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Deck Crane troubleshooting on MacGREGOR TGL 4026-2/3628-2

The vessel was loading coal at Berau Anchorage in Indonesia, when crane 3 developed a problem, luffing and slewing functions stopped to operate.

The ALATAS 24 hour crane breakdown emergency hotline was activated, and a senior, multi-disciplined crane specialist was mobilized onsite overnight out of ALATAS Singapore office.

The PLC control system, CC3000 was checked and found OK, hydraulic troubleshooting revealed that the luffing pump had a catastrophic failure. This has caused metal debris to be spread throughout the system, also damaging the hydr. luffing motor and both slewing pumps beyond repair.

ALATAS Singapore supplied new pumps & motors from ex ALATAS crane parts stock in singapore, i.e.
1x 189.4780-801 Luffing Motor A2FM107
1x 289.3872-801 Hoisting / Luffing Pump A4VG125
2x 289.3872-801 Slewing Pump A4VG 125

Parts were shipped via urgent airfreight to the next loading port in Kosichang / Thailand. One additional hydraulic engineer was mobilized and crane repairs were carried out as follows:

- Hydraulic system flushing & oil cleaning
1. Drained all oil from oil tank into spare drums
2. Opened oil tank covers an thoroughly cleaned tank from all debris & slush
3. Cleaned filter housing, changed filter elements
4. Removed all hoses & piping from hoisting, luffing & slewing system, inspect & clean them
5. Removed relieve valve(s) at pump side, dismantle & internally clean it, change O-rings.
6. Remove hydraulic motor valve block(s), fully dismantle it and clean all spools & valves, change O-rings.
7. Refill hydraulic oil via portable filtration unit

- Replaced luffing motor, luffing pump and both slewing pumps with ALATAS supplied spares
- Test run crane and carried out comprehensive function checks, pressure checks and leak-oil measurement.
- Handed crane over to Stevedores for cargo operation
- Stand by during cargo operation

The crane was fully restored and again operates reliable after ALATAS comprehensive repairs.


Vessel loading coal at Bearu Anchorage
Boom falling down due to luffing pump failure
Pump change out
Removing pumps
Faulty Luffing pump
Cleaned tank
Broken metal pieces in Luffing Pump
Broken metal pieces in Luffing Pump
Flushing hoses
New pumps
Transfering pumps
Installing pumps
Changed new filters
Completed replacing pumps
Checking slewing pressure


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