
Use a brush for cleaning, wipe off with a non-linting rag, repeat the cleaning if necessary. Finish by spraying the area of operations - hose connections etc. - with the solvent.
4. Mount protective covers immediately after removing a component, a pipe or a hose. Components, shall also be fitted with covers and plugs in order to prevent ingress of dirt.
These covers must be kept in clean and closed packages. After use, covers are to be cleaned in the workshop.
5. Observe minute cleanliness when handling all types of quick-release connectors. Spray both connectors with solvent before making up a connection. Clean all covers before reinstallation.
Storing and filling up of hydraulic oil
1. Store barrels, hoses and pump as clean as possible and best of all in a warm room. The oil viscosity will then be considerably lower, which make the filling through filter easier.
2. Barrels, hoses and pump must be carefully handled and cleaned when necessary.
3. Store barrels horizontally, so plugs (or cocks) are below the liquid level and impurities (e.g., damped air) does not penetrate the barrels.
4. Observe minute cleanliness when filling up oil -carelessness is one of the greatest sources when impurities penetrates the hydraulic system.
5. Fill up hydraulic oil. See separate instruction.
6. Never use the last drop in the barrel, as it often consists of water and other impurities dependent on how many times the barrel has been opened.
Hydraulic and Electric Symbols Hydraulische und elektrische Bildzeichen
This section covers a part of the symbols and port markings commonly used in MacGREGOR (SWE) AB, Service Division hydraulic and electric circuits, divided into three parts:
Diese Sammlung umfaftt einen Teil der allgemeinen Bild- und Anschluftzeichen, die in MacGREGOR (SWE) AB, Service Division, hydraulischen und elektrischen Schemas vorkommen, unterteilt in drei Gruppen:
1. Hydraulic symbols, basic. Hydraulische Bildzeichen, einfach.
2. Hydraulic symbols, composite. Hydraulische Bildzeichen, kombiniert.
3. Electric symbols.
Elektrische Schaltzeichen.

TABLE OF CONTENTS

No. of manuals 6 pcs:1 pcs CD rom
Certificate for BV
crane issued by:
Certificate for BV
foundation issued by:
IMO No. L9609677
Name of ship
Newbuilding No. H6107
Shipyard HMD
Owners WESTERN GROUP
Project No. 2/10108.01 RHM
Mfg. No. 62512724-Crane 1, 62512725-Crane 2, 62512726-Crane 3, 62512727-Crane 4
Type of crane GLBE3025-2/2425gr
Order specification 490 8998-801 - 804 /G
Mechanical spec. 490 8999-801 - 804 /B
Hydraulic spec. 490 9001-801 -804 /A
Electrical spec. 490 9000-801 - 804 /A
Slewing spec. 490 6432-801 /-
SAFETY DOCUMENTS
Document names written with bold letters are documents with safety aspects.
INSTRUCTION NO. REV NAME OF INSTRUCTION
GENERAL 1 1.000.6 E b SAFETY INSTRUCTIONS
1.005 E e PREFACE
1.009 E a GENERAL INSTRUCTIONS, CLEANLINESS IN HYDRAULIC SYSTEMS
1.102 E c CONVERSION FACTORS
1.518.3 ED d HYDRAULIC AND ELECTRIC SYMBOLS
TECHN. DESCRIP. 2 2/10108.01 RHM a TECHNICAL DATA
2.007.96 E a TECHNICAL DESCRIPTION
FUNCTION 3 3.110.127 E b ELECTRIC FUNCTION
3.110.132 E - HYDRAULIC BRAKE FUNCTION, ELECTRIC CRANE
3.142.41 E a CRANE CONTROL SYSTEM CC3000
3.155.6 E - THERMOSTATIC CONTROLLED VENTILATION FAN AND HEATER ELEMENTS
3.155.7 E a HEATING AND COOLING OF CABINETS IN ELECTRIC CRANES
OPERATION 4 PM40 1885-E00 a CREW CHECKLIST
PM40 5500-E00 b OPERATING INSTRUCTION
PM40 6494-E00 - OPERATION, START AND STOP
PM40 7546-E00 - CONTROLS AND INDICATORS
PM41 0001-E - EMERGENCY ESCAPE INSTRUCTIONS
PM41 0014-E00 a EMERGENCY ESCAPE INSTRUCTIONS, ROPE LADDER/FIXED LADDERS
