MacGregor GL 4524/4028-2S Crane Instruction Service and Parts Manual

Description

File Details

• Manual Type: Instruction, Service and Parts Manual
• Brand: MacGREGOR / MacGREGOR-HÄGGLUNDS
• Model: GL 4524/4028-2S Hydraulic Deck Crane
• Project No.: 230.4107-2
• Manufacturing No.: 62503432 (Crane No. 1), 62503433 (Crane No. 2), 62503434 (Crane No. 3)
• Vessel: LISSY SCHULTE — Newbuilding No. NB 170/1/3
• Shipyard: Stettin
• Language: English
• Format: PDF
• Date: 2007-06-05
• Manual No.: 9012 – 9014

Chapters Covered

The MacGregor GL 4524/4028-2S instruction service and parts manual is organised into nine major sections, each addressing a critical area of crane ownership and maintenance.

• General — Preface, safety documents, general instructions with cleanliness rules for hydraulic systems, conversion factors, and a comprehensive library of hydraulic and electric symbols used throughout the manual.
• Technical Description — Technical data for the GL 4524/4028-2S, including capacities, speeds, lifting heights, wire rope specifications, electrical data, gearbox data, and hydraulic circuit data for hoisting, luffing and slewing.
• Function — Hydraulic function description covering the feed and control circuits, hoisting winch circuit, luffing winch circuit and slewing circuit. Also includes starting/stopping sequences, safety functions for single cranes, and the complete crane control system description.
• Operation — Crew checklist before taking the crane into operation, load indication, operating instructions for start-stop and handling dangerous cargo, emergency escape instructions using the rescue harness, parking and sea stowing procedures, and handling hatches by deck crane.
• Maintenance — Maintenance chart with daily, 200-hour, 500-hour, 1000-hour, 2000-hour and four-yearly intervals. Inspection of stressed components and structures, lubricating chart, filters, hydraulic oil tank, oil sampling procedures and lubricant specifications for deck machinery.
• Service — How to order spare parts, global service contacts, measures before and during service work, troubleshooting charts for overheating, pumps and hydraulic motors. Detailed service instructions for the slewing gearset, hydraulic motors series 63, 64 and 84, feed pump unit, high pressure pumps, hydraulic piston accumulators, brakes, tightening torques, rope reeving diagrams, handling and checking steel wire ropes, replacement of wires, electronic troubleshooting, emergency operation boards, electrical equipment maintenance, slip-ring unit, oil level float switch, limit switches, slack wire safety switch, and emergency brake release procedures.
• Extra Equipment — Additional equipment fitted at customer request.
• Appendices — Supplementary information not covered in other sections.
• Spare Parts — Comprehensive parts listings with exploded-view illustrations for the hoisting winch, luffing winch, slewing gear, hydraulic motors, brake assemblies, brake cylinders, parking lock, pump unit, feed pump unit, oil cooler, tandem assembly kit, oil tank, mechanical equipment, slewing rim mount, slack wire switches, limit switches, crane jib with bearing, inclinometer, cab, lifting equipment, wire ropes, hydraulic circuit diagram components, hydraulic hoses, electrical block and circuit diagrams, component lists, control panels, controllers, cubicles, slipring unit, deck lights, fire extinguisher, anti-dazzling screen, rescue equipment, hand pump, warning lights and fault indicator.

This MacGregor GL 4524/4028-2S crane instruction service and parts manual is the complete factory documentation set for the hydraulic deck crane installation aboard the LISSY SCHULTE. It brings together the operating procedures, technical specifications, maintenance schedules, troubleshooting guides, hydraulic and electrical schematics, and the full spare parts catalogue with exploded views — all in a single indexed PDF. Whether you are operating the crane, performing routine maintenance, diagnosing a hydraulic fault, replacing a wire rope, adjusting brakes, or ordering a replacement hydraulic motor, this manual provides the procedures and data required. The parts section alone covers every major assembly with itemised part numbers, quantities and supplementary data, making it an indispensable reference for any technician responsible for keeping this crane operational.

Technical Specifications at a Glance

• Hoisting Capacity: MAX 40 ton
• Jib Radius: MAX 28 m / MIN 3.6 m
• Lifting Height H: 8.0 m
• Lifting Height K: 22.0 m (Crane No. 1), 25.0 m (Crane No. 2), 28.0 m (Crane No. 3)
• Hoisting Speed: 38 m/min at 18/16 ton, 19 m/min at 45/40 ton
• Luffing Time (max to min jib radius): 60 seconds
• Slewing Speed: MAX 0.7 rev/min
• Main Motor: 150 kW continuous, 225 kW S6 15% intermittent, 1785 rpm, 440 V, 3–60 Hz
• Hydraulic Pumps: 125 cm³/rev displacement (hoisting, luffing, slewing circuits)

What This Manual Enables You to Do

Armed with this manual, a technician or crane operator can confidently handle the full range of tasks associated with the GL 4524/4028-2S. You can perform the pre-operation crew checklist, start and stop the crane correctly in both summer and winter conditions, understand the safety functions that protect against overload and slack wire, and operate the crane within its design parameters.

For maintenance, the manual provides the complete maintenance chart with intervals and procedures. You can check and adjust brake settings using the pointer and dial indicators, replace brake bands, test slack wire switches, inspect wire ropes for damage using the detailed photographic examples, and sample hydraulic oil for cleanliness analysis. The lubrication chart specifies exactly which oils and greases to use for the hydraulic system, slewing gear case, jib bearing, roller bearings, ropes and open spur gears.

When problems arise, the troubleshooting charts guide you through the likely causes and remedies for overheating, pump failures and hydraulic motor issues. The electronic troubleshooting section explains how to read the B-cabinet display and replace PC, SL and MDC cards. The emergency operation procedures cover brake release using the hand pump in the event of main pump unit failure or complete power failure, including the exact hose connections for 63, 64 and 84 series motors.

The spare parts section is exhaustive. Every major assembly — hoisting winch, luffing winch, slewing gear, hydraulic motor series 84 and 64, brake assemblies, brake cylinders, parking lock, pump unit, feed pump unit, oil cooler, oil tank, mechanical equipment, slack wire switches, limit switches, crane jib, cab, lifting equipment, accumulators and hydraulic hoses — is documented with exploded-view drawings and itemised part numbers. This means you can identify and order the exact component needed without guesswork, using the article numbers, descriptions and supplementary data provided.

Why This Manual Matters

Hydraulic deck cranes are complex, high-value assets where incorrect maintenance or operation can lead to costly downtime, safety incidents or premature component failure. The MacGregor GL 4524/4028-2S manual provides the precise pressure settings, torque values, clearances, adjustment procedures and safety sequences that the manufacturer specifies. Following these procedures protects the crane, the cargo, the vessel and the crew.

Having the complete instruction service and parts manual available in PDF form means you can search for the information you need instantly, print only the pages relevant to the job at hand, and keep the manual accessible on any device — laptop, tablet or smartphone — whether you are in the crane house, the engine room or the ship’s office.

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Instant PDF Delivery

This MacGregor GL 4524/4028-2S crane instruction service and parts manual is delivered as a PDF file immediately after payment. There is no shipping, no waiting for a physical book to arrive, and no risk of a lost parcel. You can download it straight away, save it to your device, and start using it within minutes. The PDF is viewable on any device with a PDF reader and can be printed in full or in part as needed. Whether you are the chief engineer, a deck officer, a crane technician or a shore-based maintenance planner, this manual gives you the complete documentation for the GL 4524/4028-2S hydraulic deck crane in one convenient, searchable file.