4.620.31 E a PARKING THE CRANE, SEA STOWING, GENERAL INSTRUCTION
4.630 E - HANDLING HATCHES BY DECK CRANE
4.630.7 E . EMERGENCY OPERATION OF HATCH COVERS BY DECK CRANE
INSTRUCTION NO. REV NAME OF INSTRUCTION
MAINTENANCE 5 5.005.70 E MAINTENANCE CHART
5.018 E b INSPECTION OF STRESSED COMPONENTS AND STRUCTURES
PM51 1733-E00 d LUBRICATING CHART
5.250.1 E - SLEWING BEARING STUDS
5.302.37 E - BRAKE UNIT
5.315.3 E - SAMPLING OF OIL TO VERIFY THE CLEANLINESS IN HYDRAULIC SYSTEM
5.421.60 E a LUBRICANTS FOR DECK MACHINERY
SERVICE 6
6.0 6.000 E e HOWTO ORDER SPARE PARTS
6.000.1 E c STATEMENT REGARDING DELIVERY OF SPARE PARTS TO SWIVELS, LIFTING 1
6.000.2 E d RETURN FORM
6.004.1 E be WORLDWIDE SERVICE NETWORK
6.005.10 E - INTRODUCTION
6.1 6.100.11 E a MEASURES BEFORE STARTING, DURING & AFTER COMPLETED SERVICE/MAir
6.120.20 E - SLEWING GEAR
6.120.112 E b WINCHES, HOISTING/LUFFING
6.142.5 E a RECOMMENDATION FOR INSPECTION AND REPLACEMENT OF HYDRAULIC HC
6.189 E f HYDRAULIC PISTON ACCUMULATORS
6.2 6.214.1 E a TIGHTENING TORQUES, STUDS/SCREWS AND BOLTS
6.215.21 E b SERVICE DOOR (OPENING AND CLOSING), SERVICE AND LUBRICATION OF DC
6.216.116 E a ROPE REEVING FOR CRANE TYPE GLBE-2
6.222.1 E a HANDLING, INSTALLATION AND MAINTENANCE OF STEEL WIRE ROPES
6.223.26 E b REPLACEMENT OF WIRES, ONE OR TWO FALL RIGGING
625/1473 E c INDENTATION AND WEAR ON WIRE SHEAVES
625/1560 E f LIFTING BLOCK/BEAM
625/1579 E k MEASURING PROCEDURE FOR WEAR IN SLEWING BEARINGS FOR ROPE LUFI
625/1651 E - SLEWING BEARING GREASE SAMPLING PROCEDURE
6.3 6.303.61 E c CARD FRONT MENUS CT2, CC3000
6.303.66 E a TROUBLESHOOTING FOR CRANE CONTROL SYSTEM CC3000, ELECTRIC CRAI
6.303.67 E - ABSOLUTE ENCODER CALIBRATION, CC3000
424 0738 e SIGNAL OVERVIEW, CRANE CONTROL SYSTEM CC3000
424 0739 f ERROR MESSAGES, CRANE CONTROL SYSTEM CC3000
1000004064 B INSULATION TEST, ELCTRICAL CRANE
6.305.19 E - ELECTRICAL EQUIPMENT, GENERAL MAINTENANCE
6.306.7 E a INSTALLATION OF POWER SUPPLY CABLE AND CABLE FOR "GRAB...
6.307.11 E b SLIP-RING UNIT
6.311.14 E - OIL LEVEL TEMPERATURE SENSOR, BRAKE UNIT
6.320.386 E b LIMIT SWITCHES AND SOFTWARE LIMITS IN HOISTING AND LUFFING WINCH ..
6.321.18 E - SLACK WIRE SAFETY SWITCH, HOISTING AND LUFFING WINCHES
6.324.1 E b PREPARATION FOR OVERLOAD (OL) TEST MODE
6.324.2 E - PREPARATION FOR RIG MODE
6.990.61 E c EMERGENCY OPERATIONIN CASE OF COMPLETE POWER FAILURE, OPEFM
EXTRA EQUIPMENT 7 7.075.11 E - MacHEAVYVISOR RELEASE 3.3
7.076.2 E c USER MANUAL DISPLAY, CC PILOT XS
7.082.1 E - INSTALLATION OF MAINTENANCE PLATFORM ON FOUNDATION, (CUSTOMER I
APPENDICES 8
SPARE PARTS 9
SEE SEPARATE TABLE OF CONTENTS
_TABLE OF CONTENTS_
GROUP DESCRIPTION PART NUMBER FIG
HOWTO ORDER SPARE PARTS e 6.000 E
HOISTING WINCH 1212912 -/ 625-1450.212
LUFFING WINCH 1187739 B / 625-1450.184
WINCH MOUNTING SET 289 5365-801 -/ 625-2250.022
ASSEMBLY SET 1192483 -/ 625-1440.195
ASSEMBLY SET 1192647 A/ 625-1440.196
ASSEMBLY SET 1192648 -/ 625-3254.029
DRIVE IN, COMPLETE 875 13004-157 -/ 625-3256.016
SLEWING GEAR ASSEMBLY SET 391 0246-801 D / 625-3254.023B
SLEWING GEAR 1189838 -/ 625-3255.040
BRAKE PUMP UNIT 1219768 A/ 625-4935.245A
CRANE HOUSE ASSEMBLY 1219977 Cl 625-6102.580
SLEWING SPECIFICATION 490 6432-801 M 625-6122.029A
SLEWING BEARING MOUNTING 391 0032-801 M 625-6123.003
SLEWING BEARING YARD MOUNTING 391 0033-801 B / 625-6124.003
COVER MOUNTING 390 3274-801 -/ 625-6169.005A
COVER ASSEMBLY 390 3282-801 -/ 625-6169.006
JIB BEARING HOUSING 1184754 -/ 625-6170.082
JIB BEARING ASSEMBLY 1191812 -/ 625-6170.085
JIB TOP MOUNTING 1195433 -/ 625-6244.077
LIMIT SWITCHES BOX 289 5323-801 -/ 625-6245.635B
LIMIT SWITCHES BOX 289 5449-801 -/ 625-6245.643
LIMIT SWITCHES BOX, MOUNT. 489 6415-801 Cl 625-6248.001 B
SLACK WIRE DEVICE 289 3396-801 B / 625-6250.023
CRANE JIB, YARD MOUNTING 489 5409-801 Cl 625-6275.004C
MOUNTING WIRE LOCK JIB TOP 390 3374-801 -/ 625-6404.001
MOUNT. WIRELOCK JIB TOP 1184729 -/ 625-6404.003
LOAD CELL ASSEMBLY 1223123 -/ 625-6404.004
CRANE JIB MOUNTING 1195432 -/ 625-6408.120
CRANE TOP MOUNTING 1195405 -/ 625-6459.074
PROTECTIVE PLATE MOUNT. 390 7581-801 -/ 625-6459.051
INCLINOMETER, C 388 0176-801 B/ 625-6509A
CABIN ASSEMBLY CRANE HOUSE 1189584 -/ 625-6540.042
CABIN ASSEMBLY 1189585 -/ 625-6545.072
EMERGENCY DOOR ASSY 390 4053-801 A/ 625-6546.001
CAB DOOR ASSEMBLY 390 8573-801 A/ 625-6546.008
CAB CUPOLA ASSEMBLY 289 2251-801 A/ 625-6560.007A
WINDSCREEN CLEANER 387 6227-802 F/ 625-6561.001C
VENTILATION FAN 390 2115-801 B/ 625-6625.014A
VENTILATION FAN ASSEMBLY 1192902 -/ 625-6625.027
LIFTING BLOCK 1205161 -/ 625-7013.126
LOAD WIRE ROPE: SEE TECH. DATA 1221289 -/ -
LUFF. WIRE ROPE: SEE TECH. DATA 1188175 -/ -
VALVE UNIT 1204092 A/ 625-7207.018
DIRECTIONAL VALVE 1204093 -/ 625-7322.082
TABLE OF CONTENTS
GROUP DESCRIPTION PART NUMBER FIG
9.4 PRESSURE SWITCH, C 387 7053-803 U 625-7444
ACCUMULATOR 1219345 -/ 625-7951.007
HYDRAULIC HOSES 625-7970G
TUBING BRAKE 1219586 A/ 625-7994.004
HYDRAULIC SYSTEM SPECIFICATION 1226154 -/ 1000019019
9.5 DRIVERS DESK 1189978 A/ 625-8563.069
EL. INST. CRANE HOUSE 1212847 A/ 625-8564.023
EL. INST. JIB LIGHT, CRANE 124 0647-801 A/ 625-8567.045A
EL. INST. JIB LIGHT (PACKING) 124 0648-801 B / 625-8567.046C
CONTROLLER, C 314 2721-802 Cl 625-8595
CONTROLLER, LUFFING/SLEWING 314 2006-802 D / 625-8592C
CONTROLLER 414 6792-801 A/ 625-8596
CONTROL PANEL 1189898 -/ 625-8597.057
EL. INST. JIB LIGHT (CABIN) 324 2043-801 A/ 625-8597.061
EL. INST. DECK LIGHT (CABIN) 324 1722-801 A/ 625-8597.062
EL. INST. FORCE LIMIT GRAB (CA 324 1724-801 A/ 625-8597.063
EL. INST. VENTILATION FAN (CAB) 324 2098-801 B / 625-8597.069
EL. INST. AIR CIRCULAT FAN (CAB) 324 1848-801 A/ 625-8597.074
CABIN DISPLAY ASSEMBLY 1182879 -/ 625-8597.081
ELECTRICAL CABINET CT1/CT2 1213177 -/ 625-8598.140
EL. CABINET (CT10) 1213017 -/ 625-8598.141
ELECTRICAL CABINET (CT13) 1213018 -/ 625-8598.142
EL. CABINET (CT14) 1189233 Cl 625-8598.110A
RELAY CARD WITH LED'S 324 0089-801 M 625-8599.020
CABINET CONTROL 1196427 M 625-8600.020
ELECTRIC MOTOR 1188770 M 625-8635.007
ELECTRIC MOTOR 1188769 M 625-8635.008
ELECTRIC MOTOR 1188771 M 625-8635.011
EL. INST. IMPULSE RELAY 224 0116-801 M 625-8650.001
EL. INST. FORCE LIMIT GRAB CT1 224 0547-801 M 625-8650.005
EL. INST. POWER SUPPLY (CT1) 224 0506-801 M 625-8650.010
CABIN DISPLAY 424 0715-801 Cl 625-8655.001
SLIPRING DEVICE 1192979 -/ 625-8750.023
POWER / CABLE CONNECTION 1000007286 -/ 1000007286
ELECTRICAL SYSTEM SPEC. 1212845 -ID 1000011517
MC-SPARE CARD 1194171 B / -
CC-SPARE CARD 1194172 B/ -
9.7 MOUNTING ENCODER 390 9851-801 A/ 624-2180.014
MOUNTING ENCODER 390 9852-801 A/ 624-2180.015
ENCODER ASSEMBLY 1191997 -/ 624-2180.018
ABSOLUTE SINGLETURN ENCODER 324 1408-801 A/ 624-2180.023
INCREMENTAL ENCODER 5000 324 1409-801 A/ 624-2180.025
ELECTRICAL PEDESTAL ASSEMBLY 1196430 D/ 624-2196.001
JUNCTION BOX, X71A 1196543 A/ 624-2196.002
JUNCTION BOX, X71B 1196773 B/ 624-2196.003A
CABINET ADD. COMPONENTS 1201179 -/ 624-2196.005
PEDESTAL PUSHBUTTON 1202077 A/ 624-2196.015
HAND PUMP 189 6211-801 Cl 624-2498
_TABLE OF CONTENTS_
GROUP DESCRIPTION PART NUMBER FIG
9.7 FIRE EXTINGUISHER, MOUNT CABIN DISPLAY ASSEMBLY LIFE LINE
490 4074-801 A/
1182916 -/A
388 0962-801 -/
624-2524A
GENERAL 1.000.6 E rev.:b 2011-12-07

Improper Use

1. Elevation of persons.
2. Exposing persons to the risks of falling cargo.
3. Overloading.
4. Unlocking the crane or crane jib or operating the equipment at sea without full acceptance and control of personnel and equipment safety.
5. Unprofessional, intended or unintended, adjustment of safety locks, hydraulic or electric adjustments.
6. Disregard of occupational and safety standards of work.
Functions, Installations and Equipment
General
The MacGregor crane has built-in safety functions and installations to allow for safe normal use, operation, care, and control. This is applicable to instructed personnel without specific professional education or certification, but working according to this manual.
Specific service and repair of the electrical, hydraulic and the mechanical functions, controls and adjustments require professional service personnel knowledgeable of risks involved.
Regular Care and Control (Maintenance)
This manual contains checklists for regular care and control of crane equipment, wire ropes and hydraulic filters. These checklists routine contain inspections and maintenance regularly prescribed for safe function, e.g.:
Chapter 4 contains:
Safety Precautions Checklist for Single and Twin Cranes.
Chapter 5 contains, if applicable:
Inspection of Stressed Components and Structures. Electrical chart,Crane.
Lubrication chart; Crane.
Lubrication chart; Cable Winch and Stabilizing Equipment.
Lubrication chart; Power Swivel.
Filters.
Before maintenance and service work is started, cer-
tain measures and procedures must be obeyed. Chapter 6 contains:
Measures before Starting Service/Maintenance Work. Handling, Installation and Maintenance of Steel Wire Ropes.
Examine the brake adjustments. (Valid for winches which have electric motors.)
Electric Motors, Electrical Equipment, General Maintenance.
Safety Functions and Equipment
Specific safety equipment is installed and delivered with this crane and must be available for its intended use. The owner/operator of the ship and its equipment is responsible to make that safety functions, installations and equipment are maintained to operational standards and are not being removed, by-passed or worn to non-working condition.
This manual features important presentations of safety functions, installations and equipment. A summary is presented below.
1. Safety Functions
a. Manoeuvring functions:
1. All the crane’s working functions are stopped and the brakes will automatically operate when the emergency stop button is pressed. The button is loacated in cabin. This action operates the safety stops and automatic lock positions.
2. The crane has several fail-safe functions to overrule or stop the operator’s manoeuvring in the event that the normal electrical or hydraulic functions fail, a sudden uncontrolled movement occurs or during uncontrolled speed operation (see below).
3. There are limits for hoisting/lowering and luffing outreaches, which are controlled by software limits which monitors the encoders' position in the limit switch box.
4. AutoLaodstep, stop limits and speed reduce for load-dependent outreach are controlled by the software.
5. Safety cams are mechanical stop limits for hoisting, full/empty drum and luffing min/max
GENERAL 1.000.6 E rev.:b 2011-12-07
outreaches, if there is a failure in the software.
6. A check cam in the centre of the working range of hoisting/lowering motion and luffing outreaches, are used to verify the function of the encoders' position.
b. Hydraulic functions:
1. Hydraulic valve functions are adjusted for exact pressure. Any change in the adjustments adversely affects the crane operation and must exclusively be adjusted by MacGregor supervisor (see instructions Hydraulic function).
2. In case of a ruptured control pressure the oil pipe/hose or other control pressure drops, the oil control pressure will collapse. If the control pressure decreases the pump automatically starts and the control pressure increases.
3. Each winch has an electric motor flanged to the drive in complete. The hydraulic operated multi-disc brakes provide braking of the winch. The winches have one brake each.
4. An electric motor is flanged to each slewing gear and provides hydraulic operated multi-disc brake of the slewing gears. The slewing gears have one brake each.
5. If there is a multi-disc brake failure of the parking brake, caused by worn out brake discs, sticking cylinder, brake pilot valve or valve spool, the function of regenerative braking through the electric motor by the winches and slewing gears is still available. Push the Start/Stop pushbutton position "0" and the system awaits the activating of the brakes and the crane then stops.
6. In case of overheating oil in the hydraulic system, or oil level drops below the minimum permissible level the crane stops and the multi-disc brakes are applied.
7. Efficient oil filters with exclusive bypass to the hydraulic oil tank protect the system from harmful oil conditions. Dirty filter might cause malfunction to the system.
c. Electrical functions:
1. The crane control system CC3000, adjusts the crane outreach to suit each load. The load is weighed by a loadcell and the outreach is measured using an angle encoder. CC3000
receives information about the torque of the electric motor from each frequency converter and is used to measure whether the value of the loadcell is correct. See also "Crane Control System CC3000" in section 3 .
2. During a complete power failure all solenoid valves are de-energized and all multi-disc brakes will be applied.
3. The electronic cabinets have power failure indicators. This function closes the electronic signals down which automatically applies all multi-disc brakes.
4. The heat sensors in the electric motors stop the operation that is working, i.e. luffing, hoisting or slewing, and apply all multi-disc brakes.
If the electric motor is about to overheat temperature switch (klixon) ramps down each movement, luffing, hoisting or slewing operation, of the crane and stops the crane.
5. The overcurrent protections on each electric motor prevent the electric motors from overloading.
Each electric motor is overcurrent protected and stops the crane operation and applies the brakes.
6. A separate electrical feed for the crane house lights, operator’s cabin and on jib, maintains function of lights even during feed disruption to the crane operating functions. As there is not a separate emergency illuminating system for the crane (this is dependent on the ship’s systems) the owner of the crane must provide a battery type flash-light for the operator’s cabin.
d. Mechanical functions:
1. Automatic sensors recognize dangerous wire slacks and stop hoisting and luffing movements that threaten safe control and the equipment itself.
GENERAL 1.000.6 E rev.:b 2011-12-07
2. Each working circuit has two independent brake systems.
Dynamic braking, deceleration, is achieved by
the regenerative function of the electric motor. True static braking (parking brakes) is provided by multiple-disc brakes.
The mechanical brakes are automatically operated in the event of dangerous oil pressure. High speed winches are provided with multiple-disc brakes. One for each drive in complete on the hoisting/luffing winch.
Each slewing gear unit has one multiple-disc brake.
2. Safety Installations
a. Warning lights, measuring instruments and me-
ters:
1. The operator’s panel has a warning light which indicates "Low oil level" in the oil tank for the brake unit.
2. During crane start-up a warning light on the operator’s panel indicates that the starting procedures are still running and that the working conditions are not acceptable before the lamp goes off. Manoeuvres are not to be ordered before the warning light goes off.
3. A pushbutton siren is found in the crane operator’s cabinet, with which the operator can tell persons in the working area (e.g. against prohibited riding on the load or against load movements).
4. Measuring instruments and meters (e.g. to examine the crane functions, adjustment of valve positions and functional positions) are supplied as per agreement with the crane buyer/owner. Tools and equipment which are eliminated from the original order to MacGregor are delivered at the discretion of the owner.
b. Covers and houses:
1. Unauthorized visitors in the crane house, especially during crane operation, is prohibited. The crane is a dangerous working area and requires special permission to enter. Instructions given by the superintendent or responsible officer must be obeyed.
2. Covers for electric boxes must be opened only by authorized personnel.
c. Alert and warning signs:
The crane has a system of danger, warning, caution, and notice signs. These signs are presented on pages 6-15.
3. Safety Equipment
a. Locks, seals and keys:
1. Functions and equipment that are essential for oil pressure adjustments, coordination of controls and crane movements or expose dangerous high-voltage electricity are locked. All keys to locked positions and switches must be kept and controlled by the responsible officer onboard and are only to be used by approved personnel.
2. Safety valves for hydraulic pressure adjustments and switches for electric safety circuits are sealed to secure correct position and trim. Sealed equipment may be opened and positions changed only after consulting the MacGregor service organization for proper handling.
b. Safety belt, rescue line, safety chains:
1. For maintenance, service or entry to the open-air outside the crane house, personnel must wear a safety belt. The connector hook should be anchored to rails and fixed position while staying or working on the crane top.
2. The rescue line and equipment for emergency evacuation of the crane operator must always be easily accessible on the interior wall-side of the crane cabin. The equipment status and completeness must be inspected regularly by the responsible officer onboard.
3. The safety chains on the open-air crane top and work platforms inside the crane, must be used for attendant’s safety during stay and work.
c. Fire-fighting equipment:
A fire extinguisher shall be made available by the owner in the operator’s cabin.
The fire extinguisher is for emergency use inside the crane.
The equipment must be regularly inspected for
GENERAL
proper pressure reading at the meter and must be serviced annually. This is to be supervised by the responsible officer onboard.
d. Test device:
At delivery, the MacGregor crane has two pressure gauges.
Danger, Warning, Caution and Notice Signs
Principles of Risk Classification
1. DANGER SIGNS are attached to equipment or are related to operations that will expose personnel to a life-threatening danger (e.g. high-voltage electricity).
Safety installations, covers or houses prevent exposure during normal working conditions, but cannot eliminate the imminent risk for any unprofessional/ non-certificated person, should the danger sign not be obeyed.
Those risks classified as DANGER sign are presented and explained below.
2. WARNING SIGNS are attached to equipment or are related to operations that will expose personnel to severe risk of physical injury. The injury is not expected to be life-threatening. A warning sign is also used to warn against misuse that risks severe equipment and property damage.
The danger does not exist unless protection installations or devices are removed and if the procedures are obeyed.
3. CAUTION SIGNS are attached to equipment or related to operations that may produce a physical risk to any person who is not cautious or aware of the risk.
Any person should be able to avoid the danger.
4. NOTICE SIGNS are attached to equipment and provide references to procedures and instructions
1.000.6 E rev.: b 2011-12-07
or policies to obey to avoid danger to the function and operation of the equipment or damage to the equipment itself.
Responsible officers onboard must make sure that the signs are in good condition and readable to any person admitted to the crane area.
Replacement signs must refer to international and national standards. Signs of non-MacGregor design are not allowed. MacGregor does not accept responsibility for unauthorized signs.
Specific Presentation of Signs and their Message
All signs attached to the crane are illustrated on the following pages. Each sign is given a specific number to which it is referred.
GENERAL
1.000.6 E rev.: b 2011-12-07
Alert / Warning signs
All signs used in MacGregor cargo handling cranes are presented below. Each sign in your specific crane has a number on it, which can be found in the list and in the illustrations below.
PM40 7101-E00 REPORT TO SUPERINTENDENT OR OPERATOR’S ROOM FOR PERMIT TO ENTER
Any visitor to the crane must obtain a special permit from responsible officer onboard.
For authorized entry during crane operation, the operator must be fully knowledge¬
able of safety precautions. The foundation, platform and crane are a dangerous working
environment and requiers that the authorized visitor understands relevant safety.
NOTICE SIGN This sign is at the bottom entrance to the crane foundation.
PM40 7102-E00 DO NOT ENTER DURING CRANE OPERATION - MOVING CRANE HOUSE AND MACHINE
PARTS ...
Authorized entry requires that visitor is aware of the character of general risk and that visitor has ad¬
equate manual information about how to avoid the exposure.
WARNING SIGN This sign is at the bottom entrance to the crane foundation.
PM40 7103-E00 HIGH NOISE LEVEL - USE EAR PROTECTION!
Motors and winches produce a noise level that is harmful to personnel
after lengthy exposure. To eliminate the risk, adequate ear protection is required.
CAUTION SIGN This sign is at the bottom entrance to the crane foundation.
PM40 7104-E00 LADDER WILL ROTATE WITH CRANE - WATCH OUT!
This is specifically warn of exposure of the ladder leading up to the crane house. Upon crane
rotation, this ladder rotates and moves suddenly without warning.
WARNING SIGN This sign is at the bottom entrance to the crane (twin) platform.
PM40 7105-E00 RISK OF GETTING CAUGHT BETWEEN WIRE AND DRUM - WATCH OUT!
At start of and during winch operation there is a riskof getting caught and jammed by moving wire. A safe
distance from wire and drums must be maintained and adequate caution must be regarded.
WARNING SIGN Attached to the crane wall surfaces close to winches.
PM40 7106-E00 RISK OF GETTING CAUGHT BETWEEN DRUM AND BRACKET - WATCH OUT!
This sign warns the visitor about the risk of getting jammed during drum rotation.
Adequate caution must be regarded.
WARNING SIGN Attached to brackets and walls of work platforms inside crane
GENERAL
1.000.6 E rev.: b 2011-12-07
PM40 7108-E00 RISK OF GETTING CAUGHT BETWEEN WIRES DURING CRANE OPERATION -
WATCH OUT!
This sign warns about the risk of moving wires that may catch and jam personnel.
The authorized visitor must be aware of the risk and be cautious to avoid being seriously hurt.
WARNING SIGN This sign is attached to the steel bracket side at the open-air crane top entry.
PM40 7109-E00 RISK OF FALLING DOWN - USE SAFETY BELT!
During any visit to the crane top (e.g. for service jobs), the authorizing officer and the person
entering to the area must fully understand the risks involved.
The safety belt must be worn during any visit to the crane top.
WARNING SIGN This sign is attached to the steel bracket side at the open-air crane top entry.
PM40 7111-E00 ROTATING FAN - KEEP HANDS OFF!
CAUTION SIGN The rotating fans are protected by grids and the risk is for anyone who sticks fingers or hand
inside. This can be avoided by sign information.
Allauhed lo lari houses ori lire open-air crane lop arid lo wall surlaues near lire lop rool ol lire
crane.
PM40 7112-E00 RIDING ON CARGO FORBIDDEN
For the attention of the crane operator, to observe that the crane is a Cargo Handling device.
The crane operator is obliged to stop operation and to alert any person riding to keep off.
The operator’s alarm bell, in the crane operator’s cabin, may be used, preferably.
DANGER SIGN Attached on the wall side of the crane operator’s cabin.
PM40 7114-E00 DANGEROUS OIL PRESSURE - BE CAREFUL!
The oil pressure inside oil pressure pipes is 25- 100 bar.
Under normal working conditions, this exposes no risk for personnel because of rigorous pipe
quality control and dimensions and specifications applied to the equipment. For specific ser¬
vice work, exchange of parts or equipment, the exposure may be dangerous for unqualified or
uninformed personnel.
Instructions for service must be followed and must be restricted to qualified personnel only.
WARNING SIGN Attached to surfaces close to pipes inside the crane house.
PM40 7115-E00 SLIPPERY SURFACES - WATCH OUT!
Also under normal working conditions, all walking surfaces are slippery from dirt, oil spill, etc. The re¬
sponsible officers onboard must have the crane ladders and work platform surfaces cleaned regularly.
Any person who is admitted to the area must be aware of the risk of slippery surfaces.
WARNING SIGN This sign is attached generally to the walls of work platforms.
GENERAL
1.000.6 E rev.: b 2011-12-07
PM40 7117-E00 HIGH VOLTAGE INSIDE - DO NOT OPEN! AUTHORIZED PERSONNEL ONLY
High voltage equipment, couplings and boxes are covered and do not expose risk unless co¬
vers or hoses are removed. Access is restricted to qualified and authorized personnel only.
DANGER SIGN Attached to electrical equipment and boxes where 110 V or 440 V is exposed after covers are
removed.
PM40 7118-E00 RISK OF FALLING DOWN - APPLY SAFETY CHAIN!
During any visit to the work platforms, the authorizing officer and the person entering the area
must fully understand the risks involved.
The safety chains (at work platforms) must be used to prevent personnel from falling.
WARNING SIGN Attached to the steel bracket side at the open-air crane top platform, and at the crane
work platforms inside the crane house.
PM40 7119-E00 HIGH VOLTAGE INSIDE - DO NOT OPEN BEFORE MAIN SWITCH (Q1) IS SWITCHED OFF!
AUTHORIZED PERSONNEL ONLY
High voltage equipment, couplings and boxes are covered and do not expose risk unless co¬
vers or hoses are removed. Access is restricted to qualified and authorized personnel only.
DANGER SIGN Attached to electrical equipment e. g. electric main motor.
PM40 7122-E00 RISK OF BODILY INJURY - SUSPENDED LOAD - WATCH OUT!
The crane operator must ensure that the suspended load does not expose personnel below to
risks of falling material.
The crane operator must stop operation and alert personnel.
The operator’s alarm bell in the crane operator’s cabin is preferably used.
DANGER SIGN Applied on the wall side of the crane operator’s cabin.
PM40 7123-E00 RISK OF GETTING CAUGHT BETWEEN WIRE AND WIRE SHEAVES - WATCH OUT!
This sign warns of the risk of moving wires that may catch and jam personnel.
The authorized visitor must be aware of the risk and be cautious to avoid being seriously hurt.
WARNING SIGN This sign is attached to the steel bracket side of the open-air crane top entry.
PM40 7124-E00 RISK OF BODILY INJURY. EMERGENCY OPERATION, AUTHORIZED PERSONNEL ONLY
OPERATE WITH UTMOST CARE, SEE INSTRUCTION
Emergency operation of luffing and slewing, in the event of complete power failure or main
pump unit failure, is extremely difficult and dangerous.
This operation must be undertaken with great care and only
by skilled personnel. Instructions must be observed at all times.
DANGER SIGN Attached to the wall side of the crane operator’s cabin.
GENERAL
1.000.6 E rev.: b 2011-12-07
PM40 7125-E00 DANGER - KEEP OUT OF WORKING AREA!
The working area of the crane, over deck as well as over the deck-sides, is dangerous for
personnel, equipment or property. Items lifted or articles dropped may cause death, injury or
severe damage.
The crane operator must stop operation and alert personnel.
The operator’s alarm bell must also be used for attention.
DANGER SIGN Attached on both sides of the crane jib.
PM40 7129-E00 STARTS AUTOMATICALLY WITHOUT NOTICE AT +25°C (+80°F)
Under normal working conditions, of risk is not exposed to any person near of fans. During
service or upon removal of covers, the risk must be recognized. Such operation is restricted to
qualified personnel only.
NOTICE SIGN Attached to cooling fans, at the open-air crane top, and at the inside top roof.
PM40 7130-E00 DANGEROUS OIL PRESSURE. BE CAREFUL!
The oil pressure inside oil pressure pipes is 25- 100 bar.
Under normal working conditions, this exposes no risk for personnel because of rigorous pipe
quality control and dimensions and specifications applied to the equipment. For specific ser¬
vice work, exchange of parts or equipment, the exposure may be dangerous for unqualified or
uninformed personnel.
Instructions for service must be followed and must be restricted to qualified personnel only.
WARNING SIGN Attached to surfaces close to pipes inside the crane house.
PM40 7131-E00 RISK OF GETTING CAUGHT BETWEEN DRUM AND BRACKET - WATCH OUT!
This sign warns the visitor about the risk of getting jammed when the drum is rotating.
Adequate caution must be exercised.
WARNING SIGN Attached to brackets and walls of work platforms inside the crane.
PM40 7132-E00 HOT OIL AND SURFACES - WATCH OUT!
Surfaces of equipment in which there is hot oil can be extremely hot when
the crane is in operation. When service personnel are working on such equip¬
ment (e.g. checking and setting valves) they must be aware of the danger.
NOTICE SIGN Attached to surfaces inside the crane housing, close to pumps, valves, pipes, and manifold
blocks. Also in the foundation, close to oil tank and pipes.
PM40 7134-E00 RISK OF GETTING CAUGHT BETWEEN WIRE AND DRUM. WATCH OUT!
When the winch is started and during operation, there is a risk of getting caught and
jammed by moving wire. A safe distance from wires and drums must be maintained and adequate
caution must be exercised.
WARNING SIGN Attached to the crane wall surfaces close to winches.
GENERAL
1.000.6 E rev.: b 2011-12-07
PM40 7135-E00 RISK OF GETTING CAUGHT BETWEEN DRUM AND BRACKET - WATCH OUT!
This sign warns the visitor about the risk of getting jammed when the drum is rotating.
Adequate caution must be exercised.
WARNING SIGN Attached to brackets and walls of work platforms inside the crane.
PM40 7136-E00 RISK OF GETTING CAUGHT BETWEEN WIRES DURING CRANE OPERATION - WATCH
OUT!
This sign warns about the risk of moving wires, that may catch and jam personnel.
Authorized visitors must be aware of the risk and be very cautious to avoid serious injury.
WARNING SIGN This sign is attached to the steel bracket at the open-air crane top entry.
PM40 7140-E00 HIGH VOLTAGE, SEPARATE FEED, EVEN WHEN MAIN SWITCH (Q1) IS SWITCHED OFF.
AUTHORIZED PERSONNEL ONLY.
High voltage equipment, couplings and boxes are covered and do not expose risk unless covers
or hoses are removed.
Boxes with this sign are powered even if main switch has shut off other electrical power. Access
is restricted to qualified and authorized personnel only.
DANGER SIGN Attached to electric cabinet CT1.
PM40 7142-E00 HIGH VOLTAGE INSIDE. DO NOT OPEN! AUTHORIZED PERSONNEL ONLY
This high-voltage equipment is covered and does not expose risk unless cover is removed.
The electrical equipment inside cover is powered even if the main switch has shut off other
electrical supply.
Access is restricted to qualified and authorized personnel only.
DANGER SIGN Attached to the cover of slipring device in the foundation.
PM40 7143-E00 DO NOT DISCONNECT MPC-CARDS BEFORE MAIN SWITCH Q1 IS SWITCHED OFF IN
ELECTRIC CABINET (CT1)
NOTICE SIGN Attached on the door inside the cabinet CT2.
PM40 7147-E00 STARTS AUTOMATICALLY WITHOUT NOTICE
Under normal working conditions, of risk is not exposed to any person near of fans. During
service or upon removal of covers, the risk must be recognized. Such operation is restricted to
qualified personnel only.
NOTICE SIGN Attached on the electric motor fan protection.
PM40 7148-E00 700V DC INSIDE. VOLTAGE REMAINS FOR 5 MINUTES AFTER ALL POWER IS
SWITCHED OFF. AUTHORIZED PERSONNEL ONLY
DANGER SIGN Attached on line units or where there is voltage after all power is switched off.
GENERAL
1.000.6 E rev.: b 2011-12-07
PM40 7150-E00 HIGH VOLTAGE INSIDE EVEN IF BOTH MAIN SWITCHES (01) ARE OFF. AUTHORIZED
DANGER SIGN PERSONNEL ONLY
Attached on connection box of luffing motors M31 and M32.<
1226128 INSULATION TEST (MEGGER TEST) CAN CAUSE SERIUOS DAMAGE ON ELECTRICAL
CAUTION SIGN EQUIPMENT. SEE INSTRUCTION "INSULATION TEST, ELECTRICAL CRANE".
Attached on the door outside the electrical cabinets
GENERAL
1.000.6 E rev.: b 2011-12-07
NOTICE
REPORT TO SUPERINTENDENT OR OPERATOR'S ROOM FOR s PERMIT TO ENTER
Fig. 1. PM40 7101-E00
A WARNING
DO NOT ENTER DURING CRANE OPERATION
MOVING CRANE HOUSE AND MACHINE PARTS MAY SUDDENLY CAUSE BODILY INJURY OR DEATH
BEFORE ENTERING THE CRANE g HOUSE REPORTTO OPERATOR S TO STOP ALL ACTIVITIES
Fig. 2. PM40 7102-E00
A WARNING
LADDER WILL ROTATE WITH CRANE
f WATCH OUT!
Fig. 4. PM40 7104-E00
^WARNING
RfSK OF GETTING CAUGHT BETWEEN WIRE AND DRUM
I WATCH OUT!
Fig. 5. PM40 7105-E00
A WARNING
RISK OF GETTING CAUGHT BETWEEN DRUM AND s BRACKET
1 WATCH OUT!
Fig. 6. PM40 7106-E00
Fig. 3. PM40 7103-E00
AWARNING
RISK OF GETTING CAUGHT BETWEEN WIRES DURING CRANE OPERATION
WATCH OUT!
Rating: 4.8 / 5 (Votes: 52)
Reply
vietmx06 31-Jul-2014 10:56
Deck crane GLBE3025-2/2425GR - MacGregor / INSTRUCTION MANUAL [2012, PDF]
Thank you very much for your share
0
Reply
job castillo 03-Dec-2014 02:30
Problem :the crane cannot start because the feedpump is no pressure
0
Reply
Guest 27-Apr-2015 05:00
Is any body know, why at the hydraulic crane Mac Gregor GP 100-0514-2 do not work luffing jib limit switch? The pushing limit switch does not solve the problem. Te oil to the limit switch does not come.Only if I press the luffing limit in the same line, oil come to the luffing limit switch.
0
Reply
GOOGLE BOT 27-Apr-2015 05:00
 
Guest 27-Apr-2015 05:04
Sorry, mistake:
Only if I press the SLEWING limit in the same line, oil come to the luffing limit switch.
0
Reply
Guest 20-Jan-2016 16:54
is any body know, why hoisting or slewing travel with gab cargo suddenly stop the motor with no indication of error from the mc card of hoisting and slewing.
0
Reply

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